A Novel Flow Characteristic Regulation Method for Two-Stage Proportional Valves Based on Variable-Gain Feedback Grooves

The two-stage proportional valve is a key control component in heavy-duty equipment, where its signal-flow characteristics critically influence operational performance. This study proposes an innovative flow characteristic regulation method using variable-gain feedback grooves. Unlike conventional throttling notch optimization, the core mechanism actively adjusts pilot–main valve mapping through feedback groove shape and area gain adjustments to achieve the desired flow curves. This approach avoids complex throttling notch issues while retaining the valve’s high dynamics and flow capacity. Mathematical modeling elucidated the underlying mechanism. Subsequently, trapezoidal and composite feedback grooves are designed and investigated via simulation. Finally, composite feedback groove spools tailored to construction machinery operating conditions are developed. Comparative experiments demonstrate the following: (1) Pilot–main mapping inversely correlates with area gain; increasing gain enhances micro-motion control, while decreasing gain boosts flow gain for rapid actuation. (2) This method does not significantly increase pressure loss or energy consumption (measured loss: 0.88 MPa). (3) The composite groove provides segmented characteristics; its micro-motion flow gain (2.04 L/min/0.1 V) is 61.9% lower than conventional valves, significantly improving fine control. (4) Adjusting groove area gain and transition point flexibly modifies flow gain and micro-motion zone length. This method offers a new approach for high-performance valve flow regulation.