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Customized
MDP Hydraulics
Core structure and design
A high-quality hydraulic center valve block is the perfect combination of its design, materials and manufacturing process.
• Valve body: As the basic carrier, it is usually made of high-quality carbon steel (such as 45# steel), forged steel, or high-strength aluminum alloy (such as 6061, 2024) through overall milling or forging. The material selection is based on the working pressure, weight requirements, and environmental corrosiveness. For example, high-strength steel is commonly used in construction machinery to withstand high pressure and impact, while aerospace equipment prioritizes the use of high-strength aluminum alloy to reduce weight.
• Internal flow channels: This is the essence of the design. The design is optimized using 3D CAD software and computational fluid dynamics software to ensure smooth transitions of the flow channels and avoid sharp corners, in order to minimize pressure loss, hydraulic shock and noise. The processing of deep holes and intersecting holes (such as using alloy steel plugs for reliable sealing) is crucial in the manufacturing process.
• Installation interface: The surface of the valve block has been finely processed to ensure the sealing performance of the installed hydraulic valves (such as directional valves, plug-in valves). Common sealing methods include O-ring sealing, flat sealing, etc.
• Standard Oil Port: Clearly mark the standard oil port, for example:
◦ P: Pressure oil inlet (connected to the pump)
◦ T: Return oil port (connected to the fuel tank)
◦ A, B: Operating oil ports of the actuator (connected to the hydraulic cylinder or motor)
◦ X: Controls the pressure oil outlet
◦ L: Oil discharge port
2. Functionality and Customization
The function of the hydraulic center valve block is entirely dependent on its internal flow channel design and the valves installed within. It can achieve:
• Coordinated control of multiple actuators: such as controlling the complex combined movements of the boom, dipper, and bucket of an excavator.
Pressure grading control: By integrating relief valves and pressure reducing valves, different stable pressures are provided for different branches of the system.
• Precise speed adjustment: By integrating throttle valves and speed control valves, the movement speed of the actuator can be precisely controlled.
We offer fully customized services, designing, simulating, manufacturing and testing on a one-to-one basis, based on your device schematic diagram, space layout and performance requirements.
Hydraulic center valve blocks are widely used in fields where there are high requirements for space, weight, reliability and control performance:
• Construction machinery: Excavators, concrete pump trucks, cranes, loaders, etc. These are the core components that enable the complex and reliable operations of the equipment.
• Plastic injection molding machine: Controls actions such as injection, mold closing, and molten glue application. Requires high response speed and precise repeatability.
• Metallurgical equipment: continuous casting machines, rolling mills, etc., operate in harsh environments with high temperatures and high dust levels, and have extremely high requirements for the valve blocks' ability to withstand high temperatures and maintain sealing performance.
• Aerospace: Aircraft landing gear retraction and extension systems, control systems for steering gears, etc., require extremely high power-to-weight ratios and absolute reliability.
• Ship engineering: Rudder gear, anchor gear, hatch cover control systems, must possess excellent corrosion resistance properties.
• New energy equipment: wind turbine pitch control systems, photovoltaic panel tracking systems, etc.
Q1: What information do we need to provide when customizing a hydraulic center valve block?
A1: Please provide the following key information:
1. Hydraulic system schematic diagram: This is the fundamental basis for design.
2. Model and sample of the required hydraulic valves: Ensure accurate installation dimensions and functions.
3. Equipment layout and interface dimensions: Including the approximate size limitations of the valve block, pipe connector interface specifications and orientations.
4. System operating parameters: Maximum working pressure, flow rate, type of oil.
5. Environmental information: Are there any special environmental requirements, such as high/low temperatures, corrosion, vibration, etc.
Q2: When our equipment is in operation, there is leakage at the surface of the valve block or at the interface. What could be the possible causes?
A2: Leakage is a common issue. The possible causes include:
• Sealing problem at the installation surface: The installation bolts were not tightened in the required sequence and torque; the O-ring is damaged or of the wrong type; there are scratches or impurities on the installation surface.
• Loose plug or pressure gauge connector: The sealing plug in the cross-hole has become loose due to vibration.
• Valve block body defect: Under extreme pressure, there may be casting defects (such as sand holes) or cracks inside, but this situation is extremely rare in valve blocks manufactured from a single piece of material.
Q3: The system response is sluggish, or the actuating mechanism is not powerful. Could this be related to the valve block?
A3: Yes, it is possible. The main reason might be an unreasonable internal flow channel design or processing defects:
• Excessive pressure loss: The flow channels are too narrow or the turns are too sharp, resulting in energy waste.
• Internal leakage: Due to design or manufacturing issues within the valve block, oil flows from the high-pressure chamber to the low-pressure chamber. Professional equipment is required for inspection.
Q4: How to choose the material for the valve block? Should we choose aluminum or steel?
A4:
• Select steel: When the system operates under a pressure higher than 35 MPa, or if there is high-intensity shock, vibration in the environment, or if weight sensitivity is not a concern. Steel offers better strength and wear resistance.
• Choose aluminum alloy: When weight is a critical factor (such as in mobile devices, aerospace applications), the system pressure is usually below 31.5 MPa, and good corrosion resistance (not in harsh marine environments) is required. Aluminum alloy has better processing properties than steel.
Q5: What should be noted before using the valve block?
A5:
• Thorough cleaning: This is the most crucial step! After processing, the internal parts of the new valve block may still have metal shavings and contaminants. It is necessary to use professional cleaning equipment and methods (such as high-pressure flushing) for a thorough cleaning, and immediately seal all oil ports with plugs.
• Stress test: It is recommended to conduct a stress test before installing it onto the system to check for any leaks.
