CFD-Based Steady-State Flow Force Compensation in Direct Drive Servo Valves

One of the key factors determining energy consumption and control stability in hydraulic servovalves with direct electric drive is the flow forces acting on the spool. These forces are complex in nature and consist of both steady-state and transient components, with the steady-state component exerting the dominant influence on the performance and dynamics of spool valves. In recent years, this issue has become the subject of intensive research aimed at reducing undesirable hydraulic loads while maintaining high nominal flow capacity, strong energy efficiency, and low manufacturing cost. In engineering practice, the most effective approach has proven to be the modification of the spool geometry in order to control the direction and jet angle of the outflow while keeping the valve sleeve design as simple as possible. This solution reduces the forces acting on the spool without the need to redesign the flow channels or increase production complexity. This study presents classical analytical methods used to calculate flow forces in typical spool valve designs, which serve as a reference point for subsequent investigations. Then, using CFD simulation tools, a method of flow force compensation is demonstrated for selected spool geometries, followed by a detailed comparative analysis of their effectiveness. The results may provide a foundation for developing more energy-efficient and dynamically stable direct-drive servovalve constructions.