Valve and system

Abstract

To provide a switching valve that may include an inlet, a main line outlet, a flow control outlet and a bypass member.SOLUTION: The present invention relates to a switching valve including an inlet, a main line outlet, a flow control outlet, and a bypass member. The bypass member comprises a passage extending through an axis of the bypass member, and a plurality of notches. In some embodiments, the switching valve may be configured such that the bypass member is switchable between an open position that allows flow from the inlet to the main line outlet and a flow control position that allows flow from the inlet to the flow control outlet.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] A valve including an inlet, a main line outlet, a flow control outlet, and a bypass member. Here, the bypass member includes a passage extending through the axis of the bypass member and a plurality of notches.

Summary of the Invention

[0002] A switching valve related to a switching valve that may include an inlet, a main line outlet, a flow control outlet, and a bypass member. Here, the bypass member includes a passage extending through the axis of the bypass member and a plurality of notches. In some embodiments, the switching valve may be configured to be switchable between an open position that allows flow from the inlet to the main line outlet and a flow control position that allows flow from the inlet to the flow control outlet.

Brief Description of the Drawings

[0003]

Figure 1

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DETAILED DESCRIPTION OF THE INVENTION

[0004] The following "DETAILED DESCRIPTION OF THE INVENTION" is merely illustrative and is not intended to limit the embodiments and / or application examples or usage methods of the embodiments. Furthermore, it is not intended that the explicit or implicit information presented in the preceding "TECHNICAL FIELD" or "SUMMARY OF THE INVENTION" sections, or in this "DETAILED DESCRIPTION OF THE INVENTION" section, binds the present invention.

[0005] One or more embodiments are described with reference to the drawings, and the same reference numerals are used throughout to refer to the same elements. In the following description, for the purpose of explanation, several specific details are set forth in order to provide a more thorough understanding of one or more embodiments. However, it is clear that in various cases, one or more embodiments can be implemented without these specific details.

[0006] Disclosed below is a new ball 26 valve design for a piggable system, as shown in FIGS. 1 through 8. The valve is a two-way valve and can be a two-way valve used to inspect the wear of the pig and replace the pig if necessary. When the valve is open, paint and the pig can freely flow through the valve into the paint line 40 or into the flow control system. When the valve is closed, the pig 14 can be captured, inspected, and replaced. By providing a pig inspection station 12 in the paint line 40, the end user can automatically monitor the life of the pig. When the pig 14 is completely worn out, the end user can easily attach a new pig. This pig inspection station 12 can not only omit expensive repair work due to a failed pig in the piggable paint line 40, but also save wasted production downtime. The pig inspection station 12 can include not only the main line 40, but also the solvent line 44, the air line 46, and the discharge line 48.

[0007] As used herein, the flow control device 72 can be used in the flow control line 42 and can be a device that measures and controls the exact amount of flow of paint or other coatings. A painting system used by a Tier 1 in the automotive industry may have a flow control device 72 for supplying paint to the applicator 54. When the applicator(s) 54 is not performing spray painting, the paint or coating in the line can be recovered to the paint header or the original paint container. In current systems, pigs and pigging devices are used to recover this paint. However, the pig cannot pass through the flow control device 72.

[0008] Furthermore, the paint line 40 and the flow control device 72 also need to be cleaned after the recovery process for the preparation of a new paint color or a different coating. By cleaning the main paint line 40 and the flow control device 72 independently and simultaneously, time can be saved.

[0009] Therefore, in these systems, a valve such as the switching valve 10 of the present embodiment that can separate the main paint line 40 from the flow control device 72 is required. Such a valve can block the flow to the flow control device 72 and allow the pig to pass through the valve during recovery and cleaning. The same valve must be changed in state as needed to allow the paint flow to flow into the flow control device 72. This is achieved, for example, by operating the rotary actuator 16 on the valve through the use of the actuator stem 60 acting on the bypass member 26.

[0010] When the pigging-capable paint line 40 is emptied and ready to be filled with a new color of paint, the pig 14 can be inspected. The pig 14 starts the inspection process at the capture / firing 56 block of the pig 14 located in the main color header 38. The pig 14 can be fired from there using compressed air. The pig inspection station 12 can be configured to capture the pig 14 by the rotation of the center ball of the station, where the rotation can be caused by a rotary actuator attached to the ball. The discharge valve 50 can be opened to exhaust any pressurized air on the downstream side of the pig 14 from the line. When the pig 14 seats against the center ball, the magnetic pig 14 position sensor detects the presence of the magnet 20 in the pig 14 and sends a signal to the control unit indicating that the pig 14 is in a predetermined position and ready for inspection.

[0011] When the inspection of the pig 14 is ready, the rotary actuator rotates 90° counterclockwise to place the center ball 26 in the inspection position. The pig 14 sensor is configured to continue to indicate a signal indicating "in a predetermined position". By opening the air valve 34, compressed air can fill the gap and pressurize the lower lip of the pig. During the inspection, the discharge valve 50 can be kept open to exhaust the pressurized air that has escaped around the lip of the pig 14 to the central chamber of the inspection station. The pressure sensor can monitor the pressure in the filled gap and send the data to the control unit. The pressure is monitored for a certain period of time (for example, 30 seconds). If the pressure decay during this period reaches a certain level (for example, a 25% or 2 bar drop), the wear of the lip has reached such an extent that the pig 14 cannot withstand use and needs to be replaced. It can be indicated by a signal from the control unit that the pig 14 must be replaced before the paint line 40 can be used again. If the pressure decay during this period is below the threshold value, the lip of the pig 14 is still in good condition and the pig 14 is sufficient for continued use. It can be indicated by a signal from the control unit that the pig 14 is suitable for continued use in the paint line 40. At this point, regardless of the condition of the pig 14, the air valve 34 is closed and the compressed air supply source is sealed. The discharge valve 50 is opened to allow all pressurized air to be exhausted and released.

[0012] The valve and the system can utilize the pig. The pig 14 includes a magnet 20, and the magnet 20 is configured to interact with sensors for magnets 20 arranged throughout the system to indicate the position of the pig 14 within the system. The pig 14 can include a pig body 18 that is configured to be attached to the end cap 22 via at least one holding valve 24. Additionally, an adhesive may be used to attach the end cap 22 to the pig body 18. The pig body 18 and the end cap 22 surround the magnet 20.

[0013] If the pig 14 needs to be replaced, the control unit can send a (plural) signal to cause the inspection station to enter the pig 14 replacement sequence. The air valve 34 and the discharge valve 50 can be opened. The pressure applied to the upper lip of the pig 14 pushes the pig 14 downward until the pig 14 stops against the pig replacement stem. The discharge valve 50 exhausts all the pressurized air located below the pig 14 that may prevent the pig 14 from seating against the stem. The pig 14 sensor can send a signal indicating that the pig 14 is not in a predetermined position. The air valve 34 is closed and any pressurized air can be exhausted through the discharge valve 50. The user can extract the pig replacement stem. When extracting this stem 74, the stem 74 may be magnetized or manufactured from the material of the magnet 20 so that the pig 14 remains attached to the stem 74. Based on the removal of the stem 74, the old pig 14 can be discarded and a new pig can be inserted into the stem. The stem 74 can be returned into the inspection station. If for some reason the pig 14 was not seated on the stem 74 before removal, the stem 74 can be removed once and the pig 14 can be retrieved using a tool. When a new pig 14 is installed, the user can press a button on the control unit to indicate that the new pig 14 is installed and ready for use. The discharge valve 50 can be closed based on this installation.

[0014] The air valve 34 and the discharge valve 50 can be opened based on the installation. Compressed air can push the pig 14 back to the seating position within the center ball. The pig 14 position sensor indicates a signal representing "in a predetermined position" based on the detection of the magnet 20. All valves are closed.

[0015] The rotary actuator rotates the center ball 26 and returns the center ball 26 to the capture position of the pig 14. The pig 14 position sensor indicates a signal representing "being in a predetermined position". The air valve 34 can be opened. Compressed air pushes the pig 14 out of the inspection station and returns it to the launch / capture block of the main color header 38. The pig 14 sensor located in the block can transmit a signal indicating that the pig 14 has returned and is ready for normal use based on the detection of the magnet 20 inside the pig.

[0016] Paint from the main color header 38 fires the pig 14 and passes it through the main line. Sometimes, a small amount of paint is injected in front of the pig 14 to function as a lubricant. The pig 14 passes through the inspection station without stopping for inspection, passes through the main line, and continues to move forward until it reaches the capture block of the robotic arm. The preparation for spraying the paint is now completed here.

[0017] When filling the main line with a new color of paint, first the old color of paint must be removed. After the old color of paint is removed, the main line is washed with a solvent, and the old color of paint on the main line is completely removed. At this time, the inspection station is also washed, and the old paint in the central chamber and passageways is removed. If the washing is not performed, paint leakage may occur at the seal of the ball 26 after use when leakage has started from the seal of the ball 26. By performing the washing, all areas where paint may be present can be cleaned. The rotary actuator rotates 90° counterclockwise, and the center ball 26 enters the inspection position. The solvent valve 36 is opened in the same way as both discharge valves 50. For a predetermined period of time, the solvent is fed in and passes through the inspection station. After this time, the solvent valve 36 is closed, and both air valves 34 are opened. The air valves 34 are open for a predetermined period of time to remove the solvent from the inspection station. After this time, all valves are closed. The preparation for normal use of the inspection station and the main line is now completed here.

[0018] Disclosed below is a new valve design for a pickable system, which is a three-way valve used to divert / bypass the paint flow from the main paint line 40 to the flow control device. When the valve is open, the pig, paint, or cleaning material passes through the valve and moves through the main paint line. When the valve is closed, the paint is blocked from flowing through the main line and is instead switched to the flow control device 72.

[0019] When the applicator 54 is ready for spraying, the paint must be filled in the main line all the way to the applicator 54. Based on this filling, the bypass valve can be in the open position. The ball 26 can be oriented so that the paint can flow through the ball 26. A seat can be installed against the ball, which can seal the paint and prevent the paint from moving outside the main line flow path 32.

[0020] The main paint line 40, including the passage 32 through the ball, can be sized to allow the pig 14 to pass through easily and without gaps. In the paint filling cycle, the paint can push the pig 14 out of the pig 14 launch 56 valve, pass it through the line, pass it through the ball 26 of the bypass valve, and push it into the pig 14 capture valve. When the pig 14 is detected by the capture valve, the line is filled with paint. Open two valves near the flow control device 72, and the passage from the device and the passage to the device can be filled with the paint flowing in from the main line. At this point, the system is ready to spray the paint while performing flow control.

[0021] The bypass valve can be closed based on the opening of the valve in the vicinity of the flow control device 72. The flow control device 72 can be turned on simultaneously with the closing of the bypass valve. The seat on the downstream side of the ball 26 forms a seal against the ball 26, preventing the paint from flowing in any direction other than towards the applicator 54. The notch on the upstream side of the ball 26 allows the paint to flow around the ball 26 and enter the central section of the valve body. The paint flowing from the central section of the valve body can pass through the hole in the center of the ball, through the manifold and fittings, and flow into the flow control device 72. The paint flowing from the flow control device 72 can flow to another valve located downstream of the bypass valve within the main paint line 40. When this valve is opened, the flow-controlled paint can flow into the main line and out to the applicator 54. The applicator 54 is now spraying the paint while capturing the exact volume and flow rate of the paint.

[0022] Based on the end of paint use, it is advisable to recover the paint remaining in the line. The flow control device 72 can be turned off and the bypass valve can be opened again. The pig 14 within the pig 14 capture valve can be released using the pressurized air applied from behind. The pig 14 can push the paint, pass through the main line, through the bypass valve and the ball, and return to the pig 14 launch 56 valve. When the pig 14 is detected at the pig 14 launch / capture 56 valve, it means that the paint has already been recovered from the system.

[0023] While the paint is being recovered, the sheet forms a seal against ball 26 and can block any flow to or from the central section of the valve body. At this point, the cleaning of flow control device 72, the passageways leading to flow control device 72, and the passageways from flow control device 72 is initiated. Manifold block 70, which can be attached to the valve body, faces the central section of the valve body and can have a fluid passageway that directly faces the ball. Also, solvent valves and air valves 34 can be attached to manifold block 70. During paint recovery, the solvent valves and air valves 34 can be repeatedly turned on and off to alternately supply solvent and air to the central section of the valve body, the passageways to flow control device 72, and flow control device 72 (solvent air chop). In this way, it is good to clean these components and passageways. The solvent air chop can be sent to another valve after passing through flow control device 72 and discharged to a waste manifold there. During this cleaning process, all paint is removed from the outer diameter of ball 26. This can provide that there are no small areas where paint remains and which could cause color contamination of the paint. This is even more advantageous when the sheet is worn and starts to leak a small amount of paint.

[0024] Based on the recovery process taking place in the main line, separate solvent and air chops can clean these lines. This line cleaning is preferably done simultaneously with the cleaning of flow control device 72.

[0025] Flow control device 72 can be any assembly that can control the precise flow rate of paint. Examples include gear pumps and Ransburg Material Valve Regulators (MVRs) manufactured by Carlisle Fluid Technologies, Inc.

[0026] Further disclosed below is a new method for controlling the pressure and flow rate of the paint supplied to the applicator 54. This system, in addition to controlling the pressure and flow rate of the paint, provides the pig 14 with means to return the paint to the main paint line, thereby realizing cost savings for the end user through paint recovery.

[0027] This disclosure enables single pump flow control using a single-color color laminate. Each paint applicator 54 requires only a single fluid panel and a single-color color laminate, and each fluid panel requires only a single pump for flow control. The only additional requirement for flow control may be a gear pump. Further, the control of the pressure and flow rate of the paint is not implemented on the robotic arm within the spray booth. In some embodiments, the fluid panel is located in a more practical area outside the spray booth.

[0028] The embodiments disclosed herein may further be used in a 2K (two-component) system for isocyanates, polyols, and / or catalysts. The embodiments disclosed herein may similarly be used for solvent-based paints and water-based paints. The embodiments disclosed herein enable the monitoring of the overall state of the system, as the pigging-enabled flow control can be integrated into the plant's main programmable logic controller so that the state of each fluid panel can be remotely monitored. In a 2K system, a catalyst line 52 may be used.

[0029] The switching valve 10 can include an inlet 62, a main line outlet 63, a flow control outlet 64, and a bypass member 26, and the bypass member 26 includes a passage 32 extending through the axis of the bypass member 26 and a plurality of notches. In some embodiments, the switching valve 10 may be configured to be switchable between an open position that allows flow from the inlet 62 to the main line outlet 63 and a flow control position that allows flow from the inlet 62 to the flow control outlet 64. According to a particular embodiment, the switching valve 10 may further include a plurality of member sheets 58. According to a particular embodiment, with respect to the switching valve 10, there is a main line sheet 66 configured such that at least one member sheet receives the bypass member 26, and the flow may pass through the axis of the bypass member 26. In some embodiments, with respect to the switching valve 10, the plurality of member sheets 58 may include at least one flow control sheet 68 configured to receive the bypass member 26 and switch the flow to the flow control outlet 64. Based on the bypass member 26 being seated on the flow control sheet 68 using the flow notch 28, the flow can pass through the switching valve 10 and reach the flow control device 72. Based on the bypass member 26 being seated on the main line sheet 66 by using the seat notch 30, the flow can pass through the switching valve 10 and reach the main line 40.

[0030] In a particular embodiment, with respect to the switching valve 10, the flow control sheet 68 may be configured to seal the upstream and downstream sides of the bypass member 26 and force the flow around the plurality of notches. In some embodiments, with respect to the switching valve 10, the bypass member 26 may be a ball 26 or a cylinder. In some embodiments, the switching valve 10 may include a manifold block 70, where the manifold block 70 has a fluid path facing the axis of the bypass member 26.

[0031] According to some embodiments, the switching valve 10 can be included within a system including a main line and a flow control line 42, wherein the flow control line 42 comprises a flow control device 72 that is a gear pump. In certain embodiments, with respect to the system, the main line may include at least one pig 14 launch 56 valve and at least one pig 14 capture valve. In some embodiments, with respect to the system, at least one launch 56 valve may be configured to discharge the pig 14 and paint to a bypass member 26 and pass through its axis to reach the pig 14 capture valve. In some embodiments, with respect to the system, the switching valve 10 may be configured to switch to a flow control mode based on the reception of the pig 14 within the pig 14 capture valve in the robot. In some embodiments, with respect to the system, the flow control device 72 may be a gear pump or a material valve regulator. In some embodiments, with respect to the system, the main line may include a paint applicator 54. According to some embodiments, with respect to the system, the main line may include a main color header 38.

[0032] According to certain embodiments, the system can include a valve, wherein when the valve is in an open position, it is configured such that paint and the pig 14 flow through the valve into the painting system, and when in a closed position, it is configured to inspect the wear of the pig 14 in a pig 14 inspection system connected to the valve. In one embodiment, the system can be a painting system, wherein the painting system includes a flow control system. According to certain embodiments, the system can include a pig 14 inspection system, wherein the pig 14 inspection system includes a discharge valve 50 downstream of the pig 14 that is configured to discharge pressure exceeding ambient pressure to the atmosphere downstream of the pig.

[0033] In some embodiments, the pig 14 inspection system may include an air valve 34 configured to increase the pressure applied to the upstream side of the pig. In some embodiments, the pig 14 inspection system may include a second discharge valve 50 configured to discharge to the atmosphere the portion of the pressure applied to the upstream side of the pig that exceeds atmospheric pressure. According to a particular embodiment, the pig 14 inspection system may be configured to monitor a pressure difference on the upstream side of the pig 14, which is the pressure difference between the start and the end of a predetermined length of time. In some embodiments, the pig 14 inspection system may include a control unit configured to receive an indicator regarding the quality of the pig 14. In a particular embodiment, the indicator of the quality of the pig 14 is based on the pressure difference during a certain length of time being within a specified threshold value.

[0034] According to a particular embodiment, the system may further include a pig 14 position sensor for the magnet 20 configured to communicate with the control unit, wherein the control unit is configured to receive a signal indicating that the pig 14 and the valve are in a predetermined position for inspection. In some embodiments, the system may further include a pig 14 exchange system. According to a particular embodiment, the pig 14 exchange system may include a pig 14 exchange stem 74 configured to receive the pig. In some embodiments, the pig 14 exchange stem 74 may be disengaged to allow for manual removal of the pig 14 and insertion of a replacement pig.

[0035] The descriptions of the various embodiments have been presented for purposes of illustration, but are not intended to be exhaustive or limiting of the embodiments of the present disclosure. Many variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terms used herein are selected in order to best explain the principles of the embodiments or the practical applications or technical improvements found in the marketplace, or to enable those skilled in the art to understand the embodiments disclosed herein. It should be noted that the present disclosure also includes the following aspects. 〔Aspect 1〕 A switching valve, comprising an inlet, a main line outlet, a flow control outlet, and a bypass member, and wherein the bypass member includes a passage extending through the axis of the bypass member and a plurality of notches. 〔Aspect 2〕 The switching valve according to Aspect 1, wherein the bypass member is configured to be switchable between an open position allowing flow from the inlet to the main line outlet and a flow control position allowing flow from the inlet to the flow control outlet. 〔Aspect 3〕 The switching valve according to Aspect 2, further comprising a plurality of member sheets. 〔Aspect 4〕 The switching valve according to Aspect 3, wherein at least one member sheet is a main line sheet configured to receive the bypass member, and the flow passes through the axis of the bypass member. 〔Aspect 5〕 The switching valve according to Aspect 3, wherein the plurality of member sheets includes at least one flow control sheet configured to receive the bypass member and switch the flow to the flow control outlet. 〔Aspect 6〕 The switching valve according to Aspect 5, wherein the flow control sheet seals the upstream and downstream sides of the bypass member and is configured to force the flow around the plurality of notches 25. 〔Aspect 7〕 The switching valve according to Aspect 1, wherein the bypass member is a ball or a cylinder. 〔Aspect 8〕 The switching valve according to Aspect 1, further comprising a manifold block, and wherein the manifold block has a fluid path facing the axis of the bypass member. 〔Aspect 9〕 A system, A system comprising the switching valve according to aspect 1 and a main line, wherein the main line includes a flow control line, and the flow control line is provided with a flow control device. [Aspect 10] The system according to aspect 9, wherein the main line is provided with at least one pig launch valve and at least one pig capture valve. [Aspect 11] The system according to aspect 10, wherein the at least one launch valve is configured to discharge a pig and paint towards the bypass member and pass through the shaft to reach the pig capture valve. [Aspect 12] The system according to aspect 11, wherein the switching valve is configured to switch to a flow control mode based on the reception of a pig in the pig capture valve of the robot. [Aspect 13] The system according to aspect 9, wherein the flow control device is a gear pump or a material valve regulator. [Aspect 14] The system according to aspect 9, wherein the paint flow line includes a paint applicator. [Aspect 15] The system according to aspect 9, wherein the main line includes a main color header.

Claims

1. A switching valve, comprising: the bypass member includes a passageway extending through an axis of the bypass member and a plurality of notches; and The changeover valve further comprises a manifold block, the manifold block having a fluid path oriented toward the axis of the bypass member.

2. 2. The diverter valve of claim 1, wherein the bypass member is configured to be switchable between an open position allowing flow from the inlet to the main line outlet and a flow control position allowing flow from the inlet to the flow control outlet.

3. The changeover valve of claim 2 , further comprising a plurality of member seats.

4. The diverter valve of claim 3 , wherein at least one member seat is a main line seat configured to receive the bypass member and wherein the flow passes through the axis of the bypass member.

5. 4. The diverter valve of claim 3, wherein the plurality of member seats includes at least one flow control seat configured to receive the bypass member and divert flow to the flow control outlet.

6. The switching valve according to claim 1 , wherein the bypass member is a ball or a cylinder.

7. 1. A system comprising: A system comprising the diverter valve of claim 1 and a main line, the main line including a flow control line, the flow control line comprising a flow control device.

8. The system of claim 7 , wherein the main line comprises at least one pig launch valve and at least one pig capture valve.

9. The system of claim 8 , wherein the at least one pig launch valve is configured to release pigs and paint toward the bypass member, through the shaft and to the pig capture valve.

10. The system of claim 9 , wherein the switching valve is configured to switch to a flow control mode based on receipt of a pig in the pig capture valve of a robot.

11. The system of claim 7 , wherein the flow control device is a gear pump or a material valve regulator.

12. The system of claim 7 , wherein the main line includes a paint applicator.

13. 8. The system of claim 7, wherein the main lines include a main color header.

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