Flow control device and method for controlling pressure in fluid flow

Abstract

A flow control device includes a housing forming an inlet passage, an outlet passage, and a fluid passage between the inlet passage and the outlet passage. A magnetization shaft is positioned entirely within the housing between the inlet passage and the outlet passage, and a plurality of vanes are fixed to the magnetization shaft and positioned in the fluid passage. The first wire coil is movably positioned around a first end of the magnetization axis and outside the housing, and is linearly movable in a direction parallel to a longitudinal axis of the magnetization axis.

Description

Technical Field

[0001] The present disclosure relates generally to control devices and, more particularly, to flow control devices for pressure control in fluid flow. Background Art

[0002] In a typical flow control device, such as a control valve, a shaft, valve stem or other structure often extends through the wall of the housing in order to control an internal component, such as a valve plug, in order to control the pressure through the device. Having a structure extending through the housing can provide an external leak path through the housing and require packing to seal the area between the structure and the opening in the housing, which can allow fugitive emissions to escape from a typical flow control device, particularly when used in processes at high temperatures. This is particularly problematic for flow control devices used in hazardous processes, which may allow fugitive emissions of hazardous materials. Additionally, packing friction can lead to problems with actuators being oversized to withstand the forces. Summary of the invention

[0003] According to an exemplary aspect of the invention, a flow control device includes a housing, the housing forming an inlet passage, an outlet passage, and a fluid passage between the inlet passage and the outlet passage. A magnetization axis is completely positioned within the housing and between the inlet passage and the outlet passage, and a plurality of vanes are fixed to the magnetization axis and positioned in the fluid passage. A first wire coil is movably positioned around a first end of the magnetization axis, the first wire coil is located outside the housing and is linearly movable in a direction parallel to a longitudinal axis of the magnetization axis.

[0004] Further according to any one or more of the aforementioned exemplary aspects of the present invention, the flow control device may also include any one or more of the following preferred forms in any combination.

[0005] In one preferred form, the flow control device includes a first radial flange extending around and positioned at the end of the inlet passage and a second radial flange extending around and positioned at the end of the outlet passage.

[0006] In another preferred form, the flow control device includes a first cavity formed in the housing, the first cavity extending from the fluid passage and configured to receive a first end of the magnetized shaft.

[0007] In another preferred form, a first wire coil can be positioned around the first cavity.

[0008] In another preferred form, the flow control device includes a second wire coil movably positioned about a second end of the magnetizing axis, the second wire coil being located outside the housing and being linearly movable in a direction parallel to the longitudinal axis of the magnetizing axis.

[0009] In another preferred form, the flow control device includes a second cavity formed in the housing, the second cavity extending from the fluid passage and configured to receive the second end of the magnetized axis, wherein the second wire coil can be positioned around the second cavity.

[0010] In another preferred form, the flow control device includes a second magnetizing axis that is completely positioned within the housing and between the inlet passage and the outlet passage. A plurality of vanes are secured to the second magnetizing axis, and a second wire coil is movably positioned around a second end of the second magnetizing axis. The second wire coil is located outside the housing and is linearly movable in a direction parallel to the longitudinal axis of the second magnetizing axis.

[0011] According to another exemplary aspect of the present invention, a flow control device includes a housing that forms an inlet passage, an outlet passage, and a fluid passage between the inlet passage and the outlet passage. A shaft is completely positioned within the housing and between the inlet passage and the outlet passage, and a first magnet is fixed to the shaft near a first end of the shaft. A plurality of blades are fixed to the shaft and positioned in the fluid passage. A first wire coil is movably positioned around the first end of the shaft, the first wire coil is located outside the housing, and is capable of linear movement in a direction parallel to the longitudinal axis of the shaft.

[0012] Further according to any one or more of the aforementioned exemplary aspects of the present invention, the flow control device may also include any one or more of the following preferred forms in any combination.

[0013] In one preferred form, the flow control device includes a first radial flange extending around and positioned at the end of the inlet passage and a second radial flange extending around and positioned at the end of the outlet passage.

[0014] In another preferred form, the flow control device includes a first cavity formed in the housing, the first cavity extending from the fluid passage and configured to receive the first end of the shaft.

[0015] In another preferred form, a first wire coil can be positioned around the first cavity.

[0016] In another preferred form, the flow control device includes a second magnet and a second wire coil, the second magnet being fixed to the shaft near a second end of the shaft, the second end of the shaft being opposite to the first end of the shaft, and the second wire coil being movably positioned around the second end of the shaft. The second wire coil is located outside the housing and is linearly movable in a direction parallel to the longitudinal axis of the shaft.

[0017] In another preferred form, the flow control device includes a second cavity formed in the housing, the second cavity extending from the fluid passageway and configured to receive the second end of the shaft, wherein the second wire coil is positionable about the second cavity.

[0018] In another preferred form, the flow control device includes a second shaft that is completely positioned within the housing and between the inlet passage and the outlet passage. A plurality of vanes are secured to the second shaft. A second magnet is secured to the second shaft near a second end of the second shaft, and a second wire coil is movably positioned around the second end of the second shaft, the second wire coil being located outside the housing and capable of linear movement in a direction parallel to a longitudinal axis of the second shaft.

[0019] According to another exemplary aspect of the present invention, a method for controlling pressure in a fluid flow includes: positioning a shaft completely within a housing, the housing forming an inlet passage, an outlet passage, and a fluid channel between the inlet passage and the outlet passage; fixing a plurality of blades to the shaft and positioning the plurality of blades in the fluid channel; positioning a first wire coil to surround a first end of the shaft, the first wire coil being located outside the housing and being capable of linear movement in a direction parallel to a longitudinal axis of the shaft; positioning the housing in a path of fluid flow; and moving the first wire coil relative to the first end of the shaft to control pressure in the fluid flow.

[0020] Further according to any one or more of the aforementioned exemplary aspects of the present invention, the method may also include any one or more of the following preferred forms in any combination.

[0021] In one preferred form, the shaft is magnetized.

[0022] In another preferred form, the method includes securing a magnet proximate the first end of the shaft.

[0023] In another preferred form, the method includes positioning a second wire coil around a second end of the shaft, the second wire coil being located outside the housing and being capable of linear movement in a direction parallel to the longitudinal axis of the shaft, and moving the second wire coil relative to the second end of the shaft to control pressure in the fluid flow.

[0024] In another preferred form, the method includes: positioning a second shaft completely within the housing, securing a plurality of blades to the second shaft; positioning a second wire coil around a second end of the second shaft, the second wire coil being located outside the housing and being capable of linear movement in a direction parallel to a longitudinal axis of the second shaft; and moving the second wire coil relative to the second end of the second shaft to control pressure in the fluid flow.

[0025] In another preferred form, the second shaft is magnetized, or a second magnet is secured near the second end of the second shaft. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 showing a perspective view of a first exemplary flow control device;

[0027] Figure 2 Shown along Figure 1 Line 2-2 in the plot Figure 1 A cross-sectional view of a flow control device;

[0028] Figure 3 Shown along Figure 1 Line 3-3 in the plot Figure 1 A cross-sectional view of a flow control device;

[0029] Figure 4 showing a perspective view of a second exemplary flow control device;

[0030] Figure 5 Shown along Figure 4 Line 5-5 is drawn in Figure 4 A cross-sectional view of a flow control device;

[0031] Figure 6 Shown along Figure 4 Line 6-6 in the plot Figure 4 A cross-sectional view of a flow control device;

[0032] Figure 7 showing a perspective view of a third exemplary flow control device;

[0033] Figure 8 Shown along Figure 7 Line 8-8 in the plot Figure 7 A cross-sectional view of a flow control device;

[0034] Fig. 9 Shown along Figure 7 Line 9-9 is drawn in Figure 7 A cross-sectional view of a flow control device;

[0035] Fig.10 showing a perspective view of a fourth exemplary flow control device;

[0036] Fig.11 Shown along Fig.10 The line 11-11 in the Fig.10 A cross-sectional view of a flow control device;

[0037] Fig.12 Shown along Fig.10 The line 12-12 in the Fig.10 A cross-sectional view of a flow control device; and

[0038] Fig.13 A flow chart showing an exemplary method of pressure control in a fluid flow is shown. DETAILED DESCRIPTION

[0039] Examples disclosed herein relate to flow control devices and methods of using flow control devices for pressure control in fluid flow. The exemplary flow control devices disclosed herein include a magnetic shaft and blades (rotor) completely located within a housing and a wire coil (stator) located outside the housing, the wire coil using magnetic induction to resist the rotation of the shaft and blades to control the pressure drop through the flow control device. The use of a shaft and blades completely located within the housing and a wire coil outside the housing provides a sealed device with no external leakage paths and no emissions. Unlike a typical control valve, because there is no shaft, valve stem or other structure extending through the housing to control internal components, the exemplary flow control device is controlled externally and does not require packing, thereby eliminating fugitive emissions that would be discharged from a typical pressure control device.

[0040] The exemplary flow control devices disclosed herein can also be used to generate electricity to charge or power other devices by converting energy from the process flow via the shaft and blades and magnetic induction. The energy generated can be monitored and collected, thereby reducing the carbon footprint.

[0041] The example flow control devices disclosed herein may also be used as flow measurement devices by correlating pulses emitted on the shaft captured by the wire coil.

[0042] The exemplary flow control devices disclosed herein can also potentially be used to diagnose bearing wear and failure. By first calibrating the resistance provided by the flow control device under a certain fluid flow, and then monitoring the resistance over time, it is possible to estimate when a bearing is worn or fails.

[0043] Reference Figure 1-3, the first exemplary flow control device 100 includes a housing 102 that forms an inlet passage 104, an outlet passage 108, and a fluid passage 112 between the inlet passage 104 and the outlet passage 108. A first radial flange 106 may extend around and be positioned at an end of the inlet passage 104, and a second radial flange 110 may extend around and be positioned at an end of the outlet passage 108 to allow the flow control device 100 to be installed in a fluid system and maintain a face-to-face requirement, so that the flow control device 100 can be retrofitted to replace an existing pressure control valve.

[0044] The shaft 118 is completely positioned within the housing 102 and between the inlet passage 104 and the outlet passage 108, such that no portion of the shaft 118 extends outside the housing 102. As shown, the shaft 118 can have at least one first magnet 122 fixed to the shaft 118 near the first end 120 of the shaft 118, forming a rotor. Alternatively, the shaft 118 itself can be magnetized, rather than having magnets fixed to the shaft, thereby eliminating the need for the first magnet 122. A first cavity 114 is formed in the housing 102 and extends outwardly from the fluid passage 112, and a second cavity 116 is formed in the housing 102, opposite the first cavity 114, and extending outwardly from the fluid passage 112. The first end 120 of the shaft 118 is received in the first cavity 114, and the second end 124 of the shaft 118 is received in the second cavity 116. One or more bearings, O-rings or other seals 150 may be positioned around the first end 120 and the second end 124 of the shaft 118 to support the shaft 118 in the first cavity 114 and the second cavity 116 and allow the shaft 118 to rotate in the first cavity 114 and the second cavity 116. Disposing the shaft 118 completely within the housing 102 forms a sealed device with no external leakage paths and therefore no emissions. In addition, since there is no shaft, valve stem or other structure extending through the housing 102 or extending outside the housing 102 to control any internal components, packing is not required.

[0045] A plurality of blades 140 are fixed to and extend radially from the shaft 118 and are disposed in the fluid passage 112 to form a paddle wheel or turbine. The blades 140 may have a variety of shapes and / or sizes that will allow the fluid flowing through the housing 102 to engage with the blades 140 and provide a force against the blades 140 to rotate the shaft 118. Efficiency gains may also be achieved by varying the size / shape of the blades 140 and / or the size / shape of the housing 102 (e.g., angle body, Y body, etc.). The blades 140 may be fixed to the shaft 118 in any desired manner, such as bolting the blades 140 to the shaft 118, welding the blades 140 to the shaft 118, press fitting the blades 140 into the shaft 118, installing the blades 140 into machined grooves of the shaft 118, inserting a rod into the shaft 118 and attaching the blades 140 to the rod, etc. The blades 140 may be secured to the shaft 118 after the shaft 118 has been disposed within the housing 102, or the blades 140 may be secured to the shaft 118 outside the housing 102 and the shaft 118 and blades 140 disposed as a unit within the housing 102. Alternatively, the blades 140 and shaft 118 may be a single, unitary, unitary structure (e.g., the blades 140 and shaft 118 may be machined or 3D printed as a single unit), rather than securing individual blades to the shaft.

[0046] A first wire coil 142 is disposed around the first end 120 of the shaft 118 and, in the example shown, around the first magnet 122, forming a stator. The first wire coil 142 is located outside of the housing 102 so that it is positioned around the first cavity 114 and can move linearly in a direction parallel to the longitudinal axis 128 of the shaft 118. The first wire coil 142 can be a single wire coil or can include multiple coils mounted in series in a cylindrical pattern. As shown, the first wire coil 142 can be wound around and mounted on a generally cylindrical non-magnetic armature 144, which can be connected to an actuator (e.g., and electric or pneumatic actuator) (not shown) to cause the armature 144 and therefore the first wire coil 142 to move linearly back and forth along the longitudinal axis 128 of the shaft 118.

[0047] As the fluid flows through the flow control device 100, the fluid engages the plurality of vanes 140 and causes the shaft 118 to rotate. Moving the first wire coil 142 over the shaft 118 and the first magnet 122 (if used) generates an electric current in the first wire coil 142 and generates electromagnetic induction, which slows the rotation of the shaft 118 and increases the pressure drop in the flow control device 100. The first wire coil 142 can be moved toward the housing 102, which will cause more of the shaft 118 (and the first magnet 122) to be covered by the first wire coil 142, thereby increasing the induced magnetic field, increasing the resistance to fluid flow, and increasing the pressure drop. Conversely, the first wire coil 142 can also be moved away from the housing 102, which will cause less of the shaft 118 (and the first magnet 122) to be covered by the first wire coil 142, thereby reducing the induced magnetic field, reducing the resistance to fluid flow, and reducing the pressure drop. Therefore, by positioning the first wire coil 142 above the first end 120 of the shaft 118 (and the first magnet 122), the pressure drop generated by the flow control device 100 can be controlled.

[0048] Reference Figure 4-6 , the second exemplary flow control device 200 includes a housing 202 that forms an inlet passage 204, an outlet passage 208, and a fluid passage 212 between the inlet passage 204 and the outlet passage 208. A first radial flange 206 may extend around and be positioned at an end of the inlet passage 204, and a second radial flange 210 may extend around and be positioned at an end of the outlet passage 208 to allow the flow control device 200 to be installed in a fluid system and maintain a face-to-face requirement, so that the flow control device 200 can be retrofitted to replace an existing pressure control valve.

[0049] The shaft 218 and the second shaft 230 are coaxially aligned and completely positioned within the housing 202 and between the inlet passage 204 and the outlet passage 208 so that no portion of the shaft 218 or the second shaft 230 extends outside the housing 202. As shown, the shaft 218 can have at least one first magnet 222 fixed to the shaft 218 near the first end 220 of the shaft 218, forming a rotor. Alternatively, the shaft 218 itself can be magnetized instead of fixing a magnet to the shaft, thereby eliminating the need for the first magnet 222. A first cavity 214 is formed in the housing 202 and extends outwardly from the fluid passage 212, and a second cavity 216 is formed in the housing 202, opposite the first cavity 214, and extending outwardly from the fluid passage 212. The first end 220 of the shaft 218 is received in the first cavity 214, and the second end 234 of the second shaft 230 is received in the second cavity 216. One or more bearings, O-rings or other seals 250 may be positioned around the first end 220 of the shaft 218 and the second end 234 of the second shaft 230 to support the shaft 218 in the first cavity 214, support the second shaft 230 in the second cavity 216, and allow the shaft 218 to rotate in the first cavity 214 and the second shaft 230 to rotate in the second cavity 216. Disposing the shaft 218 and the second shaft 230 completely within the housing 202 forms a sealed device with no external leakage paths and therefore no emissions. In addition, since there are no shafts, valve stems, or other structures extending through the housing 202 or extending outside the housing 202 to control any internal components, packing is not required.

[0050] A plurality of blades 240 are fixed to and radially extend from the shaft 218 and the second shaft 230, positioned in the fluid passage 212 to form a paddle wheel or turbine. The blades 240 can have a variety of shapes and / or sizes that will allow the fluid flowing through the housing 202 to engage with the blades 240 and provide a force against the blades 240 to rotate the shaft 218 and the second shaft 230. Efficiency gains can also be achieved by varying the size / shape of the blades 240 and / or the size / shape of the housing 202 (e.g., angled, Y-shaped, etc.). The blades 240 may be secured to the shaft 218 and the second shaft 230 in any desired manner, such as bolting the blades 240 to the shaft 218 and the second shaft 230, welding the blades 240 to the shaft 218 and the second shaft 230, press-fitting the blades 240 to the shaft 218 and the second shaft 230, installing the blades 240 into machined grooves of the shaft 218 and the second shaft 230, inserting a rod into the shaft 218 and the second shaft 230 and attaching the blades 240 to the rod, etc. The blades 240 may be secured to the shaft 218 and the second shaft 230 after the shaft 218 and the second shaft 230 have been positioned within the housing 202, or the blades 240 may be secured to the shaft 218 and the second shaft 230 outside the housing 202, and the shaft 218, the second shaft 230, and the blades 240 are positioned within the housing 202 as a unit. Alternatively, the blade 240, shaft 218, and second shaft 230 may be a single, unitary, unitary structure (eg, the blade 240, shaft 218, and second shaft 230 may be machined or 3D printed as a single unit), rather than having separate blades secured to the shaft.

[0051] The first wire coil 242 is positioned around the first end 220 of the shaft 218 and, in the example shown, around the first magnet 222, forming a stator. The first wire coil 242 is located outside the housing 202 so that it is positioned around the first cavity 214 and can move linearly in a direction parallel to the longitudinal axis 228 of the shaft 218 and the longitudinal axis 238 of the second shaft 230. The first wire coil 242 can be a single wire coil or can include multiple coils mounted in series in a cylindrical pattern. As shown, the first wire coil 242 can be wound and mounted on a generally cylindrical non-magnetic armature 244, which can be connected to an actuator (e.g., an electric or pneumatic actuator) (not shown) to cause the armature 244 and therefore the first wire coil 242 to move linearly back and forth along the longitudinal axis 228 of the shaft 218.

[0052] As the fluid flows through the flow control device 200, the fluid engages the plurality of vanes 240 and causes the shaft 218 and the second shaft 230 to rotate. The first wire coil 242 is moved over the shaft 218 and the first magnet 222 (if used), generating a current in the first wire coil 242 and creating electromagnetic induction, which slows the rotation of the shaft 218 and increases the pressure drop in the flow control device 200. The first wire coil 242 can be moved toward the housing 202, which will cause more of the shaft 218 (and the first magnet 222) to be covered by the first wire coil 242, thereby increasing the induced magnetic field, increasing the resistance to fluid flow, and increasing the pressure drop. Conversely, the first wire coil 242 can also be moved away from the housing 202, which will cause less of the shaft 218 (and the first magnet 222) to be covered by the first wire coil 242, thereby reducing the induced magnetic field, reducing the resistance to fluid flow, and reducing the pressure drop. Thus, by positioning the first wire coil 242 above the first end 220 of the shaft 218 (and the first magnet 222), the pressure drop generated by the flow control device 200 may be controlled.

[0053] refer to Figure 7-9 , the third exemplary flow control device 300 includes a housing 302 that forms an inlet passage 304, an outlet passage 308, and a fluid passage 312 between the inlet passage 304 and the outlet passage 308. A first radial flange 306 may extend around and be positioned at an end of the inlet passage 304, and a second radial flange 310 may extend around and be positioned at an end of the outlet passage 308 to allow the flow control device 300 to be installed in a fluid system and maintain a face-to-face requirement, so that the flow control device 300 can be retrofitted to replace an existing pressure control valve.

[0054] The shaft 318 is positioned entirely within the housing 302 and between the inlet passage 304 and the outlet passage 308 such that no portion of the shaft 318 extends outside of the housing 302. As shown, the shaft 318 can have at least one first magnet 322 fixed to the shaft 318 near a first end 320 of the shaft 318 and at least one second magnet 326 fixed to the shaft 318 near a second end 324 of the shaft 318 opposite the first end 320, forming a rotor. Alternatively, the shaft 318 itself can be magnetized, rather than having magnets fixed to the shaft, thereby eliminating the need for the first magnet 322 and the second magnet 326. The first cavity 314 is formed in the housing 302 and extends outwardly from the fluid passage 312, and the second cavity 316 is formed in the housing 302, opposite the first cavity 314, and extends outwardly from the fluid passage 312. The first end 320 of the shaft 318 is received in the first cavity 314, and the second end 324 of the shaft 318 is received in the second cavity 316. One or more bearings, O-rings or other seals 350 may be positioned around the first end 320 and the second end 324 of the shaft 318 to support the shaft 318 in the first cavity 314 and the second cavity 316 and allow the shaft 318 to rotate within the first cavity 314 and the second cavity 316. Disposing the shaft 318 completely within the housing 302 forms a sealed device with no external leakage paths and therefore no emissions. In addition, since there is no shaft, valve stem or other structure extending through the housing 302 or extending outside the housing 302 to control any internal components, packing is not required.

[0055] A plurality of blades 340 are secured to and extend radially from the shaft 318, positioned in the fluid passage 312 to form a paddle wheel or turbine. The blades 340 may have a variety of shapes and / or sizes, which allow the fluid flowing through the housing 302 to engage the blades 340 and provide a force against the blades 340 to rotate the shaft 318. Efficiency gains may also be achieved by varying the size / shape of the blades 340 and / or the size / shape of the housing 302 (e.g., angled, Y-shaped, etc.). The blades 340 may be secured to the shaft 318 in any desired manner, such as bolting the blades 340 to the shaft 318, welding the blades 340 to the shaft 318, press-fitting the blades 340 to the shaft 318, installing the blades 340 into machined grooves in the shaft 318, threading a rod through the shaft 318 and attaching the blades 340 to the rod, etc. The blades 340 may be secured to the shaft 318 after the shaft 318 has been positioned within the housing 302, or the blades 340 may be secured to the shaft 318 outside the housing 302 and the shaft 318 and blades 340 are positioned as a unit within the housing 302. Alternatively, the blades 340 and shaft 318 may be a single, unitary, unitary structure (e.g., the blades 340 and shaft 318 may be machined or 3D printed as a single unit), rather than securing individual blades to the shaft.

[0056] The first wire coil 342 is positioned around the first end 320 of the shaft 318 (and around the first magnet 322 in the example shown), and the second wire coil 346 is positioned around the second end 324 of the shaft 318 (and around the second magnet 326 in the example described), forming a stator. The first wire coil 342 and the second wire coil 346 are located outside the housing 302 so that the first wire coil 342 is positioned around the first cavity 314 and can move linearly in a direction parallel to the longitudinal axis 328 of the shaft 318, and the second wire coil 346 is positioned around the second cavity 316 and can move linearly in a direction parallel to the longitudinal axis 328. The first wire coil 342 and the second wire coil 346 can each be a single wire coil, or can include multiple coils mounted in series in a cylindrical pattern. As shown, the first wire coil 342 can be wound and mounted on a generally cylindrical non-magnetic armature 344, and the second wire coil 346 can be wound and mounted on a generally cylindrical non-magnetic second armature 348. The armature 344 and the second armature 348 can be connected to respective actuators or a common actuator (e.g., one or more electric or pneumatic actuators) (not shown) to cause the armature 344 and the second armature 348 and thus the first wire coil 342 and the second wire coil 346 to move linearly back and forth along the longitudinal axis 328 of the shaft 318.

[0057] As the fluid flows through the flow control device 300, the fluid engages the plurality of vanes 340 and causes the shaft 318 to rotate. Moving the first wire coil 342 over the first end 320 of the shaft 318 and the first magnet 322 (if used), and moving the second wire coil 346 over the second end 324 of the shaft 318 and the second magnet 326 (if used), generates current in the first wire coil 342 and the second wire coil 346, and generates electromagnetic induction, which slows the rotation of the shaft 318 and increases the pressure drop in the flow control device 300. The first wire coil 342 and the second wire coil 346 can move toward the housing 302, which will cause more of the first end 320 of the shaft 318 (and the first magnet 322) to be covered by the first wire coil 342, and more of the second end 324 of the shaft 318 (and the second magnet 326) to be covered by the second wire coil 346, thereby increasing the induced magnetic field, increasing the resistance to fluid flow, and increasing the pressure drop. Conversely, the first and second wire coils 342, 346 may also be moved away from the housing 302, which would result in less of the first end 320 of the shaft 318 (and the first magnet 322) being covered by the first wire coil 342 and less of the second end 324 of the shaft 318 (and the second magnet 326) being covered by the second wire coil 346, thereby reducing the induced magnetic field, lowering the resistance to fluid flow, and reducing the pressure drop. Thus, by positioning the first wire coil 342 above the first end 320 of the shaft 318 (and the first magnet 322) and positioning the second wire coil 346 above the second end 324 of the shaft 318 (and the second magnet 326), the pressure drop generated by the flow control device 300 may be controlled. As shown in the flow control devices 100 and 200, the use of multiple individual wire coils (stators) each interacting with an opposite end of the shaft may provide greater resistance to fluid flow, utilize more energy, and allow for a greater pressure drop through the flow control device 300 than using a single wire coil positioned around one end of the shaft.

[0058] Reference Figure 10-12 , the fourth exemplary flow control device 400 includes a housing 402 that forms an inlet passage 404, an outlet passage 408, and a fluid passage 412 between the inlet passage 404 and the outlet passage 408. A first radial flange 406 may extend around and be positioned at an end of the inlet passage 404, and a second radial flange 410 may extend around and be positioned at an end of the outlet passage 408 to allow the flow control device 400 to be installed in a fluid system and maintain a face-to-face requirement, thereby allowing the flow control device 400 to be retrofitted to replace an existing pressure control valve.

[0059] The shaft 418 and the second shaft 430 are coaxially aligned and positioned completely within the housing 402 and between the inlet passage 404 and the outlet passage 408, such that no portion of the shaft 418 or the second shaft 430 extends outside the housing 402. As shown, the shaft 418 can have at least one first magnet 422 fixed to the shaft 418 near the first end 420 of the shaft 418, and the second shaft 430 can have at least one second magnet 436 fixed to the second shaft 430 near the second end 434 of the second shaft 430, forming a rotor. Alternatively, the shafts 418 and the second shafts 430 can themselves be magnetized, rather than having magnets fixed to the shafts, thereby eliminating the need for the first magnet 422 and the second magnet 436. A first cavity 414 is formed in the housing 402 and extends outwardly from the fluid passage 412, and a second cavity 416 is formed in the housing 402 opposite the first cavity 414 and extends outwardly from the fluid passage 412. A first end 420 of a shaft 418 is received in the first cavity 414, and a second end 434 of a second shaft 430 is received in the second cavity 416. One or more bearings, O-rings, or other seals 450 may be positioned around the first end 420 of the shaft 418 and the second end 434 of the second shaft 430 to support the shaft 418 in the first cavity 414 and the second shaft 430 in the second cavity 416, and to allow the shaft 418 to rotate in the first cavity 414 and the second shaft 430 to rotate in the second cavity 416. Disposing the shaft 418 and the second shaft 430 completely within the housing 402 forms a sealed device with no external leak paths and therefore no emissions. Furthermore, since there is no shaft, valve stem, or other structure extending through or outside of housing 402 to control any internal components, packing is not required.

[0060] A plurality of blades 440 are fixed to and extend radially along the shaft 418 and the second shaft 430 and are disposed in the fluid passage 412 to form a paddle wheel or turbine. The blades 440 may have a variety of shapes and / or sizes so that the fluid flowing through the housing 402 engages with the blades 440 and generates a force on the blades 440 to rotate the shaft 418 and the second shaft 430. Efficiency gains may also be achieved by varying the size / shape of the blades 440 and / or the size / shape of the housing 402 (e.g., angled, Y-shaped, etc.). The blades 440 may be secured to the shaft 418 and the second shaft 430 in any desired manner, such as bolting the blades 440 to the shaft 418 and the second shaft 430, welding the blades 440 to the shaft 418 and the second shaft 430, press-fitting the blades 440 into the shaft 418 and the second shaft 430, installing the blades 440 into machined grooves of the shaft 418 and the second shaft 430, inserting a rod into the shaft 418 and the second shaft 430 and attaching the blades 440 to the rod, etc. The blades 440 may be secured to the shaft 418 and the second shaft 430 after the shaft 418 and the second shaft 430 have been positioned within the housing 402, or the blades 440 may be secured to the shaft 418 and the second shaft 430 outside the housing 402, and the shaft 418, the second shaft 430, and the blades 440 are positioned within the housing 402 as a unit. Alternatively, the blade 440, shaft 418, and second shaft 430 may be a single, unitary, unitary structure (eg, the blade 440, shaft 418, and second shaft 430 may be machined or 3D printed as a single unit), rather than having separate blades secured to the shaft.

[0061] The first wire coil 442 is positioned around the first end 420 of the shaft 418 (and around the first magnet 422 in the example shown), and the second wire coil 446 is positioned around the second end 434 of the second shaft 430 (and around the second magnet 436 in this example), forming a stator. The first wire coil 442 and the second wire coil 446 are located outside the housing 402 so that the first wire coil 442 is positioned around the first cavity 414 and can move linearly in a direction parallel to the longitudinal axis 428 of the shaft 418, and the second wire coil 444 is positioned around the second cavity 416 and can move linearly in a direction parallel to the longitudinal axis 428 and the longitudinal axis 438 of the second shaft 430. The first wire coil 442 and the second wire coil 446 can each be a single wire coil, or can include multiple coils mounted in series in a cylindrical pattern. As shown, a first coil of wire 442 may be wound around and mounted to a generally cylindrical, non-magnetic armature 444, and a second coil of wire 446 may be wound around and mounted to a generally cylindrical, non-magnetic second armature 448. The armature 444 and the second armature 448 may be connected to respective actuators or a common actuator (e.g., one or more electric or pneumatic actuators) (not shown) to linearly move the armature 444 and the second armature 448, and thus the first coil of wire 442 and the second coil of wire 446, back and forth along the longitudinal axis 428 of the shaft 418 and the longitudinal axis 438 of the second shaft 430.

[0062] As the fluid flows through the flow control device 400, the fluid engages the plurality of vanes 440 and causes the shaft 418 and the second shaft 430 to rotate. Moving the first wire coil 442 over the first end 420 of the shaft 418 and the first magnet 422 (if used), and moving the second wire coil 446 over the second end 434 of the second shaft 430 and the second magnet 436 (if used), generates current in the first wire coil 442 and the second wire coil 446, and generates electromagnetic induction, which slows the rotation of the shaft 418 and the second shaft 430 and increases the pressure drop in the flow control device 400. The first wire coil 442 and the second wire coil 446 can move toward the housing 402, which will cause more of the first end 420 of the shaft 418 (and the first magnet 422) to be covered by the first wire coil 442, and more of the second end 434 of the second shaft 430 (and the second magnet 436) to be covered by the second wire coil 446, thereby increasing the induced magnetic field, increasing the resistance to fluid flow, and increasing the pressure drop. Conversely, the first wire coil 442 and the second wire coil 446 may also be moved away from the housing 402, which will result in less of the first end 420 of the shaft 418 (and the first magnet 422) being covered by the first wire coil 442 and less of the second end 434 of the second shaft 430 (and the second magnet 436) being covered by the second wire coil 446, thereby reducing the induced magnetic field, reducing fluid flow resistance, and reducing pressure drop. Therefore, by positioning the first wire coil 442 above the first end 420 of the shaft 418 (and the first magnet 422) and positioning the second wire coil 446 above the second end 434 of the second shaft 430 (and the second magnet 436), the pressure drop generated by the flow control device 400 can be controlled. As shown in the flow control devices 100 and 200, the use of multiple separate wire coils (stators) each interacting with a separate shaft can provide greater resistance to fluid flow, utilize more energy, and allow for a greater pressure drop through the flow control device 400 than using a single wire coil positioned around one end of the shaft.

[0063] refer to Fig.13 , a method of pressure control in a fluid flow (eg, using flow control apparatus 100, 200, 300, 400) is shown.

[0064] At step 500, a shaft (e.g., shaft 118, 218, 318, 418) is completely positioned within a housing (e.g., housing 102, 202, 302, 402). The shaft can have a magnet (e.g., first magnet 122, 222, 322, 422) fixed near a first end of the shaft (e.g., first end 120, 220, 320, 420), or the shaft itself can be magnetized. If the shaft itself is not magnetized, if a fluid control device having a shaft and two wire coils (e.g., fluid control device 300) is used, the shaft can also have a second magnet (e.g., second magnet 326) fixed near a second end of the shaft (e.g., second end 324).

[0065] In step 502, a plurality of blades (e.g., blades 140, 240, 340, 440) are positioned in a fluid passage (e.g., fluid passage 112, 212, 312, 412) of a housing and secured to a shaft. If a fluid control device (e.g., fluid control device 200, 400) having two shafts (e.g., second shaft 230, 430) is used, the plurality of blades are also secured to the second shaft. The plurality of blades may be secured to the one or more shafts after the one or more shafts have been positioned within the housing, or the plurality of blades may be secured to the one or more shafts outside the housing, and the one or more shafts and blades are positioned within the housing as a unit. Optionally, the blades and shaft may be a single, unitary, unitary structure (e.g., the blades and shaft may be machined or 3D printed as a single unit as a whole), rather than securing individual blades to the shaft.

[0066] At step 504, a first wire coil (e.g., first wire coil 142, 242, 342, 442) is positioned around a first end of the shaft (e.g., first end 120, 220, 320, 420) such that the first wire coil is outside the housing and is linearly movable in a direction parallel to the longitudinal axis of the shaft (e.g., longitudinal axis 128, 228, 328, 428). If a fluid control device (e.g., fluid control device 300) having two wire coils (e.g., first wire coil 342 and second wire coil 346) is used, a second wire coil (e.g., second wire coil 346) is positioned around a second end of the shaft (e.g., second end 324) such that the second wire coil is outside the housing and is linearly movable in a direction parallel to the longitudinal axis of the shaft. If a fluid control device (e.g., fluid control device 400) having two axes (e.g., axis 418 and second axis 430) and two wire coils (e.g., first wire coil 442 and second wire coil 446) is used, the second wire coil (e.g., second wire coil 446) is positioned around a second end (e.g., second end 434) of the second axis (e.g., second axis 430) such that the second wire coil is outside the housing and can move linearly in a direction parallel to a longitudinal axis (e.g., longitudinal axis 438) of the second axis.

[0067] The housing of the flow control device is then placed in the path of the fluid flow at step 506. For example, the housing can be secured between two existing pipes or other structures via a first flange (e.g., first radial flange 106, 206, 306, 406) and a second flange (e.g., second radial flange 110, 210, 310, 410) on the housing.

[0068] Once the housing has been positioned in the path of the fluid flow, pressure in the fluid flow may be controlled by moving the first wire coil relative to the end of the shaft to control the resistance provided by the blades, thereby controlling the pressure of the fluid flowing through the flow control device, at step 508. If a second wire coil is also used, the second wire coil may also be moved relative to the second end of the shaft (or second shaft) to further help control the resistance provided by the blades, thereby controlling the pressure of the fluid flowing through the fluid control device.

[0069] The drawings and descriptions provided herein depict and describe preferred embodiments for illustrative purposes only. Those skilled in the art will readily recognize from the above discussion that alternative embodiments of the components shown herein may be adopted without departing from the principles described herein. Therefore, after reading this disclosure, those skilled in the art will understand that there are other optional structural and functional designs. Therefore, although specific embodiments and applications have been shown and described, it should be understood that the disclosed embodiments are not limited to the precise structures and components disclosed herein. It will be apparent to those skilled in the art that various modifications, changes and variations may be made to the arrangement, operation and details of the methods and components disclosed herein without departing from the spirit and scope defined in the appended claims.

Claims

1. A flow control device comprising: a housing forming an inlet passage, an outlet passage, and a fluid passage between the inlet passage and the outlet passage; a magnetization axis positioned completely within the housing and between the inlet passage and the outlet passage; a plurality of vanes fixed to the magnetized shaft and positioned in the fluid passage; as well as A first wire coil is movably positioned around a first end of the magnetizing axis, the first wire coil being located outside of the housing and being linearly movable in a direction parallel to a longitudinal axis of the magnetizing axis.

2. The flow control device according to claim 1 comprises a first radial flange and a second radial flange, wherein the first radial flange extends around the end of the inlet passage and is positioned at the end of the inlet passage, and the second radial flange extends around the end of the outlet passage and is positioned at the end of the outlet passage. 3 . The flow control device of claim 1 , comprising a first cavity formed in the housing, the first cavity extending from the fluid passage and configured to receive the first end of the magnetized axis.

4. The flow control device according to claim 3, wherein: The first wire coil can be positioned around the first cavity.

5. The flow control device of claim 1 , comprising a second wire coil movably positioned around a second end of the magnetizing axis, the second wire coil being located outside the housing and capable of linear movement in a direction parallel to the longitudinal axis of the magnetizing axis.

6. The flow control device of claim 5, comprising a second cavity formed in the housing, the second cavity extending from the fluid passage and configured to receive the second end of the magnetized axis, wherein The second wire coil can be positioned around the second cavity.

7. The flow control device according to claim 1, comprising: a second magnetizing axis positioned completely within the housing and between the inlet passage and the outlet passage, wherein the plurality of vanes are secured to the second magnetizing axis; and A second wire coil is movably positioned about a second end of the second magnetizing axis, the second wire coil being located outside the housing and being linearly movable in a direction parallel to the longitudinal axis of the second magnetizing axis.

8. A flow control device comprising: a housing, the housing forming an inlet passage, an outlet passage, and a fluid passage between the inlet passage and the outlet passage; a shaft positioned completely within the housing and between the inlet passage and the outlet passage; a first magnet secured to the shaft proximate a first end of the shaft; a plurality of blades secured to the shaft and positioned in the fluid passage; as well as A first wire coil is movably positioned about the first end of the shaft, the first wire coil being located outside of the housing and being linearly movable in a direction parallel to a longitudinal axis of the shaft.

9. A flow control device according to claim 8, comprising a first radial flange and a second radial flange, wherein the first radial flange extends around the end of the inlet passage and is positioned at the end of the inlet passage, and the second radial flange extends around the end of the outlet passage and is positioned at the end of the outlet passage.

10. The flow control device of claim 8, comprising a first cavity formed in the housing, the first cavity extending from the fluid passage and configured to receive the first end of the shaft.

11. The flow control device of claim 10, wherein: The first wire coil can be positioned around the first cavity.

12. The flow control device of claim 8, comprising a second magnet and a second wire coil, wherein the second magnet is fixed to the shaft near the second end of the shaft, the second end of the shaft being opposite to the first end of the shaft, the second wire coil being movably positioned around the second end of the shaft, the second wire coil being located outside the housing and capable of linear movement in a direction parallel to the longitudinal axis of the shaft.

13. The flow control device of claim 12, comprising a second cavity formed in the housing, the second cavity extending from the fluid passage and configured to receive the second end of the shaft, wherein: The second wire coil can be positioned around the second cavity.

14. The flow control device of claim 8, comprising: a second shaft positioned completely within the housing and between the inlet passage and the outlet passage, wherein the plurality of vanes are secured to the second shaft; a second magnet secured to the second shaft proximate a second end of the second shaft; and A second wire coil is movably positioned about the second end of the second shaft, the second wire coil being located outside of the housing and being linearly movable in a direction parallel to the longitudinal axis of the second shaft.

15. A method for controlling pressure in fluid flow, comprising: positioning the shaft completely within a housing, the housing defining an inlet passage, an outlet passage, and a fluid passage between the inlet passage and the outlet passage; securing a plurality of blades to the shaft and positioning the plurality of blades in the fluid passage; positioning a first wire coil about a first end of the shaft, the first wire coil being located outside of the housing and being linearly movable in a direction parallel to a longitudinal axis of the shaft; positioning the housing in a path of flow of the fluid; as well as The first coil of wire is moved relative to the first end of the shaft to control the pressure in the fluid flow.

16. The method according to claim 15, wherein: The shaft is magnetized.

17. The method of claim 15, comprising securing a magnet proximate the first end of the shaft.

18. The method of claim 15, comprising positioning a second wire coil around the second end of the shaft, the second wire coil being located outside the housing and capable of linear movement in a direction parallel to the longitudinal axis of the shaft, and moving the second wire coil relative to the second end of the shaft to control the pressure of the fluid flow.

19. The method according to claim 15, comprising: positioning the second shaft completely within the housing; securing the plurality of blades to the second shaft; positioning a second wire coil about the second end of the second shaft, the second wire coil being located outside the housing and being linearly movable in a direction parallel to the longitudinal axis of the second shaft; as well as The second coil of wire is moved relative to the second end of the second shaft to control the pressure in the fluid flow.

20. The method according to claim 19, wherein: The second shaft is magnetized, or a second magnet is fixed near the second end of the second shaft.

Images