For 3 Cartridge Relief Valves in the same system, AAK integrated 3 into 1, and reduced the cost by 40%

China [CN]

Mayer has been working in a hydraulic equipment company in Brazil for 3 years. In the first half of this year, they customized a hydraulic power unit for a customer. The pressure supply range is 20bar to 450bar. 3 direct-acting cartridge relief valves, high, medium and low pressure, are used. The equipment was debugged smoothly, and the customer was also very satisfied. However, the batch order was stuck because of the price. The customer reported that the price of similar equipment in the market was 20% cheaper than theirs, and requested that the price of this hydraulic power unit be reduced by 15% before the batch order could be confirmed. The boss asked the engineer to optimize the system to reduce cost. The engineer said that the only way to reduce the cost was to combine the 3 cartridge direct-acting relief valves into 1. The original cartridge relief valve manufacturer was powerless. Mayer contacted more than 10 cartridge valve manufacturers. They were either not interested or unable to optimize. 2 weeks later, no results were achieved. Mayer was worried.

Mayer browsed AAK hydraulic valve in Google and left a message:

1. Can you customize the cartridge direct-acting relief valve with the applicable pressure range of 20bar to 450bar?

2. The original system uses 3 high, medium and low pressure cartridge relief valves. Can they be combined into 1 without affecting the function?

3. What is the lead time and cost for sample development?

According to his message, I judged that either the cost was challenged or the customer was dissatisfied with the system. After communication, I learned the trouble he faced. Based on his production drawings of cartridge direct-acting relief valve and the system principle of the equipment, AAK engineers had a discussion and came out a plan, but only 90% is sure. Mayer may be hesitating and did not give us any news for a week. I thought he chose another cartridge relief valve manufacturer, but I suddenly received his trial order. After 50 days, 10 samples of AAK newly designed cartridge direct-acting relief valves were sent out.

1 month later, Mayer sent us a PO for 360 cartridge direct-acting relief valves, and mentioned that AAK newly designed direct-acting cartridge relief valves were used in equipment, and did not affect its functions, and helped them reduce the cost by more than 15%. Only then did customer place order for bulk equipment. According to the 3 levels of pressure, AAK has changed the structure of the original hydraulic direct-acting cartridge relief valve, reducing the manufacturing cost by more than 40%, in the following way:

1. A spring is arranged between the poppet valve spool and the pressure regulating screw plug, and the vertical position at the front end of the poppet valve spool corresponds to a cylindrical oil chamber, which is connected with the oil inlet hole.

2. The horizontal position at the front end of the poppet valve spool corresponds to the oil return hole. At the same time, a thrust belt is arranged around the front end of the poppet valve spool, and the poppet valve spool is provided with an oil hole. 

3. The pressure oil enters the cylindrical oil chamber from the oil inlet hole, and the oil pressure acts on the thrust ring. When the generated thrust is less than the spring pressure, the poppet valve spool is closed; when its thrust is greater than the spring pressure, the poppet valve spool opens the overflow, which is suitable for the generalization of high, medium and low pressure overflow.

Mayer told me privately that he was promoted to the position of purchasing manager a few days ago, and he was more and more energetic.

AAK hydraulic direct-acting cartridge relief valve is applicable to all kinds of pressures. You can also have a small try!

https://www.aakindustry.com/info-detail/cartridge-relief-valves-aak418