A high-capacity intelligent steam trap
By designing a pilot channel and solenoid valve system for an intelligent steam trap, combined with a capacitive level sensor and a PLC controller, the problems of low efficiency and poor stability of existing steam traps under large-volume drainage are solved, achieving an efficient and stable drainage process and precise adjustment, and reducing maintenance costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- GANSU HONGFENG MASCH CO LTD
- Filing Date
- 2025-05-29
- Publication Date
- 2026-07-31
AI Technical Summary
Existing steam traps are inefficient under high-volume drainage requirements, have high installation requirements, poor stability, and lack intelligent control methods, making them prone to steam leakage and unable to accurately regulate the drainage process.
An intelligent drain valve including a pilot channel and a solenoid valve was designed. Combined with a capacitive liquid level sensor and a PLC controller, the draining process is automatically regulated by opening and closing the solenoid valve. The piston structure enables large-volume draining and is equipped with a filter screen to prevent clogging.
It achieves efficient and stable operation of large-capacity drainage, precisely regulates the drainage process, avoids steam leakage, reduces maintenance costs, and improves energy utilization efficiency.
Smart Images
Figure CN224580109U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of steam trap technology, specifically a large-capacity intelligent steam trap. Background Technology
[0002] Many industrial systems, such as steam heating systems and chemical reaction units, generate large amounts of condensate during operation. Timely and efficient removal of this condensate is crucial for ensuring normal equipment operation, improving energy efficiency, and maintaining system safety and stability. Existing steam traps have some shortcomings.
[0003] Traditional mechanical steam traps have limited drainage capacity and are ill-suited for handling large-volume drainage needs. Float-type steam traps require precise installation location and angle, and are prone to malfunctions due to improper installation. Thermodynamic steam traps exhibit poor operational stability under large load variations and are prone to steam leakage, resulting in energy waste. Furthermore, most existing steam traps lack intelligent control methods and cannot accurately adjust the drainage process based on the actual liquid level. Utility Model Content
[0004] The purpose of this utility model is to provide a large-capacity intelligent steam trap with reasonable structural design, novel concept, convenient operation, easy processing, low processing cost, which can meet the needs of rapid discharge of large amounts of condensate in industrial production, effectively improve the drainage efficiency, and can accurately adjust the drainage process according to the actual liquid level to avoid steam leakage and improve energy utilization efficiency.
[0005] This utility model discloses a large-capacity intelligent drain valve, including a valve body, an inlet on one side of the valve body, and an outlet on the other side of the valve body; a valve cover is fixedly installed on the surface of the valve body, and a pilot channel is provided inside the valve cover. The top end of the pilot channel is connected to a solenoid valve, and the bottom end of the pilot channel is connected to a water supply pipe, which is located inside the valve body; a piston is installed inside the valve body.
[0006] The pilot channel includes a first pilot channel, a second pilot channel, and a third pilot channel. The first pilot channel is L-shaped, with one end connected to a water supply pipeline and the other end connected to a solenoid valve. The second pilot channel is connected inside the solenoid valve and is arranged parallel to the first pilot channel inside the solenoid valve. The bottom end of the second pilot channel is connected to the third pilot channel, and the included angle between the third pilot channel and the second pilot channel is 120°-135°.
[0007] The valve cover and valve body constitute the main components of the entire water supply valve. The pilot channels inside the valve cover include a first pilot channel, a second pilot channel, and a third pilot channel. When condensate enters through the inlet on one side of the valve body, it flows through the water supply pipeline. The condensate in the water supply pipeline flows into the first pilot channel. When the condensate flow rate reaches a certain amount, the solenoid valve opens, and the condensate in the first pilot channel enters the second pilot channel, flows through the third pilot channel, and then enters the piston upper chamber inside the valve body. The pilot channels provide a flow path for the water entering the piston upper chamber and provide power for the piston's operation. At the same time, the opening of the solenoid valve can be automatically adjusted according to the condensate flow rate.
[0008] The solenoid valve is connected to the PLC controller via a solenoid valve signal line; the PLC controller is connected to a capacitive liquid level sensor via a capacitive liquid level sensor signal line, and the capacitive liquid level sensor is installed inside the water inlet through the side wall of the valve body.
[0009] A capacitive level sensor is installed inside the inlet, penetrating the side wall of the valve body. It can accurately detect the liquid level within the valve body in real time. When condensate enters the inlet, and the flow rate reaches the set level monitoring threshold, the capacitive level sensor detects this and converts the detected level information into an electrical signal. This signal is transmitted to the PLC controller via the sensor's signal line. The PLC controller receives and processes the signal, and based on the preset level control value, sends an open or closed command to the solenoid valve, controlling it to open. When the solenoid valve opens, condensate flows through the first pilot channel to the second pilot channel, then through the third pilot channel and the piston inlet into the piston's upper chamber. When the condensate flow rate into the piston's upper chamber reaches a certain amount, the piston seat is compressed, causing the piston rod to move downwards, opening the main valve. Condensate is then discharged through the main valve seat orifice and the main valve seat orifice. At this point, the condensate level in the inlet drops. When it reaches the set lower limit, the capacitive level sensor transmits the detected signal to the PLC. After receiving a signal, the PLC controller will control the solenoid valve to close. The piston rod moves upward under the action of the return spring, thereby closing the main valve. Therefore, the flow rate of the steam trap will be intelligently controlled according to the preset value, making the operation more precise and convenient. It can achieve precise control of condensate flow rate, realize intelligent operation, save manpower and material resources, and simplify the daily operation process of operators. As a pilot valve, the solenoid valve has a fast response speed, high control accuracy, and is not prone to failure. The entire steam trap has a reasonable structural design and can work stably under different working conditions, reducing maintenance costs and downtime, and ensuring the stable operation of the entire water supply process.
[0010] The piston includes a piston seat and a piston rod, with the piston rod fixedly installed inside the piston seat. An upper piston chamber is provided inside the valve body, and a piston inlet is provided on the surface of the upper piston chamber, communicating with a third pilot channel. A piston seat is installed inside the upper piston chamber, and a piston rod is installed on the piston seat. The piston rod penetrates the bottom surface of the upper piston chamber, and its bottom end is connected to a main valve seat. A return spring is fixedly connected to the side wall of the main valve seat, and the bottom surface of the return spring is fixedly connected to the bottom surface of the valve body.
[0011] The piston upper chamber is designed so that when the solenoid valve is opened, condensate enters the piston upper chamber, and the resulting water pressure pushes the piston seat downward. The piston seat drives the piston rod downward, which connects to the main valve seat. The piston rod then drives the main valve seat downward as the return spring is compressed, at which point the main valve seat opens, and condensate flows out through the outlet via the main valve seat hole. When the solenoid valve is closed, the amount of condensate decreases, and the water pressure also decreases. As the compressed return spring returns to its original position, the main valve seat drives the piston rod and piston seat upward, at which point the main valve seat closes, stopping water delivery. The cooperation between the piston upper chamber and the piston enables large-volume drainage. By adopting a pilot-operated water delivery mode, while providing power, the main valve seat has a large flow area when it is open, which can meet the needs of rapid discharge of large amounts of condensate in industrial production, effectively improving drainage efficiency.
[0012] A filter screen is fixedly installed at the inlet end of the first pilot channel. The filter screen is horizontally set and its side wall is connected to the water supply pipe.
[0013] A filter screen is installed at the inlet end of the first pilot channel. This screen can effectively intercept solid impurities in the water supply pipeline from entering the pilot channel and the upper chamber of the piston, preventing the steam trap from becoming clogged and avoiding liquid accumulation, thus ensuring the normal operation of the steam trap. The filter screen can also intercept impurities, reducing wear and corrosion of the internal components of the steam trap. This prevents the steam trap from needing major repairs or replacements due to blockage or damage, thereby reducing maintenance costs and extending the service life of the steam trap.
[0014] The beneficial effects of this utility model are: 1) The solenoid valve and valve body constitute the main components of the entire water supply valve. The pilot channels inside the solenoid valve include a first pilot channel, a second pilot channel, and a third pilot channel. When condensate enters through the inlet on one side of the valve body, it flows through the water supply pipeline. The condensate in the water supply pipeline flows into the first pilot channel. When the condensate flow rate reaches a certain amount, the solenoid valve opens, and the condensate in the first pilot channel enters the second pilot channel, flows through the third pilot channel, and then enters the piston upper chamber inside the valve body. The pilot channels provide a flow path for the water entering the piston upper chamber and provide power for the piston's operation. At the same time, the opening of the solenoid valve can be automatically adjusted according to the condensate flow rate.
[0015] 2) The capacitive level sensor is installed inside the inlet, penetrating the side wall of the valve body. It can accurately detect the liquid level in the valve body in real time. When condensate enters the inlet, and the water flow reaches the set liquid level monitoring value, the capacitive level sensor will detect it and convert the detected liquid level information into an electrical signal. This signal is then transmitted to the PLC controller via the capacitive level sensor signal line. After receiving the signal, the controller analyzes and processes it. Based on the preset liquid level control value, it sends an open or close command to the solenoid valve, controlling it to open. When the solenoid valve opens, condensate flows through the first pilot channel into the second pilot channel, and then through the third pilot channel and the piston inlet into the piston upper chamber. When the condensate flow rate into the piston upper chamber reaches a certain amount, the compression piston seat drives the piston rod downward, opening the main valve seat. Condensate is then discharged through the main valve seat orifice and the main valve seat orifice. At this time, the condensate level in the inlet drops. When it reaches the set lower limit, the capacitive liquid level sensor transmits the detected signal to the PLC controller. After receiving the signal, the controller will control the solenoid valve to close, and the piston rod will move upward under the action of the return spring, thereby closing the main valve seat. Therefore, the flow rate of the steam trap will be intelligently controlled according to the preset value, making the operation more precise and convenient. It can achieve precise control of condensate flow rate, realize intelligent operation, save manpower and material resources, and simplify the daily operation process of operators. As a pilot valve, the solenoid valve has a fast response speed, high control accuracy, and is not prone to failure. The entire steam trap has a reasonable structural design and can work stably under different working conditions, reducing maintenance costs and downtime, and ensuring the stable operation of the entire water conveyance process.
[0016] 3) The piston upper chamber is designed so that when the solenoid valve is opened, condensate enters the piston upper chamber, and the resulting water pressure pushes the piston seat downward. The piston seat drives the piston rod downward, and the piston rod connects to the main valve seat, causing the main valve seat to move downward as the return spring is compressed. At this time, the main valve seat opens, and condensate flows through the main valve seat hole and out through the outlet. When the solenoid valve is closed, the amount of condensate decreases, and the water pressure also decreases. As the compressed return spring returns to its original position, the main valve seat drives the piston rod and piston seat upward, at which point the main valve seat closes, stopping water delivery. The cooperation between the piston upper chamber and the piston enables large-volume drainage. The pilot-operated water delivery mode provides power while providing a large flow area when the main valve seat is open, which can meet the needs of rapid discharge of large amounts of condensate in industrial production and effectively improve drainage efficiency.
[0017] 4) A filter screen is installed at the inlet end of the first pilot channel, which can effectively intercept solid impurities in the water supply pipeline from entering the pilot channel and the upper chamber of the piston, so as to prevent the steam trap from being blocked, avoid liquid accumulation, and ensure the normal operation of the steam trap. The filter screen can intercept impurities, reduce the wear and corrosion of impurities on the internal components of the steam trap, avoid the need for major repairs or replacement of the steam trap due to blockage or damage, thereby reducing maintenance costs and extending the service life of the steam trap.
[0018] 5) This steam trap features a reasonable structural design, novel concept, convenient operation, and easy processing, resulting in low manufacturing costs. It meets the industrial production demand for rapid discharge of large amounts of condensate, effectively improving drainage efficiency. The drainage process can be precisely adjusted according to the actual liquid level, preventing steam leakage and improving energy efficiency. Utilizing a capacitive level sensor to accurately detect liquid level changes in real time, combined with the intelligent analysis and control of a PLC controller, the drainage process can be precisely adjusted according to the actual liquid level, preventing steam leakage and improving energy efficiency. The upper and lower limits of the liquid level can be flexibly set via the PLC controller to adapt to the drainage needs of different industrial systems, demonstrating broad application prospects. Attached Figure Description
[0019] Figure 1 This is a schematic diagram of the structure of this utility model.
[0020] In the diagram: Valve body 1, water supply pipe 1-1, water inlet 2, capacitive level sensor 3, capacitive level sensor signal line 3-1, solenoid valve 4, solenoid valve signal line 4-1, PLC controller 5, first pilot channel 6-1, second pilot channel 6-2, third pilot channel 6-3, piston upper chamber 7, piston inlet 7-1, piston seat 8-1, piston rod 8-2, main valve seat 9, water outlet 10, return spring 11, filter screen 12, valve cover 13, main valve seat hole 14. Detailed Implementation
[0021] Example 1. The present invention will be further described below with reference to the accompanying drawings.
[0022] This utility model includes a valve body 1, a water supply pipe 1-1, a water inlet 2, a capacitive liquid level sensor 3, a capacitive liquid level sensor signal line 3-1, a solenoid valve 4, a solenoid valve signal line 4-1, a PLC controller 5, a first pilot channel 6-1, a second pilot channel 6-2, a third pilot channel 6-3, a piston upper chamber 7, a piston inlet 7-1, a piston seat 801, a piston rod 802, a main valve seat 9, a water outlet 10, a return spring 11, and a valve cover 13. Specifically, the valve body 1 has a water inlet 2 on one side and a water outlet 10 on the other side. A valve cover 13 is fixedly installed on the surface of the valve body 1. A pilot channel is provided inside the valve cover 13. The top end of the pilot channel is connected to the solenoid valve 4, and the bottom end of the pilot channel is connected to the water supply pipe 1-1, which is located inside the valve body 1. A piston 8 is installed inside the valve body 1.
[0023] The pilot channel includes a first pilot channel 6-1, a second pilot channel 6-2, and a third pilot channel 6-3. The first pilot channel 6-1 is L-shaped, with one end connected to the water supply pipe 1-1 and the other end connected to the solenoid valve 4. The second pilot channel 6-2 is connected inside the solenoid valve 4. The second pilot channel 6-2 and the first pilot channel 6-1 are arranged side by side inside the solenoid valve 4. The bottom end of the second pilot channel 6-2 is connected to the third pilot channel 6-3. The included angle between the third pilot channel 6-3 and the second pilot channel 6-2 is 120°-135°.
[0024] The solenoid valve 4 is connected to the PLC controller 5 via the solenoid valve signal line 4-1; the PLC controller 5 is connected to the capacitive liquid level sensor 3 via the capacitive liquid level sensor signal line 3-1, and the capacitive liquid level sensor 3 is installed inside the water inlet 2 through the side wall of the valve body 1.
[0025] The piston includes a piston seat 8-1 and a piston rod 8-2. The piston rod 8-2 is fixedly installed inside the piston seat 8-1. The valve body 1 has an upper piston chamber 7 inside, and a piston inlet 7-1 is provided on the surface of the upper piston chamber 7. The piston inlet 7-1 is connected to the third pilot channel 6-3. The piston seat 8-1 is installed inside the upper piston chamber 7. The piston rod 8-2 is installed on the piston seat 8-1. The piston rod 8-2 passes through the bottom surface of the upper piston chamber 7. The bottom end of the piston rod 8-2 is connected to the main valve seat 9. A return spring 11 is fixedly connected to the side wall of the main valve seat 9. The bottom surface of the return spring 11 is fixedly connected to the inner bottom surface of the valve body 1.
[0026] The solenoid valve 4 is model SMC VXS255HA; the PLC controller 5 is model Gumei EX3G-43C; and the capacitive liquid level sensor 3 is model Hollicol HPT621.
[0027] Instructions for use: 1) Before use, install valve body 1 on the drainage pipe of the industrial system according to the design requirements, ensuring that the inlet 2 is tightly connected to the equipment that generates condensate, and the outlet 10 is firmly connected to the drainage pipe to ensure good sealing and prevent leakage; 2) Insert the capacitive level sensor 3 into the inlet flange of valve body 1 to accurately reflect changes in liquid level. During installation, ensure that the capacitive level sensor 3 is firmly fixed to avoid affecting the detection accuracy due to vibration or other factors. Connect the capacitive level sensor 3 to the PLC controller 5 through the capacitive level sensor signal line 3-1; 3) Install the solenoid valve 4 on the pilot channel 6-1 of valve cover 13, connect the control line 4-1 of solenoid valve 4 to the pipeline of the pilot channel, and ensure reliable connection. Connect the control line 4-1 of solenoid valve 4 to the PLC controller 5; 4) Install piston seat 8-1, piston rod 8-2 and main valve seat 9 inside valve body 1, ensuring that piston seat 8-1 and piston rod 8-2 can move flexibly in the upper chamber 7 of the piston, and that the main valve seat 9 fits well with valve body 1; 5) Connect the PLC... The controller 5 is installed in a location that is easy to operate and maintain. It is powered on and parameters such as the upper and lower limits of the liquid level are set according to the actual application scenario.
[0028] After installation, conduct trial operation: 1) After installation, perform comprehensive debugging. Check whether the installation of each component is correct, whether the connection is firm, and whether the electrical circuit is normal; 2) Introduce a small amount of condensate into the system and observe the operation of the capacitive level sensor 3 to check whether it can accurately detect the liquid level and transmit the signal to the PLC controller 5; 3) Manually control the opening and closing of the solenoid valve 4 through the PLC controller 5 and observe whether the action of the piston seat 801, piston rod 802, and main valve seat 9 is normal, and whether the main valve seat 9 channel can drain normally; 4) Set appropriate upper and lower limits for the liquid level and let the system run automatically. Observe the operation of the steam trap at different liquid levels and check whether it can accurately perform the condensate drainage operation according to the preset strategy and whether there are problems such as steam leakage; 5) Conduct long-term operation tests on the system to monitor its working stability and reliability, and make necessary adjustments and optimizations to the parameters based on the test results.
[0029] In use: When condensate enters through the inlet 2 on one side of valve body 1, it flows through water supply pipe 1-1. The condensate entering water supply pipe 1-1 flows into the first pilot channel 6-1. When the condensate flow rate reaches a certain amount, and when the flow rate reaches the set liquid level monitoring value, the capacitive liquid level sensor 3 will detect it and convert the detected liquid level information into an electrical signal, which is transmitted to the PLC controller 5 through the capacitive liquid level sensor signal line 3-1. After receiving the signal, the controller 5 analyzes and processes it. Based on the preset liquid level control value, it sends an opening command to the solenoid valve 4, controlling the solenoid valve 4 to open. When the solenoid valve 4 opens, condensate will enter the second pilot channel 6-2 through the first pilot channel 6-1, and then enter the upper chamber 7 of the piston through the third pilot channel 6-3 and the piston inlet 7-1. The resulting water pressure will push the piston seat 8-1 downward, causing the piston rod 8-2 to move downward. The piston rod 8-2 is connected to the main valve seat 9, causing the main valve seat 9 to move downward with the compression of the return spring 11. At this time, the main valve seat 9 opens, and the condensate flows through the main valve seat hole 14 and out through the outlet 10. When the flow rate of condensate entering the upper chamber 7 of the piston reaches a certain amount, the condensate level in the inlet 2 will drop. When the set lower limit of the water level is reached, the capacitive liquid level sensor 3 transmits the detected signal to the PLC controller 5. After receiving the signal, the controller 5 will control the solenoid valve 4 to close, which will reduce the amount of condensate and the water pressure. As the compressed return spring 11 returns to its original position, the main valve seat 9 will drive the piston rod 8-2 and piston seat 8-1 to move upward. At this time, the main valve seat 9 will close and stop water supply. The cooperation between the piston upper chamber 7, piston seat 801, and piston rod 802 can achieve large-volume drainage.
[0030] Post-use maintenance: 1) Regularly check the working status of the capacitive level sensor 3, clean the probe of the capacitive level sensor 3 to prevent dirt and impurities from affecting the detection accuracy, and calibrate or replace the capacitive level sensor 3 if necessary; 2) Check whether the valve core of the solenoid valve 4 is flexible and whether the seal is good, and regularly clean the air inlet or power interface of the solenoid valve 4 to prevent dust and debris from entering; perform regular performance tests on the solenoid valve 4 to ensure that it can open and close normally; 3) Observe the wear of the piston 8 and the main valve seat 9, and replace any severely worn parts in time; regularly clean the internal channels of the valve body 1 to prevent impurities from accumulating and affecting the drainage effect; 4) Check the operation of the PLC controller 5, check for fault alarm information, regularly back up the program and data of the PLC controller 5 to prevent data loss, and update the software version of the PLC controller 5 in time to improve the performance and stability of the system.
[0031] Example 2. This utility model includes a valve body 1, a water supply pipe 1-1, a water inlet 2, a capacitive liquid level sensor 3, a capacitive liquid level sensor signal line 3-1, a solenoid valve 4, a solenoid valve signal line 4-1, a PLC controller 5, a first pilot channel 6-1, a second pilot channel 6-2, a third pilot channel 6-3, a piston upper chamber 7, a piston inlet 7-1, a piston seat 801, a piston rod 802, a main valve seat 9, a water outlet 10, a return spring 11, a filter screen 12, and a valve cover 13. Specifically, the valve body 1 has a water inlet 2 on one side and a water outlet 10 on the other side. A valve cover 13 is fixedly installed on the surface of the valve body 1. A pilot channel is provided inside the valve cover 13. The top end of the pilot channel is connected to the solenoid valve 4, and the bottom end of the pilot channel is connected to the water supply pipe 1-1, which is located inside the valve body 1. A piston 8 is installed inside the valve body 1.
[0032] The pilot channel includes a first pilot channel 6-1, a second pilot channel 6-2, and a third pilot channel 6-3. The first pilot channel 6-1 is L-shaped, with one end connected to the water supply pipe 1-1 and the other end connected to the solenoid valve 4. The second pilot channel 6-2 is connected inside the solenoid valve 4. The second pilot channel 6-2 and the first pilot channel 6-1 are arranged side by side inside the solenoid valve 4. The bottom end of the second pilot channel 6-2 is connected to the third pilot channel 6-3. The included angle between the third pilot channel 6-3 and the second pilot channel 6-2 is 120°-135°.
[0033] The solenoid valve 4 is connected to the PLC controller 5 via the solenoid valve signal line 4-1; the PLC controller 5 is connected to the capacitive liquid level sensor 3 via the capacitive liquid level sensor signal line 3-1, and the capacitive liquid level sensor 3 is installed inside the water inlet 2 through the side wall of the valve body 1.
[0034] The piston includes a piston seat 8-1 and a piston rod 8-2. The piston rod 8-2 is fixedly installed inside the piston seat 8-1. The valve body 1 has an upper piston chamber 7 inside, and a piston inlet 7-1 is provided on the surface of the upper piston chamber 7. The piston inlet 7-1 is connected to the third pilot channel 6-3. The piston seat 8-1 is installed inside the upper piston chamber 7. The piston rod 8-2 is installed on the piston seat 8-1. The piston rod 8-2 passes through the bottom surface of the upper piston chamber 7. The bottom end of the piston rod 8-2 is connected to the main valve seat 9. A return spring 11 is fixedly connected to the side wall of the main valve seat 9. The bottom surface of the return spring 11 is fixedly connected to the inner bottom surface of the valve body 1.
[0035] A filter screen 12 is fixedly installed at the inlet end of the first pilot channel 6-1. The filter screen 12 is horizontally set and its side wall is connected to the water supply pipe 1-1. The pore size of the filter screen 12 is 0.4 mm to 1.2 mm. It is used to filter impurities in the condensate water to prevent impurities from clogging the drain hole, thereby ensuring the normal operation of the drain valve; at the same time, it is convenient to disassemble and clean.
[0036] Instructions for use: 1) Before use, valve body 1 can be installed on the drainage pipe of the industrial system according to the design requirements, ensuring that the inlet 2... 1) Ensure a tight connection with the equipment that generates condensate, and a secure connection between the outlet 10 and the drainage pipe to guarantee a good seal and prevent leakage; 2) Insert the capacitive level sensor 3 into the inlet flange of the valve body 1 to accurately reflect changes in liquid level. During installation, ensure the capacitive level sensor 3 is firmly fixed to avoid affecting detection accuracy due to vibration or other factors. Connect the capacitive level sensor 3 to the PLC controller 5 via the capacitive level sensor signal line 3-1; 3) Install the solenoid valve 4 on the first pilot channel 6-1 of the valve cover 13. A filter screen 12 is fixedly installed at the end of the first pilot channel 6-1. Connect the control line 4-1 of the solenoid valve 4 to the pipeline of the pilot channel to ensure a reliable connection. Connect the control line 4-1 of the solenoid valve 4 to the PLC controller 5; 4) Install the piston seat 801, piston rod 802, and main valve seat 9 inside the valve body 1, ensuring that the piston seat 801 and piston rod 802 can move flexibly within the upper chamber 7 of the piston, and that the main valve seat 9 fits well with the valve body 1; 5) Connect the PLC... The controller 5 is installed in a location that is easy to operate and maintain. It is powered on and parameters such as the upper and lower limits of the liquid level are set according to the actual application scenario.
[0037] After installation, conduct trial operation: 1) After installation, perform comprehensive debugging. Check whether the installation of each component is correct, whether the connection is firm, and whether the electrical circuit is normal; 2) Introduce a small amount of condensate into the system and observe the operation of the capacitive level sensor 3 to check whether it can accurately detect the liquid level and transmit the signal to the PLC controller 5; 3) Manually control the opening and closing of the solenoid valve 4 through the PLC controller 5 and observe whether the action of the piston seat 801, piston rod 802, and main valve seat 9 is normal, and whether the main valve seat 9 channel can drain normally; 4) Set appropriate upper and lower limits for the liquid level and let the system run automatically. Observe the operation of the steam trap at different liquid levels and check whether it can accurately perform the condensate drainage operation according to the preset strategy and whether there are problems such as steam leakage; 5) Conduct long-term operation tests on the system to monitor its working stability and reliability, and make necessary adjustments and optimizations to the parameters based on the test results.
[0038] In use: When condensate enters through the inlet 2 on one side of valve body 1, it flows through water supply pipe 1-1. The condensate entering water supply pipe 1-1 flows into the first pilot channel 6-1. When the condensate flow rate reaches a certain amount, and when the flow rate reaches the set liquid level monitoring value, the capacitive liquid level sensor 3 will detect it and convert the detected liquid level information into an electrical signal, which is transmitted to the PLC controller 5 through the capacitive liquid level sensor signal line 3-1. After receiving the signal, the controller 5 analyzes and processes it. Based on the preset liquid level control value, it sends an opening command to the solenoid valve 4, controlling the solenoid valve 4 to open. When the solenoid valve 4 opens, condensate will enter the second pilot channel 6-2 through the first pilot channel 6-1, and then enter the upper chamber 7 of the piston through the third pilot channel 6-3 and the piston inlet 7-1. The resulting water pressure will push the piston seat 8-1 downward, causing the piston rod 8-2 to move downward. The piston rod 8-2 is connected to the main valve seat 9, causing the main valve seat 9 to move downward with the compression of the return spring 11. At this time, the main valve seat 9 opens, and the condensate flows through the main valve seat hole 14 and out through the outlet 10. When the flow rate of condensate entering the upper chamber 7 of the piston reaches a certain amount, the condensate level in the inlet 2 will drop. When the set lower limit of the water level is reached, the capacitive liquid level sensor 3 transmits the detected signal to the PLC controller 5. After receiving the signal, the controller 5 will control the solenoid valve 4 to close, reducing the amount of condensate and the water pressure. As the compressed return spring 11 returns to its original position, the main valve seat 9 drives the piston rod 8-2 and piston seat 8-1 to move upward. At this time, the main valve seat 9 closes, stopping water delivery. The cooperation of the piston upper chamber 7, piston seat 801, and piston rod 802 enables large-volume drainage. The filter screen 12 effectively intercepts solid impurities in the water delivery pipe 1-1 from entering the pilot channel and piston upper chamber 7, preventing the steam trap from clogging and avoiding liquid accumulation, thus ensuring the normal operation of the steam trap. The filter screen 12 can intercept impurities, reducing wear and corrosion of the internal components of the steam trap, avoiding the need for major repairs or replacement due to clogging or damage, thereby reducing maintenance costs and extending the service life of the steam trap.
[0039] Post-use maintenance: 1) Regularly check the working status of the capacitive level sensor 3, clean the probe of the capacitive level sensor 3 to prevent dirt and impurities from affecting the detection accuracy, and calibrate or replace the capacitive level sensor 3 if necessary; 2) Check whether the valve core of the solenoid valve 4 is flexible and whether the seal is good, and regularly clean the air inlet or power interface of the solenoid valve 4 to prevent dust and debris from entering; perform regular performance tests on the solenoid valve 4 to ensure that it can open and close normally; 3) Observe the wear of the piston 8 and the main valve seat 9, and replace any severely worn parts in time; regularly clean the internal channels of the valve body 1 to prevent impurities from accumulating and affecting the drainage effect; 4) Check the operation of the PLC controller 5, check for fault alarm information, regularly back up the program and data of the PLC controller 5 to prevent data loss, and update the software version of the PLC controller 5 in time to improve the performance and stability of the system.
Claims
1. A large capacity intelligent drain valve characterized by: The valve body (1) includes a valve body (1), an inlet (2) on one side of the valve body (1) and an outlet (10) on the other side of the valve body (1); a valve cover (13) is fixedly installed on the surface of the valve body (1), a pilot channel is provided inside the valve cover (13), the top end of the pilot channel is connected to the solenoid valve (4), the bottom end of the pilot channel is connected to the water supply pipe (1-1), and the water supply pipe (1-1) is located inside the valve body (1); a piston is installed inside the valve body (1).
2. A large capacity intelligent drain trap as defined in claim 1, wherein: The pilot channel includes a first pilot channel (6-1), a second pilot channel (6-2), and a third pilot channel (6-3). The first pilot channel (6-1) is L-shaped. One end of the first pilot channel (6-1) is connected to the water supply pipe (1-1), and the other end of the first pilot channel (6-1) is connected to the solenoid valve (4). The second pilot channel (6-2) is connected inside the solenoid valve (4). The second pilot channel (6-2) and the first pilot channel (6-1) are arranged side by side inside the solenoid valve (4). The bottom end of the second pilot channel (6-2) is connected to the third pilot channel (6-3). The included angle between the third pilot channel (6-3) and the second pilot channel (6-2) is 120°-135°.
3. A large capacity intelligent drain trap as defined in claim 2 wherein: The solenoid valve (4) is connected to the PLC controller (5) via the solenoid valve signal line (4-1); the PLC controller (5) is connected to the capacitive liquid level sensor (3) via the capacitive liquid level sensor signal line (3-1), and the capacitive liquid level sensor (3) is installed inside the water inlet (2) through the side wall of the valve body (1).
4. A large capacity intelligent drain trap as defined in claim 3 wherein: The piston includes a piston seat (8-1) and a piston rod (8-2). The piston rod (8-2) is fixedly installed inside the piston seat (8-1). The valve body (1) is provided with an upper piston chamber (7). The surface of the upper piston chamber (7) is provided with a piston inlet (7-1). The piston inlet (7-1) is connected to the third pilot channel (6-3). The upper piston chamber (7) is provided with a piston seat (8-1). The piston rod (8-2) is installed on the piston seat (8-1). The piston rod (8-2) passes through the bottom surface of the upper piston chamber (7). The bottom end of the piston rod (8-2) is connected to the main valve (9). The side wall of the main valve (9) is fixedly connected with a spring (11). The bottom surface of the spring (11) is fixedly connected to the bottom surface of the valve body (1).
5. A large capacity intelligent drain trap as defined in claim 4 wherein: A filter screen (12) is fixedly installed at the inlet end of the first pilot channel (6-1). The filter screen (12) is set horizontally and its side wall is connected to the water supply pipe (1-1).