Top mounted wear resistant shear valve

Abstract

The application relates to the technical field of valves, in particular to a top-mounted wear-resistant shear valve which comprises a valve body, a valve cover fixed at the top of the valve body and a shear gate located in a vertical installation cavity in the valve body; the bottom end of the shear gate is provided with a bevel shear blade which is built up with a hard alloy layer, a detachable valve seat with a scraper surface is arranged on the downstream side of a flow passage of the valve body, a longitudinal guide rail matched with the shear gate is arranged on the inner wall of the vertical installation cavity, and a slag discharge groove is arranged at the bottom of the valve body. The top-mounted structure can realize integral hoisting and maintenance of internal components without disassembling pipelines, thereby shortening the maintenance time; the cooperation of the bevel shear blade and the scraper surface can forcibly cut off hard particles in the medium, and the cooperation of the guide rail support and the slag discharge design can significantly improve the wear resistance, sealing tightness and operation reliability of the valve.

Description

Technical Field

[0001] This invention relates to the field of valve manufacturing technology, and in particular to a top-mounted wear-resistant shear valve. Background Technology

[0002] With the development of industrial fluid control technology, shear valves, as control elements capable of handling high-viscosity, particulate media, have been widely used in chemical, petroleum, and food processing industries. Especially in applications requiring media crushing, homogenization, or emergency shut-off, the performance of shear valves directly impacts system efficiency. However, existing shear valves still exhibit technical bottlenecks such as rapid seal failure and difficult maintenance when exposed to highly abrasive media over extended periods.

[0003] A search revealed a patent with publication number CN216843175U, which discloses a shear-type homogenizing valve for a homogenizer, published on June 28, 2022. This design uses a push rod to press a valve core with a shear cone into an integrated homogenizing valve seat, achieving a seal through cone-face closure. While this structure can guarantee homogenization to a certain extent, when handling industrial fluids containing hard minerals or high-hardness impurities, the conical sealing pair is prone to severe erosion wear and circumferential grooves. Furthermore, because the valve is not a top-mounted structure, when the internal core shear component wears and needs replacement, it often requires disassembling the entire pipeline or disassembling the entire valve body, resulting in long maintenance times and high maintenance costs, making it difficult to meet the requirements of continuous large-scale production for online equipment maintenance.

[0004] A search revealed CN216843175U, which discloses a low-shear plunger-type throttle valve for oil extraction and transportation, published on May 24, 2019. This product reduces the shear force generated by the fluid and increases the probability of oil droplet collision by using a corrugated guide plate and plunger structure. Although this solution has made some optimizations in reducing shear force damage and improving wear resistance, its plunger structure is insufficient for conditions requiring "hard cut-off" or "strong shear." More importantly, its internal structure is complex, with core actuating components encased deep within the valve body, lacking the top-mounted, quick-disassembly characteristics of a traditional valve. In the complex and harsh oil extraction environment, scale or particle deposits inside the valve can cause the valve stem to jam, and the non-top-mounted design makes cleaning and replacing damaged wear parts extremely cumbersome.

[0005] The aforementioned problems indicate that current shear valves still have significant shortcomings in balancing "high efficiency and wear resistance" with "easy maintenance." To address the issue of severe wear and difficulty in quickly replacing core components in existing technologies, this invention provides a top-mounted wear-resistant shear valve. Through its top-mounted structure and optimized wear-resistant shear pairs, it aims to extend the valve's service life and significantly shorten maintenance cycles. Summary of the Invention

[0006] The purpose of this invention is to provide a top-mounted wear-resistant shear valve to solve the problems mentioned in the background art, such as the sealing surface of the shear valve being easily eroded and worn when handling high-viscosity media containing hard particles, leading to internal leakage, and the fact that non-top-mounted structures require the entire valve body to be disassembled from the pipeline when replacing or maintaining internal parts, resulting in complicated maintenance procedures and poor convenience of online maintenance.

[0007] To achieve the above objectives, the present invention provides the following technical solution: A top-mounted wear-resistant shear valve includes a valve body and a valve cover fixed to the top of the valve body by bolts. The valve body has a fluid channel running through its left and right sides. A vertical mounting cavity perpendicular to the fluid channel is provided in the middle of the valve body. The top opening of the vertical mounting cavity is sealed to the bottom of the valve cover. A shear gate that can slide vertically is provided in the vertical mounting cavity. The top of the shear gate is connected to a valve stem through a stepped groove structure. The top of the valve stem passes through the valve cover and extends to the outside. A packing seal chamber for the valve stem to pass through is provided in the middle of the valve cover. Longitudinal guide rails are symmetrically provided on both sides of the inner wall of the vertical mounting cavity. The upper end of the longitudinal guide rail is fixed to the bottom of the valve cover and is used to move out of the vertical mounting cavity synchronously with the opening of the valve cover.

[0008] As a further refinement of this technical solution, a wear-resistant bushing is tightly fitted into the inner wall of the fluid passage of the valve body, and the end of the wear-resistant bushing extends to the inner edge of the vertical mounting cavity.

[0009] As a further refinement of this technical solution, a slag discharge trough is provided at the bottom of the vertical mounting cavity. The slag discharge trough passes through the bottom of the valve body and is connected to a drain flange. A sealing blind plate is provided on the drain flange.

[0010] As a further refinement of this technical solution, the cross-section of the longitudinal guide rail is groove-shaped; the two sides of the shear gate are respectively embedded in the corresponding longitudinal guide rail, and a self-lubricating wear-resistant block is provided between the shear gate and the longitudinal guide rail. The self-lubricating wear-resistant block is fixed to the side of the shear gate by countersunk screws; the groove depth of the longitudinal guide rail is greater than the embedding depth of the side of the shear gate, and a compensation gap is left between the self-lubricating wear-resistant block and the bottom of the groove.

[0011] As a further refinement of this technical solution, the bottom edge of the shear gate is machined with a beveled shearing blade, the beveled shearing blade having an inclination angle of 15 degrees to 30 degrees, and the surface of the beveled shearing blade is overlaid with a hard alloy layer with a thickness of 2 mm to 5 mm.

[0012] As a further refinement of this technical solution, a detachable valve seat is provided in the vertical mounting cavity on the downstream side of the fluid channel. The detachable valve seat includes a seat body and a shear sealing ring embedded in the front end of the seat body. The seat body is fixed in the vertical mounting cavity by a top pressure plate or pressure strip. The inner diameter of the shear sealing ring is consistent with the aperture of the fluid channel, and the end face of the shear sealing ring forms a sliding friction pair with the side surface of the shear gate.

[0013] As a further refinement of this technical solution, the inner edge of the shear sealing ring is machined with a right-angled sharp scraper surface, and the right-angled sharp scraper surface and the inclined shearing blade of the shear gate form a shearing point during the closing process.

[0014] As a further refinement of this technical solution, the interior of the packing sealing chamber is filled with flexible graphite packing, and the top of the packing sealing chamber is provided with a pressure cap, which is connected to the valve cover by two symmetrically arranged hinge bolts.

[0015] As a further refinement of this technical solution, a metal surrounding gasket is provided between the valve cover and the valve body. The lower surface of the valve cover is provided with an annular protrusion, and the top opening of the vertical mounting cavity of the valve body is provided with a matching annular groove. The metal surrounding gasket is placed in the annular groove and is squeezed by the annular protrusion.

[0016] As a further refinement of this technical solution, the top of the valve stem is connected to a handwheel or a drive actuator via a flat key.

[0017] The beneficial effects of this invention are: Optimized top-mounted maintenance structure: By fixing the upper end of the longitudinal guide rail to the bottom of the valve cover, when the valve cover is removed, the guide rail and internal components such as the shear gate can be lifted out of the vertical mounting cavity as a whole. This design solves the contradiction in the original solution where the guide rail was fixed to the inner wall, making the "whole lifting out" function impossible. It truly realizes online maintenance without disassembling the pipeline, significantly shortening maintenance time.

[0018] Improved valve seat maintenance convenience: The fixing method for the removable valve seat has been changed from lateral fastening bolts to top pressure plate or pressure strip fixation. Operators can complete the disassembly and assembly from the top of the vertical mounting cavity, avoiding the difficulty of using long-handled tools to operate the outer ring bolts in the deep cavity, making valve seat replacement more convenient and reliable.

[0019] To ensure the floating fit of the sealing pair: the groove depth of the longitudinal guide rail is set to be greater than the embedding depth of the shear side plate, and a compensation gap (e.g., 0.5mm-1.5mm) is left between the self-lubricating wear-resistant block and the bottom of the groove. This structure allows the shear gate to float slightly towards the detachable valve seat under medium pressure, ensuring both the guiding function of the guide rail and achieving pressure self-fitting of the sealing surface, thus resolving the technical contradiction between "free floating" and "embedded guidance".

[0020] Improved shearing and sealing performance: By incorporating a beveled shearing blade with a hard alloy layer welded to the bottom of the shear gate, and in conjunction with a sharp right-angle scraper on the removable valve seat, the mechanical force of the descending shear gate forcibly cuts through hard particles in the medium, preventing particles from becoming stuck between the sealing surfaces and improving sealing tightness. Simultaneously, a slag discharge groove at the bottom of the valve body effectively reduces slag accumulation. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a side sectional view of the present invention. Figure 3 This is a schematic diagram of the front view cross-section structure of the present invention.

[0022] Explanation of reference numerals in the attached figures: 1. Valve body; 2. Valve cover; 3. Bolt assembly; 4. Fluid passage; 5. Vertical mounting cavity; 6. Shear gate; 7. Stepped groove structure; 8. Valve stem; 9. Packing seal chamber; 10. Wear-resistant bushing; 11. Slag discharge trough; 12. Drain flange; 13. Sealing blind flange; 14. Longitudinal guide rail; 15. Self-lubricating wear-resistant block; 16. Beveled shear blade; 17. Hard alloy layer; 18. Removable valve seat; 19. Seat body; 20. Shear sealing ring; 21. Pressure strip; 22. Right-angle sharp scraper surface; 23. Flexible graphite packing; 24. Gland; 25. Hinged bolt; 26. Metal surrounding gasket; 27. Annular protrusion; 28. Annular groove. Detailed Implementation

[0023] The technical solutions of the 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 of 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.

[0024] Specific implementation examples are given below.

[0025] See Figures 1-3A top-mounted wear-resistant shear valve, the overall structure of which is designed to enable rapid maintenance of internal components without disassembling the pipeline and long-term sealing under high wear conditions. The core pressure-bearing component of this valve is the valve body 1, which has connecting flanges on both sides for connecting to industrial fluid transport pipelines. Inside the valve body 1, a fluid channel 4 is provided horizontally. To cope with the scouring of hard particles, a wear-resistant bushing 10 is tightly fitted to the inner wall of the fluid channel 4. The bushing 10 can be made of high-chromium alloy steel or tungsten carbide ceramic and its inner end extends to the inner edge of the vertical mounting cavity 5, providing all-round wear protection. The valve body 1 has a vertical mounting cavity 5 that is perpendicular to the fluid channel 4 in the middle. The top opening of the vertical mounting cavity 5 is machined with a flange face and is fixed to the valve cover 2 by bolt group 3. On the contact surface between the valve cover 2 and the valve body 1, there is a special sealing structure: the opening of the valve body 1 is provided with an annular groove 28, the lower surface of the valve cover 2 is provided with an annular protrusion 27, and a metal ring gasket 26 is placed between the two to form a reliable static seal. One of the key improvements in this embodiment is the top-mounted maintenance structure; longitudinal guide rails 14 are symmetrically arranged on both sides of the inner wall of the vertical mounting cavity 5, and their cross-section is groove-shaped; unlike the traditional fixing method, the upper end of the longitudinal guide rail 14 is fixed to the bottom of the valve cover 2 by a lug or flange structure; therefore, when the bolt group 3 is removed and the valve cover 2 is lifted, the longitudinal guide rail 14 will move out of the vertical mounting cavity 5 synchronously with the valve cover 2, thereby taking out the internal components such as the shear gate 6 together, truly realizing the overall lifting out maintenance, and solving the problem that the guide rail is fixed to the inner wall in the original solution, which makes it impossible to lift out; The two sides of the shear gate 6 are embedded in the longitudinal guide rail 14, and a self-lubricating wear-resistant block 15 is provided between them to reduce friction and withstand lateral loads. Another key improvement of this embodiment is the floating guide design: the groove depth of the longitudinal guide rail 14 is greater than the embedding depth of the side of the shear gate 6, and a compensation gap (e.g., 0.5mm-1.5mm) is left between the self-lubricating wear-resistant block 15 and the bottom of the groove. This gap allows the shear gate 6 to float slightly towards the detachable valve seat 18 under the medium pressure, so that its sealing surface can fit better, achieving both guidance and self-sealing. The bottom edge of the shear gate 6 is machined with a beveled shearing blade 16 with an inclination angle of 15 to 30 degrees, and its surface is overlaid with a hard alloy layer 17 with a hardness of not less than HRC60; the top of the shear gate 6 is connected to the valve stem 8 through a stepped groove structure 7, allowing it to float slightly in the horizontal direction; the valve stem 8 passes through the packing seal chamber 9 on the valve cover 2, which is filled with flexible graphite packing 23 and is pressed and sealed by the gland 24 and the hinge bolt 25; Another key improvement in this embodiment is the way the valve seat is fixed. The detachable valve seat 18 located downstream of the fluid channel 4 includes a seat body 19 and a shear sealing ring 20. The seat body 19 is not fixed by lateral fastening bolts, but by a "module clamping" method, which uses a pressure strip 21 from the top of the vertical mounting cavity 5 to press the seat body 19 tightly against the end of the flow channel. This fixing method allows the operator to directly remove and install the fasteners on the pressure strip 21 from the top without having to operate in a narrow and deep cavity, which greatly facilitates the replacement of the valve seat. The inner edge of the shear sealing ring 20 is machined with a right-angled sharp scraper surface 22, which cooperates with the inclined shear blade 16 to form a shearing point to cut hard particles in the medium. At the bottom of the vertical mounting cavity 5, a slag discharge trough 11 is provided and connected to a sewage discharge flange 12, which can periodically discharge sediment. The operating principle of this top-mounted wear-resistant shear valve is as follows: When the valve is closed, the drive mechanism pushes the valve stem 8 and the shear gate 6 downward along the longitudinal guide rail 14; the inclined shear blade 16 cooperates with the right-angle sharp scraper surface 22 to cut off impurities in the medium; due to the existence of compensation gap, the position of the shear gate 6 can be finely adjusted under the medium pressure, so that its sealing surface is tightly fitted with the shear sealing ring 20 to achieve reliable sealing; when maintenance is required, the bolt group 3 on the valve cover 2 is removed, and the valve cover 2, the longitudinal guide rail 14 and the internal components are lifted out as a whole. Then the pressure strip 21 can be removed from the top, and the detachable valve seat 18 can be quickly replaced; the whole process does not require disassembling the valve body 1 and the pipeline, and the maintenance efficiency is extremely high.

[0026] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A top-mounted wear-resistant shear valve, comprising a valve body (1) and a valve cover (2) fixed to the top of the valve body (1) by a bolt assembly (3), characterized in that: The valve body (1) has a fluid channel (4) running through its left and right sides inside. The valve body (1) has a vertical mounting cavity (5) that intersects the fluid channel (4) perpendicularly in the middle. The top opening of the vertical mounting cavity (5) is sealed and fitted to the bottom of the valve cover (2). The vertical mounting cavity (5) is provided with a shear gate (6) that can slide in the vertical direction. The top of the shear gate (6) is connected to a valve stem (8) through a stepped groove structure (7). The top of the valve stem (8) passes through the valve cover (2) and extends to the outside. The middle part of the valve cover (2) is provided with a packing seal chamber (9) for the valve stem (8) to pass through. The vertical mounting cavity (5) has longitudinal guide rails (14) symmetrically arranged on both sides of its inner wall. The upper end of the longitudinal guide rail (14) is fixed to the bottom of the valve cover (2) and is used to move out of the vertical mounting cavity (5) synchronously with the opening of the valve cover (2).

2. The top-mounted wear-resistant shear valve according to claim 1, characterized in that: The inner wall of the fluid passage (4) of the valve body (1) is tightly fitted with a wear-resistant bushing (10), the end of which extends to the inner edge of the vertical mounting cavity (5).

3. The top-mounted wear-resistant shear valve according to claim 1, characterized in that: The bottom of the vertical mounting cavity (5) is provided with a slag discharge groove (11), which penetrates the bottom of the valve body (1) and is connected to a drain flange (12). A sealing blind plate (13) is provided on the drain flange (12).

4. The top-mounted wear-resistant shear valve according to claim 1, characterized in that: The longitudinal guide rail (14) has a groove-shaped cross section; the two sides of the shear gate (6) are respectively embedded in the corresponding longitudinal guide rail (14), and a self-lubricating wear-resistant block (15) is provided between the shear gate (6) and the longitudinal guide rail (14). The self-lubricating wear-resistant block (15) is fixed to the side of the shear gate (6) by countersunk screws. The groove depth of the longitudinal guide rail (14) is greater than the embedding depth of the side of the shear gate (6), and a compensation gap is left between the self-lubricating wear-resistant block (15) and the bottom of the groove.

5. A top-mounted wear-resistant shear valve according to claim 1, characterized in that: The bottom edge of the shear gate (6) is machined with a beveled shearing blade (16), the beveled shearing blade (16) has an inclination angle of 15 degrees to 30 degrees, and the surface of the beveled shearing blade (16) is provided with a hard alloy layer (17) with a thickness of 2 mm to 5 mm.

6. A top-mounted wear-resistant shear valve according to claim 1, characterized in that: The vertical mounting cavity (5) is provided with a detachable valve seat (18) located downstream of the fluid channel (4). The detachable valve seat (18) includes a seat body (19) and a shear sealing ring (20) embedded in the front end of the seat body (19). The seat (19) is fixed in the vertical mounting cavity (5) by a top pressure plate or pressure strip. The inner diameter of the shear sealing ring (20) is consistent with the aperture of the fluid channel (4), and the end face of the shear sealing ring (20) forms a sliding friction pair with the side surface of the shear gate (6).

7. A top-mounted wear-resistant shear valve according to claim 6, characterized in that: The inner edge of the shear sealing ring (20) is machined with a right-angled sharp scraper surface (22), and the right-angled sharp scraper surface (22) and the inclined shearing blade (16) of the shear gate (6) form a shearing point during the closing process.

8. A top-mounted wear-resistant shear valve according to claim 1, characterized in that: The packing sealing chamber (9) is filled with flexible graphite packing (23), and the top of the packing sealing chamber (9) is provided with a pressure cap (24). The pressure cap (24) is connected to the valve cover (2) by two symmetrically arranged hinge bolts (25).

9. A top-mounted wear-resistant shear valve according to claim 1, characterized in that: A metal surrounding gasket (26) is provided between the valve cover (2) and the valve body (1). An annular protrusion (27) is provided on the lower surface of the valve cover (2). A matching annular groove (28) is provided at the top opening of the vertical mounting cavity (5) of the valve body (1). The metal surrounding gasket (26) is placed in the annular groove (28) and is squeezed by the annular protrusion (27).

10. A top-mounted wear-resistant shear valve according to claim 1, characterized in that: The top of the valve stem (8) is connected to a drive mechanism via a flat key.

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