How To Design Hydraulic Manifold Block

Design Process of Hydraulic Manifold Block

The design process of a hydraulic manifold block can be roughly divided into two stages: 

External Layout Design

Internal Porting Design

Hydraulic Manifold Block External Layout Design

To begin with, optimizing the external layout of the hydraulic manifold blocks involves several key steps:

  • Define Overall Dimensions: Determine the overall dimensions of the manifold block, aiming to keep it as compact as possible.
  • Estimate Installation Positions: Identify the installation positions, mounting surfaces, and angles of the valves, ensuring there are no interferences between components.
  • Define Parameters for Ports: Set the parameters for working ports, inlet and outlet ports, and pipe connections.

Hydraulic Manifold Block Internal Porting Design

Following the external layout design, the internal porting design builds upon the system schematic. The primary tasks include:

  • Ensure connectivity as per the system schematic.
  • Determine the positions and depths of the main passages.
  • Decide the locations and depths of process ports, minimizing their number and shortening passage lengths.
  • Ensure the passages meet the required flow areas.
  • Maintain sufficient safety wall thicknesses between passages and between passages and the valve block surface.

Challenges of hydraulic manifold block

Due to the unique structure of hydraulic manifold blocks, the internal design of the hydraulic manifold blocks involves numerous stepped bores, stepped side ports, and control oil passages, which increases the design complexity.

General Layout

Spatial Positioning

The hydraulic manifold blocks is a hexahedron. To determine the spatial positions of the valve components and passages, establish a unified manifold block spatial coordinate system. The six mounting surfaces are the front, rear, top, bottom, left, and right.

The installation angles for the hydraulic manifold blocks are typically set at right angles, i.e., 0°, 90°, 180°, and 270°.

Line Network, End Ports, Process Ports, and Routing Sequence

The interconnected passages inside the hydraulic manifold blocks form a network, including end ports and process ports.

End ports are passages that directly connect to valve ports. Once the manifold layout is determined, the designer also sets the design parameters of the end ports.

Process ports are passages added manually to achieve connectivity.

The design elements of passages include the installation surface, installation position, and depth of the holes.

Interference Checking

Hydraulic Manifold Block External Interference Checking

External interference checking involves verifying that all valve components mounted on the valve block do not interfere with each other. To simplify this, use a slightly larger rectangular volume to represent the external dimensions and the space required for installation and adjustment of the valve components.

Based on the spatial relationships of the valves, face-to-face valves are unlikely to interfere externally. Only valves on the same mounting surface need to be checked for interference.

Hydraulic Manifold Block Passage Interference Checking

Passage interference checking focuses on the positions of passages relative to each other and to the six surfaces of the hydraulic manifold blocks.

There are three scenarios for passage interference checking:

  •  Two passages on the same surface.
  • Two passages on adjacent surfaces.
  • Two passages on opposite surfaces.

Preparations Before Drawing the Hydraulic Manifold Block

Before creating the 3D model of the valve block, gather the following:

  1. Types and models of hydraulic valves.
  2. Dimensions and maximum dimensions of the hydraulic components.
  3. Information about the base plates of the hydraulic components, including the dimensions of the base plate, coordinates of the ports, bore diameters, initial depths of the ports, and the coordinates and depths of the threaded holes.
  4. Models and specifications of the fixing screws, connection bolts, positioning pins, and sealing elements.
  5. Attributes of the hydraulic components, including their preferred surfaces, prohibited surfaces, preferred angles, and prohibited angles.


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