Modular system and method for manufacturing a valve, assembly and valve

Abstract

The invention relates to a modular system having an assembly for manufacturing valves of two different valve types, comprising a valve base unit having a housing, an actuator base and a piston / spindle unit, where the piston is displaceable in the housing. An end face of the piston and an end face of the actuator base opposite the end face of the piston define a pressure chamber. The actuator base and the housing define a dead chamber on a side of the actuator base facing away from the piston. The actuator base includes at least one passage opening between the dead chamber and the pressure chamber. Closing members for producing the first valve type are each inserted into one of the passage openings so as to seal the passage opening in a gas-tight manner and permanently disconnect the dead chamber from the pressure chamber in terms of flow. To produce the second valve type, the passage opening remains open. A method of manufacturing different types of valves, an assembly and two different valve types of valves are also presented.

Description

Technical Field

[0001] The present invention relates to modular systems and methods for manufacturing different types of valves, assemblies, and valves of different valve types. Background Art

[0002] The drive unit of a pneumatically driven process valve usually comprises a piston / spindle unit arranged in a housing, in which the piston is displaceably positioned. The spindle is connected at its free end to a valve element which cooperates with a valve seat to control the flow of a medium through the valve. The piston defines a pressure chamber of variable volume which is filled with compressed air to move the piston and, via the piston, the spindle. The spindle can move the valve element between a closed position, in which the valve element is pressed against the valve seat, and an open position, in which the valve element is lifted away from the valve seat.

[0003] The pressure chamber has its smallest volume when the compressed air has been released from it. This volume is called the dead volume, because the air in this volume cannot be displaced by the movement of the piston. The dead volume of the pressure chamber has a strong influence on the opening movement of the piston, because the smaller the initial dead volume, the greater the influence of the volume change relative to the dead volume on the control pressure.

[0004] For stop valves, in which the valve element moves only between a completely open position and a completely closed position, a dead volume that is as small as possible is advantageous in order to achieve high dynamics, short switching times and low control air consumption.

[0005] However, for control valves (in which the valve element is also in a position between the fully open position and the fully closed position), a larger dead volume allows a more precise control of the medium flow, because in the case of smaller medium flows, the volume change of the control chamber is not so strongly affected and better linearity is achieved.

[0006] Pneumatically driven process valves therefore require different drive units for different applications, such as shut-off valves or control valves. This results in a large variety of parts, which has a negative impact on manufacturing costs and storage costs.

[0007] The object of the present invention is to propose a valve with a dead volume which is easy to adapt in order to reduce the number of variants and thus reduce costs. Summary of the invention

[0008] This object is achieved by a modular system for producing different types of valves, the modular system comprising the following components:

[0009] a valve base unit, the valve base unit comprising a pneumatic drive unit having a housing, an actuator base arranged in the housing, and a piston / spindle unit arranged in the housing, the piston / spindle unit comprising a piston displaceable in the housing, an end face of the piston and an end face of the actuator base opposite to the end face of the piston defining a variable-volume pressure chamber in the interior of the housing, the actuator base and the housing defining a fixed-volume dead space on a side of the actuator base facing away from the piston, and the actuator base having at least one passage opening between the dead space and the pressure chamber; and

[0010] A plurality of closure members, the plurality of closure members corresponding at least to the number of passage openings in the actuator base, the closure members being designed to be respectively inserted into one of the passage openings and to seal the passage opening in a gas-tight manner so as to selectively and permanently fluidically disconnect the dead chamber from the pressure chamber or to permanently fluidically connect the dead chamber to the pressure chamber.

[0011] During assembly of the valve, the dead volume of the valve is fixed by inserting or omitting at least one closure member, depending on the intended purpose of the valve.The valve basic unit is identical for both variants, making it possible to significantly reduce the variety of parts required.

[0012] In this way, when using the same valve basic unit, two different valve types can be realized in which the dead volume is optimized for a shutoff valve or for a control valve, respectively.

[0013] For use as a shut-off valve, the passage opening is sealed in such a way that the dead volume of the pressure chamber is as small as possible.

[0014] Since all passage openings leading to the dead space must be sealed in a gas-tight manner in order to separate the dead space from the pressure chamber, at least one corresponding closure member is of course always inserted into each of these passage openings.

[0015] In contrast, for use as a control valve, the passage opening remains open in order to provide the largest possible dead volume of the pressure chamber.

[0016] In theory, it is conceivable to provide multiple dead chambers between the actuator base and the housing to design the dead volume to be variable in multiple steps. In this case, each of the dead chambers will have one or more passage openings, which are suitable for sealing in a gas-tight manner using a closure member. Depending on the desired application of the valve, zero, one or more dead chambers in the dead chamber are then sealed with a closure member to provide the desired dead volume of the pressure chamber. However, hereinafter, only the case involving a single dead chamber including one or more passage openings is always considered to avoid unnecessary complex presentation. However, all the options described are possible, and it is also part of the present invention to subdivide the dead chamber below the actuator base into multiple separate chambers, which can then be selectively added to the dead volume, that is, selectively added to the dead volume by opening or closing their passage openings.

[0017] To simplify assembly and storage, preferably all access openings are designed identically, so that only a single type of closure member has to be used.

[0018] For example, the closing member is a sphere made of a suitable material, such as, for example, stainless steel, the diameter of which is larger than the diameter of the passage opening. The diameter of the sphere is preferably only slightly larger than the diameter of the passage opening. In this way, the closing member can simply be pressed into the respective passage opening, thereby sealing the passage opening in a gas-tight manner. It is also conceivable that the closing member is glued and / or welded in the passage opening, alternatively or additionally.

[0019] However, in the inserted state, if possible, the closing member should not protrude beyond the end face of the actuator base into the pressure chamber.For this purpose, a step or shoulder can be formed on the inner surface of the passage opening against which the closing member is pressed.

[0020] In a possible variant, the actuator base is provided with stabilizing ribs on the side facing away from the pressure chamber. In particular, the supporting ribs can be pressed against the housing. On the one hand, such stabilizing ribs allow the stability of the actuator base to be increased. On the other hand, such stabilizing ribs can also be used to create a plurality of dead spaces between them, which are then radially adjacent and can be used to make the dead volume variable in a plurality of steps, as already described above.

[0021] Typically, the actuator base comprises a central opening through which the spindle of the piston / spindle unit passes. The dead volume chamber should not be in fluid communication with this opening.

[0022] Of course, the dead space should be completely sealed from the housing, and the pressure chamber faces away from the passage opening so that it forms a dead volume. Preferably, for this purpose, the actuator base is permanently sealed to the inner surface of the housing at the circumferential edge in a gas-tight manner. The sealing is achieved, for example, by welding, gluing and / or inserting a seal.

[0023] The above object is also achieved by means of an assembly consisting of a valve basic unit as described above, the valve basic unit comprising a pneumatic drive unit with a housing, an actuator base arranged in the housing, and a piston / spindle unit arranged in the housing, the piston / spindle unit comprising a piston displaceable in the housing, the end face of the piston and the end face of the actuator base opposite to the end face of the piston defining a variable volume pressure chamber in the interior of the housing, the actuator base and the housing defining a fixed volume dead space on the side of the actuator base facing away from the piston, and the actuator base having at least one passage opening between the dead space and the pressure chamber; and comprising a plurality of closing members corresponding at least to the number of passage openings in the actuator base, each closing member being designed to be inserted into one of the passage openings and to seal the passage opening in a gas-tight manner. As already discussed above, if the dead volume of the pressure chamber is to be kept as small as possible, in particular if the valve is intended to be used as a shut-off valve, all passage openings are sealed by closing members. If, however, a larger dead volume is desired, for example if the valve is used as a control valve, the passage opening remains open and is not sealed by the closure member.

[0024] In addition, the above-mentioned object is achieved by a method for manufacturing valves of two different valve types, the dead volumes of the valves of the two different valve types are different, and the valves of the two different valve types each include a valve basic unit with the same structure. As already described above, the valve basic unit includes a pneumatic drive unit having a housing, an actuator base arranged in the housing, and a piston / spindle unit arranged in the housing, the piston / spindle unit including a piston displaceable in the housing, an end face of the piston and an end face of the actuator base opposite to the end face of the piston defining a variable volume pressure chamber in the interior of the housing, the actuator base and the housing defining a fixed volume dead chamber on the side of the actuator base facing away from the piston, and the actuator base having at least one passage opening located between the dead chamber and the pressure chamber. For valves of the first valve type, the closing member is inserted into one passage opening, or in the case of multiple passage openings, the closing member is inserted into each passage opening of the actuator base, so that the corresponding passage opening is permanently sealed in a gas-tight manner and the dead space is permanently fluidly separated from the pressure chamber, while for valves of the second valve type, at least one passage opening remains unsealed, so that the dead space is permanently fluidly connected to the pressure chamber via at least one passage opening.

[0025] In this way, during assembly of the valve, the dead space is either fluidically isolated from the pressure chamber or remains fluidically connected to the pressure chamber by sealing the passage openings or, respectively, by leaving them open. The valve type and therefore the intended use of the valve can therefore be defined by a single method step of inserting the closure member into the passage opening or avoiding inserting the closure member into the passage opening.

[0026] Two different valve types can thus be produced quickly and easily with the same valve base unit.

[0027] In valves of a first valve type, at least one closure member is inserted into each of the passage openings, which closure member permanently seals the passage opening in a gas-tight manner, so that the dead space is permanently fluidically separated from the pressure chamber.

[0028] Such valves are preferably stop valves. Small dead volumes provide high dynamics and short switching times when the valve is opened (ie when the valve element is lifted away from the valve seat). In addition, small dead volumes allow a reduction in control air consumption during switching of the valve.

[0029] In valves of the second valve type, at least one passage opening remains open and the dead space is in permanent fluid communication with the pressure chamber via the at least one passage opening.

[0030] Such a valve is preferably a control valve.The large dead space volume results in good linearity between different lift positions of the piston and thus of the valve element for controlling the flow of the medium. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The present invention will be described in more detail below based on exemplary embodiments with reference to the accompanying drawings, in which:

[0032] Figure 1 shows a schematic sectional view of a valve according to the invention according to a first valve type, which valve is produced according to the method according to the invention using the modular system according to the invention;

[0033] Figure 2 Shows Figure 1 An enlarged detailed view of the valve in an open state of the valve;

[0034] Figure 3 Shows Figure 1 an enlarged detailed view of the valve in an open state of the valve, wherein a closure member is inserted to provide a second valve type;

[0035] Figure 4 Shows Figure 2 A valve in a closed state;

[0036] Figure 5 Shows Figure 3 The valve is in the closed position; and

[0037] Figure 6 and Figure 7 Schematic diagrams of actuator bases of valves according to two valve types are shown.

[0038] For the sake of clarity, not all identical components have been provided with reference numerals. DETAILED DESCRIPTION

[0039] Figure 1 A valve 10 is shown in the form of a pneumatic process valve. Process valves control the flow of fluids through systems and pipelines.

[0040] The valve 10 comprises a valve base unit 12 having a pneumatic drive unit 14. The pneumatic drive unit 14 comprises a pot-shaped housing 16 which is closed on one side by a cover 17 and a piston / spindle unit 18 which is accommodated in the housing 16.

[0041] The piston 20 of the piston / spindle unit 18 is displaceably arranged in the cylindrical section of the housing 16. The piston 20 is in sealing contact with the interior of the housing 16 at its edge and defines a variable volume V by one of its end faces 21. D The pressure chamber 22.

[0042] The pressure chamber 22 is connected to an inlet and an outlet (not shown) for compressed air. When compressed air enters the pressure chamber 22, the piston 20 moves against the force of the spring 24 serving as a return element, and the volume V of the pressure chamber 22 increases. D Increase.

[0043] When the compressed air is released from the pressure chamber 22, the elastic force of the spring 24 causes the piston 20 to be displaced as far as possible along the axial direction A to the actuator base 26, the end surface 27 of which is opposite to the end surface 21 of the piston 20 and is also part of the boundary of the pressure chamber 22. In this process, the volume V of the pressure chamber 22 is increased. D The dead volume is reduced to a dead volume in which the compressed air from the pressure chamber 22 cannot be expelled by the piston 20 (see Figure 3 ).

[0044] The actuator base 26 is a component that is separated from the housing 16 and inserted into the housing.

[0045] The volume V of the pressure chamber 22 D It is therefore minimum when the valve 10 is in its fully closed position and maximum when the valve 10 is in its fully open position, as Figure 1 shown.

[0046] The actuator base 26 is arranged on the side of the housing 16 opposite to the cover 17 , and the end surface 27 is substantially parallel to the end surface 21 of the piston 20 .

[0047] On the side 29 of the actuator base 26 facing away from the piston 20 , a space having a fixed volume V is formed between the actuator base 26 and the inner surface of the housing 16 . T The dead chamber 28 of the actuator base 26 is installed in the housing 16 so as to be fixed and immovable. Therefore, when the piston 20 moves in the housing 16, the volume V of the dead chamber 28 T Will not change.

[0048] The end surface 21 of the piston 20 and the end surface 27 of the actuator base 26 are both oriented perpendicularly to the axial direction A of the valve 10 .

[0049] The actuator base 26 separates the pressure chamber 22 from the dead chamber 28 .

[0050] The valve element 32 cooperating with the valve seat 34 is located at one end of the spindle 30 of the piston / spindle unit 18 facing away from the pneumatic drive unit 14. Under the drive of the pneumatic drive unit 14, the valve element 32 is lifted away from the valve seat 34 or pressed against the valve seat due to the lifting of the piston 20 and the related linear movement of the spindle 30 along the axial direction A of the valve 10. This lifting movement of the valve element 32 controls the flow of the medium through the valve seat 34 in the flow channel 36.

[0051] like Figure 4 and Figure 5 As shown, depending on the degree of elasticity of the valve element 32 and / or the valve seat 34, the piston 20 is slightly spaced from the end surface 27 in its lowest position in order to avoid a double fit.

[0052] The flow channel 36 is completely fluidically separated from the pneumatic drive unit 14 , the pressure chamber 22 and the dead space 28 .

[0053] In the example shown here, the valve 10 is designed as a normally closed valve, ie the valve element 32 is in a volume V of the pressure chamber 22. D The valve element 32 is pressed against the valve seat 34 at the minimum. A normally open valve embodiment is also possible, in which case the valve element 32 is arranged so that the valve element is in the volume V of the pressure chamber 22. D At minimum lift, the valve is away from the valve seat 34 .

[0054] The actuator base 26 is provided with one or more access openings 38 extending from the end face 27 to the opposite side 29 of the actuator base 26 .

[0055] In addition to the valve 10 , the assembly 40 comprises a plurality of closure members 42 , the number of which corresponds at least to the number of passage openings 38 in the actuator base 26 .

[0056] The closure members 42 cooperate with the passage opening 38 such that they can close the passage opening in a gas-tight manner when they are inserted into the passage opening 38 .

[0057] When the passage openings 38 remain open, they constitute the only fluid communication between the pressure chamber 22 and the dead space 28. In this case, the dead volume of the pressure chamber 22 includes the dead volume that exists as residual volume between the piston 20 and the actuator base 26 when the valve 10 is closed or the pressure chamber 22 is empty, and additionally includes the volume V of the dead space 28. T (See Figure 4 ). Strictly speaking, the volume of the passage opening 38 also belongs to the dead volume, but it is so small that it is negligible for all practical purposes and is therefore not considered in this context.

[0058] In contrast, when all passage openings 38 are sealed in a gas-tight manner with corresponding closure members 42, the dead space 28 is fluidically isolated from the pressure chamber 22, i.e., there is no fluid communication between the dead space 28 and the pressure chamber 22, and the volume V of the dead space 28 is T Permanently separated from the pressure chamber 22. In this case, the dead volume of the pressure chamber 22 is defined as the dead volume between the piston 20 and the actuator base 26, and the volume V of the dead chamber 28 is T It does not contribute to the dead volume of the pressure chamber 22 (see Figure 5 ).

[0059] In this way, a modular system 44 is formed (see Figures 2 to 5 ), which comprises a valve basic unit 12 and the required number of closure components 42 in each case and which can be used to produce two different valve types.

[0060] To produce the two different valve types, the passage opening 38 is either permanently left open, which results in a valve 10 of the first valve type, or the closure member 42 is permanently inserted into the passage opening 38, which results in a valve 100 of the second valve type (see Figure 3 and Figure 5 ).

[0061] In both valve types, the dead volume of the pressure chamber 22 will not change after completion.

[0062] exist Figure 1 , Figure 2 and Figure 4 The valve 10 of the first valve type shown in FIG. 1 is used here as a control valve. Figure 3 The valve 100 of the second valve type shown in FIG. 1 is used here as a shut-off valve.

[0063] Insertion of the closure member 42 into the passage opening 38 is performed during assembly of the valve 100 , for example, prior to inserting the actuator base 26 into the housing 16 .

[0064] The closure members 42 can be fixed in any suitable manner in a gas-tight manner in the passage opening 38. For example, the closure members 42 may simply be pressed into place, but they may alternatively or additionally be glued, welded, screwed, riveted or brazed into place.

[0065] In this example, the diameter of the passage opening 38 and the size of the closure member 42 are adapted to one another so that the closure member 42 does not protrude beyond the end face 27 of the actuator base 26 when inserted (see FIG. Figure 3 and Figure 5 ).

[0066] Optionally, the passage opening 38 may have a suitable shoulder or step on its inner surface in order to precisely predetermine the position of the closure member 42 inside the respective passage opening 38 (not shown).

[0067] In the example shown here, the closure member 42 is a stainless steel sphere, the diameter of which is slightly larger than the passage opening 38 , so that it seals the passage opening 38 in a gas-tight manner when pressed in.

[0068] All passage openings 38 here have the same diameter, so that the same closure member 42 can be inserted into all passage openings and only one type of closure member 42 is required.

[0069] Figure 6 and Figure 7 One possible embodiment of an actuator base 26 is shown. The actuator base 26 comprises, on its side 29 facing away from the piston 20, a plurality of radially extending stabilizing ribs 48. The stabilizing ribs 48 extend here from the circumferential wall of a central opening 50 in the actuator base 26 through which the spindle 30 extends, to a circumferential edge 52 and, in this example, press against a bottom 54 of the housing 16 at their axial ends.

[0070] The actuator base 26 is connected to the housing 16 in a gas-tight manner (eg, by welding, gluing and / or sealing) along its circumferential edge 52. The passage of the spindle 30 through the opening 50 is also sealed.

[0071] In the above-described embodiment, all of the middle spaces 56 are radially fluidly connected to each other between the stabilizing ribs 48 , so that a single dead space 28 including all of the middle spaces 56 is formed below the actuator base 26 .

[0072] In a possible alternative embodiment, at least some of the stabilizing ribs 48 are configured such that a plurality of dead spaces are created in the intermediate space 56, the dead spaces being separated from one another in a gas-tight manner and each being connected by means of its own passage opening to the pressure chamber 22. In this case, during assembly of the valve 100, an independent decision is made for each of the dead spaces whether the respective passage opening is closed by the closure member or is kept open, so that the total dead volume of the pressure chamber 22 is determined as a function of the number of dead spaces in fluid communication.

Claims

1. A modular system (44) for manufacturing different types of valves (10, 100), the modular system comprising the following components: A valve basic unit (12), the valve basic unit comprising a pneumatic drive unit (14) having a housing (16), an actuator base (26) arranged in the housing (16), and a piston / spindle unit (18) arranged in the housing (16), the piston / spindle unit (18) comprising a piston (20) capable of displacement in the housing (16), an end face (21) of the piston (20) and an end face (27) of the actuator base (26) opposite to the end face (21) of the piston (20) defining a variable volume (V) in the interior of the housing (16). D ) pressure chamber (22), the actuator base (26) and the housing (16) delimiting a fixed volume (V) on a side (29) of the actuator base (26) facing away from the piston (20) T ) a dead chamber (28), and the actuator base (26) has at least one passage opening (38) located between the dead chamber (28) and the pressure chamber (22); and A plurality of closure members (42), the plurality of closure members at least corresponding to the number of passage openings (38) in the actuator base (26), the closure members (42) being designed to be respectively inserted into one of the passage openings (38) and to seal the passage opening (38) in a gas-tight manner to selectively and permanently fluidically disconnect the dead chamber (28) from the pressure chamber (22) or to permanently fluidically connect the dead chamber to the pressure chamber (22).

2. The modular system (44) according to claim 1, wherein: The closure member (42) is a sphere having a diameter greater than the diameter of the passage opening (38).

3. A modular system (44) according to any one of the preceding claims, wherein: The actuator base (26) is provided with a stabilizing rib (48) on a side facing away from the pressure chamber (22), which stabilizing rib in particular presses against the housing (16).

4. The modular system (44) according to any one of the preceding claims, wherein: The actuator base (26) is permanently sealed at a circumferential edge (52) to the inner surface of the housing (16) in a gas-tight manner.

5. An assembly (40) consisting of a valve basic unit (12), the valve basic unit comprising a pneumatic drive unit (14) having a housing (16), an actuator base (26) arranged in the housing (16), and a piston / spindle unit (18) arranged in the housing (16), the piston / spindle unit (18) comprising a piston (20) capable of displacement in the housing (16), an end face (21) of the piston (20) and an end face (27) of the actuator base (26) opposite to the end face (21) of the piston (20) defining a variable volume (V) in the interior of the housing (16) D ) pressure chamber (22), the actuator base (26) and the housing (16) delimiting a fixed volume (V) on a side (29) of the actuator base (26) facing away from the piston (20) T ) a dead chamber (28), and the actuator base (26) has at least one passage opening (38) located between the dead chamber (28) and the pressure chamber (22); and A plurality of closure members (42), the plurality of closure members at least corresponding to the number of passage openings (38) in the actuator base (26), each closure member (42) being designed to be inserted into one of the passage openings (38) and to seal the passage opening (38) in a gas-tight manner.

6. A method for manufacturing valves (10, 100) of two different valve types, wherein the dead volumes of the valves of the two different valve types are different and the valves of the two different valve types each comprise a valve basic unit (12) of identical construction, wherein the valve basic unit comprises a pneumatic drive unit (14) having a housing (16), an actuator base (26) arranged in the housing (16), and a piston / spindle unit (18) arranged in the housing (16), wherein the piston / spindle unit (18) comprises a piston (20) displaceable in the housing (16), an end face (21) of the piston (20) and an end face (27) of the actuator base (26) opposite to the end face (21) of the piston (20) defining a variable volume (V) in the interior of the housing (16). D ) pressure chamber (22), the actuator base (26) and the housing (16) delimiting a fixed volume (V) on a side (29) of the actuator base (26) facing away from the piston (20) T ) a dead chamber (28), and the actuator base (26) has at least one passage opening (38) located between the dead chamber (28) and the pressure chamber (22); and wherein, (a) in a valve (100) of a first valve type, a closure member (42) is inserted into one passage opening (38) or, in the case of a plurality of passage openings (38), into each of the passage openings (38) of the actuator base (26) such that the respective passage opening (38) is permanently sealed in a gas-tight manner and the dead space (28) is permanently fluidically separated from the pressure chamber (22), and (b) In the valve (10) of the second valve type, the at least one passage opening (38) remains unsealed, so that the dead space (28) is permanently in fluid communication with the pressure chamber (22) via the at least one passage opening (38).

7. A valve (100) manufactured as a valve (100) of a first valve type according to the method of claim 6, wherein: A closure member (42) is inserted into each passage opening (38), which closure member permanently seals the passage opening (38) in a gas-tight manner, so that the dead space (28) is permanently fluidically separated from the pressure chamber (22).

8. The valve (100) according to claim 7, wherein: The valve (100) is a stop valve.

9. A valve (10) manufactured as a valve (10) of the second valve type according to the method of claim 6, wherein: At least one passage opening (38) remains open and the dead space (28) is in permanent fluid communication with the pressure chamber (22) via the at least one passage opening (38).

10. The valve (10) according to claim 9, wherein: The valve (10) is a control valve.

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