Pilot Device for a Directional Valve without Internal Cable Connections

Abstract

A pilot device for a hydraulic directional valve includes a displacement sensor, a pilot valve, an actuating device, a coil assembly, and a circuit board. The displacement sensor has a sensor axis and the pilot valve has a valve axis. The valve axis and the sensor axis are arranged substantially parallel to one another so as to lie in a reference plane. The actuating device and the coil assembly are arranged adjacent to one another. The circuit board is arranged parallel to the reference plane. In each case, to establish an electrical contact, the coil assembly, the actuating device, and an electrical plug connection are either soldered directly to the circuit board or are in breakable electrical contact with a respectively associated, rigid contact assembly. The contact assembly is soldered directly to the circuit board.

Claims

1. A pilot device for a hydraulic directional valve, comprising: a housing configured to be mounted externally on the directional valve via a mounting surface, the housing equipped with an electrical plug connection that is accessible from the outside; a pilot valve received within the housing and configured as a cartridge valve having a valve axis, the pilot valve including an electromagnetic actuating device; a displacement sensor received within the housing, the displacement sensor including a soft iron core, which, in the region of the mounting surface, is coupled for movement to a control spool of the displacement valve so that it is linearly movable along a sensor axis; an electronic circuit board received within the housing; a fluid feed, a fluid return, a first control connection, and a second control connection (i) arranged on the housing in the region of the mounting surface and (ii) fluidically connected to the pilot valve; and at least two coils arranged around the soft iron core, the at least two coils combined to form a coil assembly, wherein the valve axis and the sensor axis are arranged substantially parallel to one another so that they lie in a reference plane, wherein the actuating device and the coil assembly are arranged adjacent to one another, wherein the circuit board is arranged parallel to the reference plane, wherein, in each case, to establish an electrical contact, the coil assembly, the actuating device, and the electrical plug connection are either soldered directly to the circuit board or are in breakable electrical contact with a respectively associated, rigid contact assembly, and wherein the contact assembly is soldered directly to the circuit board.

2. The pilot device according to claim 1, wherein the contact assembly is associated with the actuating device, and wherein the electrical plug connection and the coil assembly are soldered directly to the circuit board.

3. The pilot device according to claim 1, wherein: the contact assembly comprises at least two metal parts via which a breakable electrical contact is configured to be established in each case, the metal parts are soldered directly to the circuit board, and the metal parts are overmolded with a plastic sheath so that the metal parts are fixedly held by the plastic sheath.

4. The pilot device according to claim 1, wherein the electrical contact between the actuating device and the associated contact assembly is configured to be established and broken by a relative movement in the direction of the valve axis.

5. The pilot device according to claim 1, wherein: the housing comprises a base body and a cover, the mounting surface is arranged on the base body, the cover is arranged on a side of the base body opposite the mounting surface, and the circuit board and the electrical plug connection and the coil assembly are fastened to the cover.

6. The pilot device according to claim 5, wherein the circuit board, the coil assembly, the electrical plug connection, and the contact assembly project out of the cover so that the associated soldering points are accessible for a soldering operation when the cover is not installed on the base body.

7. The pilot device according to claim 5, wherein sections of the pilot valve are incorporated in a receiving bore in the base body such that the fluid connection to the fluid feed, to the fluid return, and to the first and second control connections extends exclusively in the base body.

8. The pilot device according to claim 5, wherein a bracket, which extends in the direction of the sensor axis, is integrally formed in one piece on the cover, and wherein the circuit board is fastened to the bracket.

9. The pilot device according to claim 1, wherein: the coil assembly comprises a separate pressure pipe in which the soft iron core is arranged, the pressure pipe is surrounded by a coil holder made of plastic, which supports the at least two coils, and the coil assembly is soldered to the circuit board in the region of a contact portion.

10. The pilot device according to claim 9, wherein the coil holder is configured in one piece and has a plate-like fastening portion that extends transversely to the sensor axis, and wherein the fastening portion is fastened to the cover.

11. The pilot device according to claim 10, wherein: the contact assembly comprises at least two metal parts via which a breakable electrical contact is configured to be established in each case, the metal parts are soldered directly to the circuit board, the metal parts are overmolded with a plastic sheath so that the metal parts are fixedly held by the plastic sheath, the plastic sheath abuts directly against the fastening portion, and the plastic sheath and the fastening portion are penetrated by at least one common fastening screw that is screwed into the cover.

12. The pilot device according to claim 10, wherein the contact portion is configured in one piece on the coil holder and is arranged spaced from the fastening portion in the direction of the sensor axis.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The disclosure is explained in more detail below, with reference to the accompanying drawings, which show:

[0021] FIG. 1 a longitudinal section of a pilot device according to the disclosure, wherein the associated directional valve is illustrated in part;

[0022] FIG. 2 a perspective view of the base body of the pilot device according to FIG. 1, from the mounting surface;

[0023] FIG. 3 a perspective view of the pilot device according to FIG. 1, without the base body;

[0024] FIG. 4 a further perspective view of the assembly according to FIG. 3, without the cover and without the pilot valve;

[0025] FIG. 5 a view corresponding to FIG. 4, wherein the plastic sheath of the contact assembly is omitted; and

[0026] FIG. 6 a further perspective view of the base body according to FIG. 2, from the cover.

DETAILED DESCRIPTION

[0027] FIG. 1 shows a longitudinal section of a pilot device 20 according to the disclosure, wherein the associated directional valve 10 is illustrated in part. The pilot valve 20 comprises a housing 21, which is composed of a base body 30 and a cover 80. The housing 30 and/or the cover 80 are preferably produced from aluminum or zinc in an injection molding procedure. The base body 30 has a planar mounting surface 40, which is aligned perpendicularly to a longitudinal axis 12. The mounting surface 40 abuts against the directional valve 10, wherein the pilot device 20 is preferably screwed to the directional valve 10. The directional valve 10 has a control spool 11, which is linearly movable relative to the longitudinal axis 12. The control spool 11 is equipped with a restoring spring 13, which pre-tensions the control spool 11 in a central position, wherein it projects into the base body 30 of the pilot device 20. The position of the control spool 11 is adjusted hydraulically by means of the pilot device 20, wherein, for this purpose, the control device has a first control connection 41 and a second control connection (No. 42 in FIG. 2). The corresponding pressures act on the control spool 11 at the end face from opposite sides.

[0028] A pilot valve 50, which is formed in the manner of a cartridge valve, is received in the base body 30. The pilot valve 50 comprises an electrical actuating device 52, which is surrounded by the base body 30 and by the cover 80. The actuating device 52 preferably comprises at least one actuating coil, the pilot valve 50 being adjustable by the magnetic force thereof. The hydraulic portion of the pilot valve 50 is received in an associated receiving bore 32, which is formed solely by the base body 30. The pilot valve 50 is preferably formed in the manner of a 4/3-way valve, which also leads to the use of the term volumetric control, in which volume flows alone are used to adjust the control spool and not pressures, as is the case with barometric control. The control valve has four fluid connections in total, which are accessible at the mounting surface 40, wherein further details will be explained with reference to FIG. 2. The pilot valve 50 has a valve axis 51, which is aligned parallel to the longitudinal axis 12. The pilot valve 50, with the exception of the connection socket 53, is preferably formed to be rotationally symmetrical relative to the valve axis 51. In the direction of the valve axis 51, it is held in the receiving bore 32 solely by the cover 80 of the pilot device 20.

[0029] A displacement sensor 60 is furthermore provided, which operates inductively in the present case. The displacement sensor 60 comprises a rod-like soft iron core 62, which is fixedly connected, in particular screwed and/or crimped, to the control spool 11. The soft iron core 62 therefore moves together with the control spool 11 along the longitudinal axis 12. The soft iron core 62 comprises a magnetically acting first portion 62a, which is designed to be ferromagnetic. The first portion 62a is connected to the control spool 11 via a non-magnetic second portion 62b. This results in good measuring accuracy of the displacement sensor 60. The soft iron core 62 is preferably formed to be circular-cylindrical relative to a sensor axis 61, wherein the second portion 62b preferably has a smaller diameter than the first portion 62a. The sensor axis 61 preferably coincides with the above-mentioned longitudinal axis 12 of the control spool 11. It extends, in particular, parallel to the valve axis 51 so that the sensor axis 61 and the spaced valve axis 51 span a reference plane.

[0030] A pressure pipe 63 is arranged around the soft iron core 62. The pressure pipe 63 is formed in the manner of a jar, wherein it is preferably produced from sheet metal in a deep drawing procedure. It consists of a non-magnetic metal, in particular austenitic, stainless steel, so that it does not interfere with the inductive displacement measurement. At its open end, it is pressed into the base body 30, wherein the joint is preferably sealed by a sealing ring 64. The pressure within the pressure pipe 63 is applied at the first control connection 41, which presses the control spool 11 away from the pilot device 20. Owing to the seal between the base body 30 and the pressure pipe 63, the corresponding pressure fluid is unable to make its way into the region of the base body 30 in which the circuit board 90 is located. It goes without saying that the pilot valve 50 is likewise equipped with a seal so that fluid is also unable to make its way from there into the region of the base body 30 in which the circuit board 90 is arranged. A coil assembly 70, which will be explained in more detail with reference to FIGS. 4 and 5, is arranged around the pressure pipe 63.

[0031] Reference shall furthermore be made to the electrical plug connection 23, which is preferably formed as a plastic injection molded part in which corresponding metal contact portions are cast. A sealing ring 25 is arranged between the plug connection 23 and the cover 80 so that it is not possible for any medium, for example moisture, to enter therein from the outside.

[0032] The pilot device 20 is equipped with a plurality of fastening screws 22. The cover 80 is fastened to the base body 30 by the first fastening screws 22a. These penetrate the cover 80, wherein they are screwed into an associated bore 35 in the base body 30. The plug connection 23 is fastened to the cover 80 by the second fastening screw 22b. The coil assembly 70 is fastened to the cover 80 by the third fastening screw (No. 22c in FIG. 4). The base body 30 is fastened to the directional valve 10 by the total of four fourth fastening screws 22d. These penetrate a respective fastening bore (No. 33 in FIG. 2) in the base body 30, wherein they are screwed into the directional valve 10. The circuit board 90 is fastened to a bracket 81 of the cover 80 by the fifth fastening screw (No. 22e in FIG. 3).

[0033] Reference shall also be made to the circuit board 90, which is arranged parallel to the plane of the drawing in FIG. 1 and therefore parallel to the valve axis 51 and to the sensor axis 61. The circuit board 90 extends from the plug connection 23 via the displacement sensor 60 to the pilot valve 50. The electrical connections there are therefore each arranged in the immediate vicinity of the circuit board 90, wherein they are electrically connected to the circuit board 90 without using cables. The circuit board 90 is, in particular, a component of an electronic control unit, whereof the set value is provided at the plug connection 23, wherein its actual value is determined by the displacement sensor 60, wherein its manipulated variable is the setting of the pilot valve 50. The control unit can be designed as a constant linear controller, in particular as a PI controller. The linear controller is preferably implemented using a digital processor, wherein it can also be implemented by means of an analog circuit.

[0034] FIG. 2 shows a perspective view of the base body 30 of the pilot device according to FIG. 1 from the mounting surface 40. The substantially planar, rectangular mounting surface 40 is equipped with a respective fastening bore 33 at its four corner regions, which fastening bore is penetrated in each case by an associated fastening screw (No. 22d in FIG. 1).

[0035] Within the mounting surface 40, a total of four regions are delimited from one another in a fluid-tight manner by a single-piece seal 45 made of an elastomer. A first region forms the spring recess 37, in which the restoring spring (No. 13 in FIG. 1) is arranged, wherein the first control connection 41 leads out at the base of the spring recess 37. A further region forms the second control connection 42, which is fluidically connected to the pilot valve. A further region forms the fluid feed 43, via which the pilot device is supplied with pressurized pressure fluid, wherein this is conducted to the pilot valve. The pressure fluid is preferably a liquid and most preferably hydraulic oil. The fourth region forms a fluid return 44, via which pressure fluid can flow from the pilot valve back to the directional valve, wherein it is typically transferred to a tank there. The seal 45 is preferably received in an adapted groove in the mounting surface 40, wherein it abuts against a planar counter-surface on the directional valve.

[0036] In addition to the seal 45, a first alignment projection 34, which engages in an adapted recess in the directional valve, is arranged on the mounting surface 40. An analogous second alignment projection 34a is arranged at a spacing from the first alignment projection 34. This simplifies the installation, in particular the alignment of the pilot device on the directional valve.

[0037] It can furthermore be seen in FIG. 2 how the collar of the pressure pipe 63 abuts against the base of the spring recess 37.

[0038] FIG. 3 shows a perspective view of the pilot device according to FIG. 1, without the base body. It is possible to identify the circuit board 90, which is fastened to the cover 80. On the one hand, it is screwed by means of the fifth fastening screw 22e to a bracket 81 (see also FIG. 1) integrally formed in one piece on the cover 80, so that it is held mechanically rigid. Consequently, the circuit board 90 is not prone to mechanical vibrations when the pilot device is subjected to vibrational loads. Reference shall furthermore be made to the soldering points 24. These serve primarily for establishing an electrically conductive connection between the circuit board 90 and the plug connection 23, the displacement sensor 60 and the pilot valve 50. The soldering points 24 moreover indirectly form a mechanically fixed connection between the circuit board 90 and the cover 80, since the parts 50, 60, 23 are fixedly connected to the cover. Via the four first soldering points 24a, the circuit board 90 is electrically conductively connected to the plug connection 23, which has four corresponding contacts. Via the three second soldering points 24b, the circuit board 90 is electrically conductively connected to the two coils (No. 71 in FIG. 4) of the displacement sensor 60. In this case, one of the second soldering points 24b is connected to both coils, wherein the two other second soldering points 24b are connected to a single respectively associated coil. The three third soldering points 24c are connected to the electromagnetic actuating device 52 of the pilot valve 50. This preferably comprises two separate magnetic coils, which enable two opposing actuating directions, starting from an unactuated central position. The inventive configuration of the cover 80 is advantageous in that the above-mentioned soldering points 24 are particularly easily accessible within the assembly illustrated in FIG. 3.

[0039] Reference shall furthermore be made to the cover seal 31, which surrounds the circuit board 90, the plug connection 23, the displacement sensor 60 and the pilot valve 50 in a continuous manner. The cover seal 31 is made of an elastomer. It is received in an adapted groove in the base body, wherein it abuts against a planar sealing surface on the cover 80. The four fastening bores 82 on the cover 80 are arranged flush with the fastening bores (No. 33 in FIG. 2) in the base body.

[0040] FIG. 4 shows a further perspective view of the assembly according to FIG. 3 without the cover and without the pilot valve. It is particularly possible to identify the plug connection 23, which, in an injection molding procedure, is produced from plastic in one piece with a flange portion 26 and a connecting portion 27. A total of four metal parts are cast in this plastic part such that they are electrically insulated from one another. These metal parts each terminate in the plug connection 23 at one end and at an associated first soldering point (No. 24a in FIG. 3) at the other. The flange portion is formed to be substantially plate-like with a circular-cylindrical circumferential surface. The circumferential surface abuts tightly against an adapted counter-surface on the cover, wherein the corresponding joint is sealed by a sealing ring 25. The second fastening screw 22b penetrates the cover (see FIG. 2) and is screwed into the flange portion 26. The connecting portion 27 extends from the flange portion 26 to the first soldering points, wherein, in particular, it keeps the above-mentioned metal parts electrically insulated from one another.

[0041] The displacement sensor 60 is furthermore illustrated without the soft iron core. It is particularly possible to identify the coil assembly 70, which comprises the two substantially mutually identically formed coils 71. The coil assembly 70 is penetrated with little play by the above-mentioned pressure pipe, which is fastened to the base body. The coil assembly comprises a coil holder 72, which is produced from plastic in an injection molding procedure. This is formed to be substantially tube-like, wherein the two coils 71 are wound on its outer surface. A plate-like fastening portion 73 is arranged in one piece on the coil holder 72, between the two coils 71. The third fastening screw 22c penetrates the contact assembly 91 and the fastening portion 73, wherein it is screwed into the cover (not illustrated). Accordingly, the coil assembly 70 and the contact assembly 91 are fixedly connected to the cover. Reference shall furthermore be made to the contact portion 74 integrally formed in one piece on the coil carrier. Three rod-like metal parts are placed or cast therein such that they are electrically insulated from one another, which metal parts are connected to the second soldering point (No. 24b in FIG. 3) at their one end, whilst being connected to the coils 71 at the other, opposite end.

[0042] The contact assembly 91, which produces the electrical contact with the pilot valve, can furthermore be identified in FIG. 4. It is revealed from the above that the plug connection 23 and the displacement sensor 60 are fixedly soldered to the circuit board 90. On the other hand, the pilot valve is connected to the circuit board 90 by means of a plug connection in order to simplify installation. The contact assembly 91 comprises three separate metal parts 92 for this, which each form a plug contact. The metal parts 92 are kept electrically insulated from one another by a plastic sheath 93. The contact assembly 91 is produced from plastic in an injection molding procedure, wherein the metal parts are placed in the casting mold before the liquid plastic is added, so that they are overmolded.

[0043] FIG. 5 shows a view corresponding to FIG. 4, wherein the plastic sheath of the contact assembly (No. 91 in FIG. 4) is omitted. Accordingly, it is possible to identify the shape of the three mentioned metal parts 92, which are each formed in an L shape so that they lead to the third soldering points (No. 24c in FIG. 3). It can furthermore be seen that the coil holder 72 of the coil assembly 70 is formed separately from the contact assembly (No. 91 in FIG. 4). This simplifies the production of the corresponding parts in an injection molding procedure.

[0044] FIG. 6 shows a further perspective view of the base body 30 according to FIG. 2 from the cover (No. 80 in FIG. 1). Towards the cover, the base body 30 forms a circuit board recess 36 which is closed in a fully leak-proof manner by the cover on the one hand and by the hydraulic portion of the pilot valve on the other. The circuit board (No. 90 in FIG. 3) and the bracket (No. 81 in FIG. 3) project into the circuit board recess 36, finding adequate space therein. In this case, the assembly illustrated in FIG. 3, without the pilot valve, must be aligned precisely on the pressure pipe 63, on the connection socket (No. 53 in FIG. 1) and on the actuating device (No. 52 in FIG. 1) of the pilot valve. Installation is correspondingly simple. The first fastening screws (No. 22a in FIG. 1) are screwed into the bores 35 in order to fasten the cover on the base body, wherein two first fastening screws are preferably provided. The first fastening screws are preferably formed as self-tapping or thread-cutting screws.

LIST OF REFERENCE SIGNS

[0045] 10 Directional valve [0046] 11 Control spool [0047] 12 Longitudinal axis [0048] 13 Restoring spring [0049] 20 Pilot device [0050] 21 Housing [0051] 22 Fastening screw [0052] 22a First fastening screw [0053] 22b Second fastening screw [0054] 22c Third fastening screw [0055] 22d Fourth fastening screw [0056] 22e Fifth fastening screw [0057] 23 Plug connection [0058] 24 Soldering point [0059] 24a First soldering point [0060] 24b Second soldering point [0061] 24c Third soldering point [0062] 25 Sealing ring [0063] 26 Flange portion [0064] 27 Connecting portion [0065] 30 Base body [0066] 31 Cover seal [0067] 32 Receiving bore [0068] 33 Fastening bore [0069] 34 First alignment projection [0070] 34a Second alignment projection [0071] 35 Bore [0072] 36 Circuit board recess [0073] 37 Spring recess [0074] 40 Mounting surface [0075] 41 First control connection [0076] 42 Second control connection [0077] 43 Fluid feed [0078] 44 Fluid return [0079] 45 Seal [0080] 50 Pilot valve [0081] 51 Valve axis [0082] 52 Actuating device [0083] 53 Connection socket [0084] 60 Displacement sensor [0085] 61 Sensor axis [0086] 62 Soft iron core [0087] 62a First portion of the soft iron core [0088] 62b Second portion of the soft iron core [0089] 63 Pressure pipe [0090] 64 Sealing ring [0091] 70 Coil assembly [0092] 71 Coil [0093] 72 Coil holder [0094] 73 Fastening portion [0095] 74 Contact portion [0096] 80 Cover [0097] 81 Bracket [0098] 82 Fastening bore [0099] 90 Circuit board [0100] 91 Contact assembly [0101] 92 Metal part [0102] 93 Plastic sheath