High-frequency ball valve anti-crystallization stacking structure based on asymmetric flow guiding channel

Abstract

This invention relates to the field of ball valve control equipment, specifically a PDS high-frequency ball valve suitable for high-crystallization media conditions. The valve features an anti-crystallization structure based on an asymmetric flow channel, comprising a main valve body, a secondary valve body, a ball, a valve seat, and an upper valve stem. The ball is rotatably mounted inside the main valve body, and rotates horizontally and synchronously with the upper valve stem within the main valve body's inner cavity. The secondary valve body's inner cavity serves as a media channel, with a media channel cavity in the center of the ball. The ball is sleeved with the lower valve stem. The invention also includes a sealing assembly and a discharge gasket. A discharge gasket is positioned at the contact point between the valve seat and the secondary valve body. The inner ring of the discharge gasket has several gasket bosses spaced circumferentially, forming a flow-guiding slope between adjacent gasket bosses. The discharge gasket's inner ring features several gasket bosses and several flow-guiding slopes for flow guidance. A dynamic flow-guiding and discharge structure is incorporated, with a discharge gasket featuring multi-stage flow-guiding slopes. These slopes, combined with the inner ring slope of the valve seat, form an asymmetric flow channel, facilitating the directional discharge of crystals and extending the life of the disc spring.

Description

Technical Field

[0001] This invention relates to the field of ball valve control equipment, specifically a PDS high-frequency ball valve suitable for high crystallization media conditions, which is based on an anti-crystallization accumulation structure for high-frequency ball valves with an asymmetric flow channel. Background Technology

[0002] The PDS high-frequency ball valve is a valve designed specifically for high-frequency, rapid opening and closing conditions. It is typically used in industrial systems that require fast response, high reliability, and long service life.

[0003] Traditional PDS high-frequency ball valves with anti-accumulation and low-leakage design use a spring-preloaded sealing structure for the valve seat to ensure a tight seal and prevent leakage during high-frequency operation, as illustrated in the technical solution in CN109578613B. However, in applications involving the transport of easily polymerizable media, the existing PDS high-frequency ball valve structure lacks a flow-guiding design in the valve seat spring area. This leads to the accumulation of solidified crystals at the valve seat-valve body connection, which can cause the disc spring to compress and fail, potentially resulting in severe damage to the sealing surface, internal valve leakage, and ball seizure.

[0004] Therefore, a high-frequency ball valve structure with a flow guiding and anti-accumulation structure is needed to facilitate the smooth discharge of solid materials such as crystals and solids from the narrow space between the valve seat and the valve body, thereby ensuring valve sealing while reducing valve failure rate and increasing service life. Summary of the Invention

[0005] This invention addresses the shortcomings of existing technologies by providing a high-frequency ball valve anti-crystallization and accumulation structure based on an asymmetric flow guiding channel. The structure includes a main valve body, a secondary valve body, a ball, a valve seat, and an upper valve stem. The ball is rotatably disposed inside the main valve body, and the ball and the upper valve stem rotate horizontally and synchronously within the inner cavity of the main valve body. The inner cavity of the secondary valve body serves as a media channel, and a media channel cavity is provided in the center of the ball. The ball is sleeved with the lower valve stem. The structure also includes a sealing assembly and a ash-removing washer. The ash-removing washer is positioned at the contact point between the valve seat and the secondary valve body. The inner ring of the ash-removing washer has several washer bosses spaced circumferentially, with a flow guiding slope formed between adjacent washer bosses. The ash discharge gasket has several gasket bosses and several flow-guiding ramps on its inner ring for flow guidance. The valve seat has a flow-guiding ramp on its inner ring near the ash discharge gasket. The flow-guiding ramps of the ash discharge gasket and the valve seat are opposite to each other, forming an asymmetric flow-guiding channel between them. The sealing assembly includes a butterfly spring, which is located in a spring groove on the valve seat facing away from the ball and acts on the valve seat to give it a preload force toward the ball. The asymmetric flow-guiding channel is configured to guide any crystals that may accumulate out of the area between the valve seat and the ash discharge gasket, preventing crystals from being compacted in the grooves at both ends of the butterfly spring and causing the butterfly spring to fail.

[0006] Preferably, the angle c of the guiding slope is in the range of 10° to 60°.

[0007] Preferably, the outer ring of the ash discharge gasket forms an intermittent annular guide slope.

[0008] Preferably, the angle b of the guiding slope formed by the annular guiding slope is in the range of 10° to 60°.

[0009] Preferably, the sealing assembly further includes a limiting washer and a graphite sealing ring, and the ramp for guiding the inner ring of the valve seat is disposed on one side of the butterfly spring, and the angle α formed by the ramp for guiding the flow of the valve seat is in the range of 10°~60°.

[0010] Preferably, the outer wall of the valve seat is provided with a sealing ring groove in the circumferential direction, and a flat washer and an O-ring are provided in the sealing ring groove. The graphite sealing ring is provided in the sealing end groove of the valve seat, and the graphite sealing ring, the flat washer and the O-ring form a double seal.

[0011] Compared with the prior art, the beneficial effects of the present invention are as follows: by setting a dynamic flow guiding and ash discharge structure, an ash discharge gasket with multi-stage flow guiding slope is set between the valve seat and the secondary valve body, which, together with the inner ring slope of the valve seat, forms an asymmetrical flow channel, which facilitates the directional discharge of crystals, releases the activity space of the butterfly spring, solves the problems of sealing failure, jamming and valve stem overload caused by crystal accumulation in traditional ball valves, improves the crystal discharge efficiency and extends the life of the butterfly spring. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be discussed below. Obviously, the technical solutions described in conjunction with the accompanying drawings are only some embodiments of the present invention. For those skilled in the art, other embodiments and their accompanying drawings can be obtained based on the embodiments shown in these drawings without creative effort.

[0013] Figure 1 This is a three-dimensional structural diagram of the high-frequency ball valve anti-crystallization accumulation structure based on an asymmetric flow channel according to the present invention;

[0014] Figure 2 This is a side view of the anti-crystallization and accumulation structure of the high-frequency ball valve based on the asymmetric flow channel of the present invention;

[0015] Figure 3 This is a side cross-sectional view of the high-frequency ball valve anti-crystallization accumulation structure based on an asymmetric flow channel according to the present invention;

[0016] Figure 4 This is a schematic cross-sectional view of the pipe diameter of the high-frequency ball valve anti-crystallization accumulation structure based on the asymmetric flow guiding channel of the present invention;

[0017] Figure 5 This invention relates to a high-frequency ball valve anti-crystallization and stacking structure based on an asymmetric flow guiding channel. Figure 3 Enlarged view of point A in the middle;

[0018] Figure 6 This invention relates to a high-frequency ball valve anti-crystallization and stacking structure based on an asymmetric flow guiding channel. Figure 3 Enlarged view of point B in the middle;

[0019] Figure 7 This is a schematic diagram of the three-dimensional structure of the ash discharge gasket of the high-frequency ball valve anti-crystallization accumulation structure based on the asymmetric flow channel of the present invention.

[0020] In the diagram: 100, main valve body; 110, auxiliary valve body; 120, ball; 200, upper valve stem; 210, lower valve stem; 220, base; 300, valve seat; 310, limit washer; 320, butterfly spring; 330, graphite sealing ring; 340, ash discharge washer; 341, washer boss; 342, guide ramp; 343, annular guide ramp; 400, outer valve stem; 410, packing washer; 420, packing sleeve; 430, flexible barrier; 500, stuffing box; 510, packing sleeve; 520, packing pressure plate; 600, bracket; 700, lifting ring. Detailed Implementation

[0021] The technical solutions of various embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments described in the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Embodiments of the present invention provide a high-frequency ball valve anti-crystallization accumulation structure based on an asymmetric flow guiding channel, such as... Figure 1-7 As shown, it includes a main valve body 100, a secondary valve body 110, a ball 120, a valve seat 300, and an upper valve stem 200. The secondary valve body 110 is fixedly mounted on the main valve body 100 by several bolts. The interior of the main valve body 100 and the secondary valve body 110 form an inner cavity, and the inner cavity of the secondary valve body 110 is a medium channel.

[0023] The ball 120 is rotatably disposed inside the main valve body 100, and a medium channel cavity is provided in the middle of the ball 120. The ball 120 is positioned by the outer valve stem 400 and the lower valve stem 210, so that the ball 120 and the upper valve stem 200 rotate horizontally and synchronously in the inner cavity, and the ball 120 is sleeved with the lower valve stem 210. The bottom of the upper valve stem 200 cooperates with the ball 120 for transmission. The bottom of the upper valve stem 200 has a spline, square or hexagonal structure, which is only used to transmit the torque during opening and closing and does not need to bear the lateral shear force. A bushing is provided between the ball 120 and the sleeved joints of the upper valve stem 200 and the lower valve stem 210. A bushing is provided between the ball 120 and the outer valve stem 400. Preferably, this bushing is a PEEK lubricated bushing. Alternatively, those skilled in the art can replace this bushing with one of the following: an alloy + PTFE bushing, an alloy + graphite bushing, or an alloy steel bushing. The bottom of the outer valve stem 400 has a stepped structure. The outer valve stem 400 is connected to the bushing on the inner wall of the ball 120 to bear the static pressure of the medium. The dual-valve-stem structure reduces the torque borne by the upper valve stem 200 during actuation by 40% to 60%, thus allowing for a reduction of 1 to 2 sizes in the actuator specifications.

[0024] The main valve body 100 and the auxiliary valve body 110 are sealed at their joints using a spiral wound gasket. The main valve body 100 and the lower valve stem 210 are sealed at their joints using a spiral wound washer. Each auxiliary valve body 110 has a base 220 at its bottom for supporting the entire valve assembly. The base 220 is secured using studs and nuts.

[0025] The ball 120 has a ash discharge washer 340, a valve seat 300, and a sealing assembly at the contact points between its two sides and the secondary valve body 110. The ash discharge washer 340 is fitted into the contact groove of the secondary valve body 110. The sealing assembly is fitted into the outer wall of the valve seat 300, which abuts against the ball 120. The valve seat 300 and the secondary valve body 110 are sealed together.

[0026] The ash discharge gasket 340 is disposed between the axial contact surfaces of the valve seat 300 and the secondary valve body 110. The inner and outer rings of the ash discharge gasket 340 are respectively provided with sloping structures for guiding flow. Specifically, the inner ring of the ash discharge gasket 340 on one side of the contact surface with the sealing assembly is provided with a plurality of gasket bosses 341 and a plurality of flow guiding slopes 342 spaced circumferentially. Preferably, the flow guiding inclination angle c formed by the flow guiding slopes 342 is in the range of 10°~60°. Correspondingly, the outer ring side of the ash discharge gasket 340 forms an intermittent annular flow guiding slope 343, which is a slope arranged around the entire circumference for guiding flow. The flow guiding slope structure of the ash discharge gasket 340 is arranged opposite to the flow guiding slope of the valve seat 300, forming an asymmetrical flow guiding channel between them.

[0027] Preferably, the angle b of the flow-guiding slope 343 is in the range of 10° to 60°. The slope structure design that introduces the flow guide improves the crystal discharge efficiency by more than 80%, and extends the life of the butterfly spring 320 by 2-3 times.

[0028] The sealing assembly includes a butterfly spring 320, a limiting washer 310, and a graphite sealing ring 330. The butterfly spring 320, as an elastic component, provides sealing pressure to compress the valve seat 300, ensuring the sealing performance between the valve seat 300 and the spherical surface of the ball 120. The butterfly spring 320 is disposed in a spring groove on the side of the valve seat 300 facing away from the ball 120. The valve seat 300 has a slope on one inner ring of the butterfly spring 320, forming a flow guiding angle α. Preferably, the flow guiding angle α of the valve seat 300 ranges from 10° to 60°. The slope of the valve seat 300 and the slope on the inner side of the ash discharge washer 340 form a V-shaped flow guiding channel. The included angle at the V-shaped flow guiding channel structure is preferably 20° to 120°. In use, the opening and closing of the valve seat 300 compresses the material, allowing the crystals to easily flow along the slope into the pipeline, thereby releasing the movement space of the butterfly spring 320. The valve seat 300 has a mounting groove on its outer wall away from the ball 120. The end of the limiting washer 310 away from the valve seat 300 abuts against the butterfly spring 320, while the end of the limiting washer 310 near the valve seat 300 fits into the mounting groove. The graphite sealing ring 330 is annular and is fitted into the mounting groove of the valve seat 300. The limiting washer 310 abuts against the graphite sealing ring 330, assisting in fixing the graphite sealing ring 330.

[0029] The asymmetric flow channel is configured to guide any accumulating crystals out of the area between the valve seat 300 and the ash discharge washer 340, preventing the crystals from being compacted in the grooves at both ends of the butterfly spring 320 and causing the butterfly spring 320 to fail.

[0030] The valve seat 300 has a sealing ring groove circumferentially arranged on its outer wall, and a flat washer and an O-ring are arranged in the sealing ring groove. The graphite sealing ring 330 is arranged in the sealing end groove of the valve seat 300. The graphite sealing ring 330, together with the flat washer and the O-ring, forms a double seal, which improves the reliability of the seal, reduces the probability of internal leakage of the valve, and blocks impurities in the medium under high-frequency switching of the ball valve, reducing the occurrence of jamming during ball valve operation.

[0031] The upper valve stem 200 has a shoulder at its lower part. The lower part of the upper valve stem 200 is sleeved on the upper part of the ball 120 through the outer valve stem 400. The lower outer wall of the upper valve stem 200 and the outer valve stem 400 are sleeved together by a bushing. A valve stem washer is provided between the shoulder of the lower part of the upper valve stem 200 and the boss that mates with the inner wall of the outer valve stem 400. The outer wall of the outer valve stem 400 is sleeved with the upper mounting hole of the ball 120, and a bushing is provided at the sleeve.

[0032] A lower packing ring groove is provided at the contact point between the upper part of the outer valve stem 400 and the upper valve stem 200, and the lower packing ring groove is filled with graphite packing. A packing washer 410 is provided at the bottom of the lower packing ring groove, and a packing sleeve 420 is fitted between the lower packing ring groove and the upper valve stem 200.

[0033] The outer valve stem 400 is fixed to the upper part of the main valve body 100 by an internal hexagonal screw. A stuffing box 500 is correspondingly provided at the top of the outer valve stem 400, and a metal spiral wound gasket is provided at the contact surface between the outer valve stem 400 and the stuffing box 500. An upper packing ring groove is provided on the inner ring of the top of the stuffing box 500, and is sealed by a combination of a packing pressure plate 520 and a packing pressure sleeve 510. A filling composite layer is provided inside the upper packing ring groove. The filling composite layer includes a flexible barrier element 430, packing, and a gasket. The flexible barrier element 430 is placed at the bottom of the upper packing ring groove, serving as the bottom layer of the filling composite layer. Several flexible barrier elements 430 are placed at intervals, and each layer of flexible barrier elements 430 is filled with packing, preferably graphite packing. The flexible barrier element 430 is used to prevent graphite particles from escaping due to frequent valve opening. Preferably, the flexible barrier element 430 is a thin metal sheet or PPL material.

[0034] A bracket 600 is fixedly installed on the top of the main valve body 100, and the bottom of the bracket 600 is fixed above the main valve body 100 by screws. A lifting ring 700 is also fixedly installed on the auxiliary valve body 110 to facilitate the hoisting of the entire ball valve.

[0035] The PDS high-frequency ball valve structure for preventing accumulation and low leakage disclosed in this embodiment, by configuring a flow-guiding and ash-discharging structure and setting an ash-discharging gasket with multi-stage flow-guiding slopes, forms an asymmetric flow channel with the inner ring slope of the valve seat, realizing the directional discharge of crystals. Through the dual valve stem collaborative bearing system, by optimizing the axial support structure of the valve stem part, the influence of lateral shear force on the valve stem is eliminated, making it suitable for highly corrosive and easily crystallizing media scenarios such as petrochemical and coal chemical industries.

[0036] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A high-frequency ball valve anti-crystallization accumulation structure based on asymmetric flow guide channel, comprising a main valve body (100), a secondary valve body (110), a ball body (120), a valve seat (300) and an upper valve rod (200), the ball body (120) is rotationally arranged in the main valve body (100), the ball body (120) and the upper valve rod (200) are horizontally and synchronously rotated in the inner cavity of the main valve body (100), the inner cavity of the secondary valve body (110) is a medium channel, the ball body (120) is provided with a medium channel cavity in the middle part, the ball body (120) is sleeved with a lower valve rod (210), and the anti-crystallization accumulation structure is characterized in that: the anti-crystallization accumulation structure further comprises a sealing assembly and an ash removal gasket (340), the ash removal gasket (340) is arranged at the joint of the valve seat (300) and the secondary valve body (110), the inner ring of the ash removal gasket (340) is circumferentially and intermittently provided with a plurality of gasket bosses (341), adjacent gasket bosses (341) form a flow guide slope (342), and the inner ring of the ash removal gasket (340) is provided with a plurality of gasket bosses (341) and a plurality of flow guide slopes (342) for flow guide, the inner ring of the valve seat (300) on the side close to the ash removal gasket (340) is provided with a slope for flow guide of the valve seat (300), the flow guide slope (342) of the ash removal gasket (340) is oppositely arranged with the slope of the valve seat (300), and an asymmetric flow guide channel is formed between the two, the sealing assembly comprises a butterfly spring (320), the butterfly spring (320) is arranged in a spring groove on the side of the valve seat (300) away from the ball body (120) and acts on the valve seat (300) to make the valve seat (300) have a pre-tightening force towards the ball body (120), and the asymmetric flow guide channel is configured to guide and discharge the possible accumulated crystalline substances from the area of the valve seat (300) and the ash removal gasket (340), so as to prevent the crystalline substances from being compacted in the grooves on both ends of the butterfly spring (320) and causing the butterfly spring (320) to fail. The flow guide slope (342) forms a flow guide inclination angle c in the range of 10°-60°.

2. The anti-crystallization and deposition structure of high-frequency ball valve based on asymmetric flow guiding channels according to claim 1, characterized in that: The outer ring side of the ash removal gasket (340) forms an intermittent annular flow guide slope (343).

3. The anti-crystallization and deposition structure of high-frequency ball valve based on asymmetric flow guiding channels according to claim 1, characterized in that: The annular flow guide slope (343) forms a flow guide inclination angle b in the range of 10°-60°.

4. The anti-crystallization and deposition structure of high-frequency ball valve based on asymmetric flow guiding channels according to claim 3, characterized in that: The sealing assembly further comprises a limiting gasket (310) and a graphite sealing ring (330), the slope for flow guide of the inner ring of the valve seat (300) is arranged on one side of the butterfly spring (320), and the slope for flow guide of the valve seat (300) forms a flow guide inclination angle a in the range of 10°-60°.

5. The anti-crystallization and deposition structure of high-frequency ball valve based on asymmetric flow guiding channel according to claim 1, characterized in that: The outer wall of the valve seat (300) is circumferentially provided with a sealing ring groove, a flat gasket and an O-ring are arranged in the sealing ring groove, the graphite sealing ring (330) is arranged in a sealing end groove of the valve seat (300), and the graphite sealing ring (330), the flat gasket and the O-ring form two seals.

6. The anti-crystallization and deposition structure of high-frequency ball valve based on asymmetric flow guiding channels according to claim 5, characterized in that: ​

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