New Pressure Regulator Suction Pressure Valve Control Valve 0 928 400 726 0928400726 for Auto Spare Parts

Abstract

The armature is a critical component in the electromagnetic actuator of pressure control valves, directly influencing their dynamic response, operating stability, and control precision. In high-speed hydraulic and fuel injection systems, even subtle changes in the armature’s geometric structure or material properties can lead to significant variations in valve response time and pressure regulation accuracy. This study focuses on establishing the quantitative relationship between armature structural parameters and the dynamic performance of a pressure valve through a combination of finite element simulation, dynamic testing, and response modeling.

A detailed 3D electromagnetic–mechanical coupling model of the valve assembly was developed using COMSOL and AMESim to analyze the transient behavior during the opening and closing stages. The main armature parameters — including mass, thickness, radial dimensions, air-gap length, and magnetic permeability — were systematically varied to evaluate their influence on magnetic force, response delay, and oscillatory motion. The electromagnetic force and displacement responses were validated by high-speed laser displacement sensors and coil current waveform acquisition during bench tests.

Simulation and experimental results reveal that reducing armature mass effectively shortens the response time, but excessive reduction compromises the magnetic circuit’s flux density and mechanical stability. The air-gap length exhibits a nonlinear effect: an optimal range exists (typically 0.15–0.25 mm) where magnetic attraction and mechanical rebound achieve dynamic balance. Increasing armature stiffness enhances vibration damping and valve closing stability but requires higher excitation current to overcome the restoring force. Moreover, structural asymmetry in the armature cross-section leads to uneven magnetic field distribution, inducing lateral oscillations and pressure overshoot.

A multi-objective optimization model was then established using a genetic algorithm (GA) to minimize both response time and pressure fluctuation amplitude. The optimal parameter configuration achieved a 12.6% improvement in response speed and a 9.4% reduction in steady-state pressure ripple compared with the baseline design. The results demonstrate that armature geometry plays a dominant role in shaping the valve’s transient characteristics, and a coordinated optimization of electromagnetic and mechanical parameters is essential to ensure high-frequency operation stability.

Finally, a sensitivity analysis indicated that the armature mass and air-gap length are the most influential parameters, contributing approximately 37% and 31% to total response variability, respectively. Based on these findings, a lightweight composite armature material with enhanced magnetic conductivity was proposed, achieving improved energy efficiency and durability under repeated cyclic operation.

This research provides a theoretical foundation and design reference for high-performance electromagnetic pressure valves used in diesel common-rail systems, electro-hydraulic actuators, and precision fluid control devices. The established modeling approach and optimization framework can be extended to other electromagnetic control components requiring high-speed response and stability balance.