High flow miniature proportional control valve with linear moving magnetic voice coil motor

A method of calibrating a proportional valve comprising the steps of:

• providing an actuator, wherein the actuator comprises an actuator housing that houses:
• a first magnet element and a second magnet element;
• a non-magnetic carrier in which the first magnet element and the second magnet element are mounted;
• a first wire coil located adjacent to the magnet elements and a second wire coil located adjacent to the second magnet elements on an opposite side of the magnet elements relative to the first wire coil;
• a first spring beam to which the non-magnetic carrier is suspended, the first spring beam being positioned adjacent to the first magnet element, and a second spring beam to which the non-magnetic carrier is suspended, the second spring beam being positioned adjacent to the second magnet element;
• and a flux frame that conducts magnetic field lines through the actuator;
• providing a valve assembly comprising a valve body defining an inlet and an outlet for a fluid flow through the valve body and a valve operator having a longitudinal axis and including a poppet that is moveable along the longitudinal axis between a closed position and an open position, wherein in the closed position the poppet seals against a valve seat of the valve body to prevent fluid flow between the inlet and the outlet, and in the open position the poppet is moved away from the valve seat to permit fluid flow between the inlet and the outlet;
• the valve operator further comprises an inlet diaphragm adjacent to the inlet and an outlet diaphragm adjacent to the outlet;
• setting the actuator housing relative to the valve body to position the actuator housing relative to the valve body with a preload on the spring beams to achieve desired flow and leak performance, the first and second spring beams being connected to the non-magnetic carrier to control the actuator response to the magnetic field by restraining the movement of the non-magnetic carrier to an arc of sufficient radius that said movement is quasi-linear;
• and
• positioning components of the actuator within the actuator housing in a manner that maintains the preload at which the desired flow and leak performance are achieved.