Coupler

Abstract

A coupler 30 is removably disposed between a valve 10 and an actuator 20, and has a first surface 31 facing a first contact surface 15 of the valve 10, and a second surface 32 facing a second contact surface 24 of the actuator 20. The first surface 31 has a first protrusion 35 capable of being fitted into a first recess 17 provided on the first contact surface 15, and the second surface 32 has a second protrusion 37 capable of being fitted into a second recess 26 provided on the second contact surface 24.

Description

coupler

[0001] The present invention relates to a valve-to-actuator coupler.

[0002] Conventionally, valves are installed in piping, and the flow of fluid is controlled by opening and closing the valves. The opening and closing of valves is sometimes performed by an actuator (valve body drive unit) attached to the valve. Actuation methods for such actuators include pneumatic, electrical, hydraulic, and solenoid types. The valves are rotary valves such as butterfly valves or ball valves. The valves and actuators are configured to be detachable from each other for ease of maintenance and inspection. Plate-shaped couplers that are placed between the valves and actuators are known (see, for example, Patent Documents 1 to 3).

[0003] The coupler described in Patent Document 1 has two rail-shaped fitting portions. The coupler has a fitting portion provided opposite the actuator. In Patent Document 1, by fitting the actuator between the two rails of the coupler, the coupler is prevented from rotating relative to the actuator due to the rotational force of the actuator transmitted to the valve. As a result, the coupler bears the torque generated between the valve and the actuator.

[0004] Similar to Patent Document 1, Patent Document 2 discloses a coupler having a groove or a rail formed therein, and an actuator having the other groove or rail formed therein. In Patent Document 2, as an embodiment, the rail of the actuator is fitted into the groove of the coupler, thereby preventing the coupler from rotating relative to the actuator due to the rotational force of the actuator transmitted to the valve. As a result, the coupler bears the torque generated between the valve and the actuator, and can efficiently transmit the rotational force of the actuator to the valve.

[0005] The coupler described in Patent Document 3 is sandwiched between the valve and the actuator. That is, the coupler has two parallel flat end faces, one of which abuts against the flat face of the flange of the valve, and the other abuts against the flat end face of the actuator. In this state, the coupler is penetrated by a bolt inserted from the flange of the valve and fastened integrally to the actuator.

[0006] Japanese Patent Application Laid-Open No. 2006-183857 Japanese Patent Application Laid-Open No. 10-331806 Japanese Patent Application Laid-Open No. 2003-74740

[0007] Although Patent Documents 1 and 2 disclose structural engagement between the actuator and the coupler other than by fastening with bolts or the like, they do not disclose structural engagement between the valve and the coupler. As a result, the valve and the coupler may rotate relative to each other by the clearance of the bolt holes, etc. Therefore, there is room for improvement in efficiently transmitting the rotational force of the actuator to the valve.

[0008] Patent Document 3 does not disclose any structural fitting of the coupler to both the valve and the actuator other than by fastening with bolts or the like. Therefore, the actuator and coupler, and the valve and coupler, may rotate relative to each other by the clearance of the bolt holes, etc. Therefore, the rotational force of the actuator cannot be efficiently transmitted to the valve.

[0009] An object of the present invention is to provide a coupler that can efficiently transmit rotational force by connecting a valve and an actuator without causing them to rotate relative to each other.

[0010] According to one aspect of the present invention, there is provided a coupler that is detachably arranged between a valve and an actuator, the coupler comprising a first surface facing a first abutment surface of the valve and a second surface facing a second abutment surface of the actuator, the first surface having a first fitting portion that can fit with a recess or protrusion provided on the first abutment surface, and the second surface having a second fitting portion that can fit with a recess or protrusion provided on the second abutment surface.

[0011] It is preferable that the first abutment surface has a first recess, the first fitting portion has a first convex portion that can be fitted into the first recess, and the first convex portion has at least one first rib formed thereon that can engage with the inner surface of the first recess, or that the second abutment surface has a second recess, the second fitting portion has a second convex portion that can be fitted into the second recess, and the second convex portion has at least one second rib formed thereon that can engage with the inner surface of the second recess.

[0012] It is preferable that a through hole penetrating the first surface and the second surface is formed at a distance from the first fitting portion and the second fitting portion, and a fixing device is inserted into the through hole to fix the coupler to the valve and the actuator.

[0013] It is preferable that the elastic modulus of the material of the coupler at the first surface is equal to or greater than the elastic modulus of the valve at the first abutment surface, or that the elastic modulus of the material of the coupler at the second surface is equal to or greater than the elastic modulus of the actuator at the second abutment surface.

[0014] According to the aspects of the present invention, an effect is achieved in that a coupler capable of efficiently transmitting rotational force is provided by connecting a valve and an actuator without causing them to rotate relative to each other.

[0015] Figure 1 is an exploded perspective view of the valve system. Figure 2 is a perspective view of the actuator. Figure 3 is a perspective view of the coupler. Figure 4 is another perspective view of the coupler. Figure 5 is a partial cross-sectional view of the valve system around the coupler. Figure 6 is another partial cross-sectional view of the valve system around the coupler.

[0016] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Corresponding components throughout the drawings are designated by common reference numerals.

[0017] 1 is an exploded perspective view of a valve system 1. The valve system 1 includes a valve 10 connected to a pipe, an actuator 20 for opening and closing the valve 10, and a connector 30 according to an embodiment of the present invention that is detachably disposed between the valve 10 and the actuator 20. The valve 10 is a butterfly valve, but may also be another type of rotary valve such as a ball valve. The actuator 20 may be actuated by any of a pneumatic, electric, hydraulic, solenoid, or other actuation methods.

[0018] The valve 10 has a valve body 11, a valve element 12, and a valve stem 13. In this specification, for the sake of convenience, in the valve system 1, the direction approaching the valve element 12 is defined as the inward or downward direction, and the opposite side is defined as the outward or upward direction.

[0019] A valve stem 13 connected to the valve element 12 protrudes outward from the valve body 11. A disk-shaped flange 14 is integrally formed on the valve body 11 near the upper end of the valve stem 13 so as to be perpendicular to the axis of the valve stem 13, i.e., the axis of rotation of the valve element 12.

[0020] A flat first abutment surface 15 is provided on the upper surface of the flange portion 14. Four through holes 16 that pass through the flange portion 14 are provided in the first abutment surface 15 at equal intervals along the circumferential direction with respect to the rotation axis of the valve shaft 13. In addition, two first recesses 17 are provided in the first abutment surface 15 at positions opposite to each other with respect to the rotation axis of the valve shaft 13. The first recesses 17 are formed in an arc shape with the rotation axis of the valve shaft 13 as their center.

[0021] The flange 14, and therefore the valve body 11, are made of a synthetic resin material, but may also be made of a metal material such as aluminum. Examples of synthetic resin materials for the valve body 11 include PTFE, PVDF, polyvinyl chloride (PVC), polyethylene (PE), and polypropylene (PP).

[0022] FIG. 2 is a perspective view of the actuator 20. In FIG. 2, the entire actuator 20 is shown with the underside of the actuator 20, which was not visible in FIG. 1, facing upward in the figure. The actuator 20 has a substantially rectangular pillar portion 21 extending downward. An output shaft 22, which transmits the driving force of the actuator 20 as a rotational force to the valve 10, is rotatably supported inside the pillar portion 21. The output shaft 22 has a mounting hole 23 into which the valve stem 13 of the valve 10 is inserted and attached. The valve stem 13 inserted in the mounting hole 23 is rotated by the rotational force of the actuator 20, thereby rotating the valve disc 12. As a result, the valve 10 can be opened and closed.

[0023] A flat second abutment surface 24 that surrounds the output shaft 22 is provided on the end face of the column portion 21. Four bolt holes 25 with internal threads are provided on the second abutment surface 24 at equal intervals along the circumferential direction with respect to the rotation axis of the actuator 20. In addition, four second recesses 26 are provided on the second abutment surface 24 at equal intervals along the circumferential direction with respect to the rotation axis of the actuator 20. The second recesses 26 are formed by cutting out the edge of the end face of the column portion 21 in a sector shape centered on the rotation axis.

[0024] Fig. 3 is a perspective view of the coupler 30, and Fig. 4 is another perspective view of the coupler 30. The coupler 30 is a member having an overall disk-like outer shape. The coupler 30 has a flat first surface 31 facing the first abutment surface 15 of the valve 10 and a flat second surface 32 facing the second abutment surface 24 of the actuator 20.

[0025] As shown in Fig. 3, a circular insertion hole 33 is provided in the center of the first surface 31, through which the valve stem 13 of the valve 10 is inserted. The coupler 30 has four through holes 34 that pass through the first surface 31 and the second surface 32, spaced equally apart along the circumferential direction and concentric with the circular insertion hole 33. In addition, two first protrusions 35 are provided on the first surface 31, positioned opposite each other with respect to the insertion hole 33. The first protrusions 35 are formed in an arc shape concentric with the circular insertion hole 33. One first rib 36 extending in the height direction of the first protrusion 35 is provided on each side surface at both ends of the circumferential direction of the first protrusion 35.

[0026] 4 , four second protrusions 37 are provided on the second surface 32 at equal intervals along the circumferential direction and concentric with the circular insertion hole 33. The second protrusions 37 are formed in a fan shape concentric with the circular insertion hole 33. In detail, the second protrusions 37 have four side surfaces, namely, a flat outer surface 37a facing radially outward, a cylindrical inner surface 37b facing radially inward, and two flat side surfaces 37c facing adjacent second protrusions 37. Four second ribs 38 extending in the height direction of the second protrusions 37 are provided at equal intervals on each of the two side surfaces 37c.

[0027] The coupler 30 is formed from a synthetic resin material, particularly glass fiber reinforced plastic, but may also be formed from a metal material such as aluminum. Examples of synthetic resin materials for the valve body 11 include glass fiber reinforced PTFE, PVDF, polyvinyl chloride (PVC), polyethylene (PE), and polypropylene (PP). The coupler 30 according to this embodiment is formed from glass fiber reinforced polypropylene. At least the column portion 21 of the actuator 20 described above may be formed from the same material as the coupler 30.

[0028] Figure 5 is a partial cross-sectional view of the valve system 1 around the coupler 30, and Figure 6 is another partial cross-sectional view of the valve system 1 around the coupler 30. Specifically, Figure 5 is a cross-section taken along a plane transverse to the flat valve body 12 of the closed valve 10 as shown in Figure 1, and Figure 6 is a cross-section taken along a plane spaced apart in parallel from the cross-section shown in Figure 5 and passing through the axes of two adjacent bolts 40. In the assembled state of the valve system 1, the first surface 31 of the coupler 30 abuts against the first abutment surface 15 of the valve 10, and the second surface 32 of the coupler 30 abuts against the second abutment surface 24 of the actuator 20.

[0029] 5 , the first protrusions 35 on the first surface 31 of the coupler 30 fit into the first recesses 17 on the first abutment surface 15 of the valve 10, thereby fitting the coupler 30 to the valve 10. That is, the first protrusions 35 and the first recesses 17 are formed to be substantially complementary to each other, and each first protrusion 35 is disposed in the corresponding first recess 17, fitting the first protrusions 35 to the first recesses 17. At this time, the first ribs 36 of the first protrusions 35 engage with the inner surfaces of the first recesses 17, thereby achieving a more stable fit than if the first ribs 36 were not provided. Furthermore, because the first ribs 36 are provided on each side surface at both ends in the circumferential direction of the first protrusions 35, the clearance between the coupler 30 and the valve 10 in the circumferential direction can be reduced to substantially zero.

[0030] The second protrusions 37 on the second surface 32 of the coupler 30 fit into the second recesses 26 on the second abutment surface 24 of the actuator 20, thereby fitting the coupler 30 to the actuator 20. In other words, the second recesses 26 of the actuator 20 are recesses formed by cutting out the edges of the end faces of the column portions 21. Therefore, the second protrusions 37 and the second recesses 26 fit together so as to sandwich the column portions 21 between the corresponding inner surfaces 37b of the opposing second protrusions 37 of the coupler 30. At this time, the second ribs 38 of the second protrusions 37 engage with the inner surfaces of the second recesses 26, thereby achieving a more stable fit than if the second ribs 38 were not provided. Furthermore, the second ribs 38 are provided on the side surfaces 37c at both ends in the circumferential direction of the second protrusions 37, thereby reducing the clearance between the coupler 30 and the actuator 20 in the circumferential direction to approximately zero.

[0031] The first rib 36 and the second rib 38 are capable of some degree of elastic deformation, which allows them to accommodate variations in the dimensions of the first recess 17 of the valve 10, the second recess 26 of the actuator 20, and the first protrusion 35 and the second protrusion 37 of the coupler 30, thereby ensuring a more secure fit.

[0032] 6 , with the coupler 30 fitted to the valve 10 and the actuator 20, four bolts 40 are inserted into the through holes 16 from below the flange portion 14 of the valve 10. The bolts 40 pass through the through holes 34 of the coupler 30 and are screwed into the bolt holes 25 of the actuator 20. As a result, the valve 10 and the actuator 20 are fastened together via the coupler 30, and assembly of the valve system 1 is completed.

[0033] The coupler 30 is structurally fitted to both the valve 10 and the actuator 20 in addition to fastening with the bolts 40 or the like, so that the valve 10 and the actuator 20 can be connected without rotating relative to each other. As a result, the coupler 30 can bear the torque generated between the valve 10 and the actuator 20 and efficiently transmit the rotational force of the actuator 20 to the valve 10.

[0034] A first protrusion 35 is provided on the first surface 31 of the coupler 30 as a first fitting portion that can fit into the first recess 17 of the valve 10. However, if a protrusion is provided on the first abutment surface 15 of the valve 10, a recess that can fit into the protrusion may also serve as the first fitting portion of the coupler 30. Similarly, a second protrusion 37 is provided on the second surface 32 of the coupler 30 as a second fitting portion that can fit into the second recess 26 of the actuator 20. However, if a protrusion is provided on the second abutment surface 24 of the actuator 20, a recess that can fit into the protrusion may also serve as the second fitting portion of the coupler 30.

[0035] In short, as long as the first surface 31 has a first fitting portion that can fit with a recess or protrusion provided on the first abutment surface 15 of the valve 10, and the second surface 32 has a second fitting portion that can fit with a recess or protrusion provided on the second abutment surface 24 of the actuator 20, the first and second fitting portions, and even the coupler 30, can be configured arbitrarily. The first fitting portion may or may not have a complementary shape to the recess or protrusion provided on the first abutment surface 15 of the valve 10. The second fitting portion may or may not have a complementary shape to the recess or protrusion provided on the second abutment surface 24 of the actuator 20. The first fitting portion may be at least one recess or protrusion, or a combination of at least one recess and at least one protrusion. The second fitting portion may be at least one recess or protrusion, or a combination of at least one recess and at least one protrusion. The number of recesses or protrusions of the first fitting portion does not have to be the same as the number of corresponding protrusions or recesses of the valve 10. Similarly, the number of recesses or protrusions of the second fitting portion does not have to be the same as the number of corresponding protrusions or recesses of the actuator 20.

[0036] The first recess 17 of the valve 10 described above is a lightening portion provided to prevent sink marks during molding of the synthetic resin material. That is, the first recess 17 is a recess formed for manufacturing reasons, but it may also be a recess formed for structural reasons, such as weight reduction, or a recess formed for fitting. Similarly, the second recess 26 may also be a recess formed for manufacturing or structural reasons.

[0037] Various connectors 30 having different first and second fitting portions may be prepared depending on the type and size of the valve 10 or the type of the actuator 20. This allows the connector 30 to be prepared according to the installation location of the valve system 1, preventing the incorrect installation of a valve 10, an actuator 20, or a combination of a valve 10 and an actuator 20 that does not match the design or specifications. On the other hand, connectors 30 that can be used regardless of the type and size of the valve 10 or the type of the actuator 20 may be prepared.

[0038] The first rib 36 may also be provided on the side surface facing radially outward or the side surface facing radially inward of the first convex portion 35. The second rib 38 may be provided on the inner surface 37b of the second convex portion 37. The first convex portion 35 may have at least one first rib 36. The second convex portion 37 may have at least one second rib 38. The first rib 36 may be omitted, and the second rib 38 may be omitted.

[0039] The side surfaces of the first protrusions 35 may be tapered so that the cross section of the first protrusions 35 becomes smaller toward the tip, and the first recesses 17 may be correspondingly formed so that the space within the first recesses 17 becomes smaller toward the bottom. This allows for a more stable fit as the first protrusions 35 enter the first recesses 17. Similarly, the side surfaces of the second protrusions 37 may be tapered so that the cross section of the second protrusions 37 becomes smaller toward the tip, and the second recesses 26 may be correspondingly formed so that the space within the second recesses 26 becomes smaller toward the bottom. This allows for a more stable fit as the second protrusions 37 enter the second recesses 26.

[0040] In the coupler 30, a through hole 34 is formed that penetrates the first surface 31 and the second surface 32, spaced apart from the first protrusion 35 and the corresponding first recess 17 and the second protrusion 37 and the corresponding second recess 26, i.e., spaced apart from the first fitting portion and the second fitting portion. A bolt 40 is inserted into the through hole 34 to fix the coupler 30 to the valve 10 and the actuator 20, but the coupler 30 may also be fixed by a fastener other than the bolt 40 that is inserted into the through hole 34.

[0041] The elastic modulus of the material of the coupler 30 at the first surface 31 of the coupler 30 is preferably equal to or greater than the elastic modulus of the valve 10 at the first abutment surface 15 of the valve 10. This allows the first protrusion 35 of the coupler 30, particularly the first rib 36, to bite into the inner surface of the first recess 17 of the valve 10, thereby ensuring a more secure fit. Similarly, the elastic modulus of the material of the coupler 30 at the second surface 32 of the coupler 30 is preferably equal to or greater than the elastic modulus of the actuator 20 at the second abutment surface 24 of the actuator 20. This allows the second protrusion 37 of the coupler 30, particularly the second rib 38, to bite into the inner surface of the second recess 26 of the actuator 20, thereby ensuring a more secure fit. In either case, the first rib 36 or the second rib 38 can absorb manufacturing errors in the fit between the first protrusion 35 and the first recess 17, and between the second protrusion 37 and the second recess 26.

[0042] REFERENCE SIGNS LIST 1 valve system 10 valve 11 valve body 12 valve element 13 valve stem 14 flange portion 15 first abutment surface 16 through hole 17 first recess 20 actuator 21 column portion 22 output shaft 23 mounting hole 24 second abutment surface 25 bolt hole 26 second recess 30 coupler 31 first surface 32 second surface 33 insertion hole 34 through hole 35 first protrusion 36 first rib 37 second protrusion 38 second rib 40 bolt

Claims

1. A coupler that is detachably arranged between a valve and an actuator, comprising: a first surface that faces a first contact surface of the valve; and a second surface that faces a second contact surface of the actuator, wherein the first surface has a first fitting portion that can fit into a recess or protrusion provided on the first contact surface; and the second surface has a second fitting portion that can fit into a recess or protrusion provided on the second contact surface.

2. A coupler as described in claim 1, wherein the first abutment surface has a first recess, the first fitting portion has a first protrusion that can be fitted into the first recess, and the first protrusion has at least one first rib that can be engaged with the inner surface of the first recess, or the second abutment surface has a second recess, the second fitting portion has a second protrusion that can be fitted into the second recess, and the second protrusion has at least one second rib that can be engaged with the inner surface of the second recess.

3. A coupler as described in claim 1 or 2, in which a through hole is formed through the first surface and the second surface, spaced apart from the first fitting portion and the second fitting portion, and a fixing device is inserted into the through hole to fix the coupler to the valve and the actuator.

4. A coupler as claimed in claim 1 or 2, wherein the modulus of elasticity of the material of the coupler at the first surface is equal to or greater than the modulus of elasticity of the valve at the first contact surface, or the modulus of elasticity of the material of the coupler at the second surface is equal to or greater than the modulus of elasticity of the actuator at the second contact surface.

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