Simulation analysis and experimental research on static performance of water-hydraulic pressure difference control valve

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Many hydraulic tools, like hydraulic cylinders and hydraulic artificial muscle joints are operated by adjusting pressure differences between different zones. Typically, the method employed to change the pressure difference is establishing hydraulic bridges and adjusting liquid resistance. While effective, this method's drawback is complex structures. To address this issue, a water-hydraulic pressure difference control valve, integrating two hydraulic bridges, was designed. The static performances including the output pressure difference, the flow rate and the force acting on the valve core were analyzed using AMESim and computational fluid dynamics simulations. Based on the simulation results, a prototype of voice coil motor direct drive pressure difference control valve was manufactured and the corresponding experiments were carried out. The computational fluid dynamics simulation results show that the internal leakage and the through-flow capacity difference between throttling grooves affect the flow field characteristics of the valve. When the pump pressure is 3 MPa and the valve opening is at the middle position, the internal leakage increases the flow rate from 2.25 L/min to 2.38 L/min, and the through-flow capacity difference reduces the control port pressure from the theoretical analysis of 1.5 MPa–1.41 MPa. Furthermore, combined with the analysis of the external liquid resistance, the AMESim model of the pressure difference control valve is modified. When the pump pressure is 3 MPa, the pressure difference and flow rate average deviations between the modified AMESim model and the experiment are 0.021 MPa and 0.048 L/min. Finally, a rotational angle experiment for a water hydraulic artificial muscle joints showed satisfactory control effects, suggesting the valve's application in controlling hydraulic tools and actuators.