Manual and solenoid controllled high-pressure gas valve

Abstract

The invention is related to a manually controllable valve for use in high-pressure pneumatic systems. In particular, the invention is related to a valve that can safely maintain pressurized gas in high-pressure gas applications and can be controlled by electric power when needed or manually when electricity is not available.

Description

[0001] MANUAL AND SOLENOID CONTROLLLED HIGH-PRESSURE GAS VALVE Technical Field

[0002] The invention is related to a manually controllable valve for use in high-pressure pneumatic systems. In particular, the invention is related to a valve that can safely maintain pressurized gas in high-pressure gas applications and can be controlled by electric power when needed, or manually in the absence of electricity.

[0003] State of the Art

[0004] Nowadays, solenoid-controlled, and manually controlled valves are widely used to control fluids in high-pressure gas and liquid systems. Such valves have an important role in many fields such as automotive, industrial automation, energy, aerospace, medical and chemical industries. For example, these valves are critical in brake and suspension systems in the automotive industry, in the control of pneumatic lines in industrial automation, and in gas turbines and high-pressure gas systems in the energy industry.

[0005] Solenoid valves are electromechanical valves powered by electrical energy and are usually of two-way (2 / 2), three-way (3 / 2) or four-way (4 / 2, 4 / 3) configuration. Two-position two-way valves have one inlet and one outlet port and perform basic control operations such as stopping or releasing the fluid. Such valves are often preferred due to their simple configuration and fast response time. These systems, which have low energy requirements, are widely used in industrial production lines where time precision is important thanks to their fast on / off configurations.

[0006] However, one of the main disadvantages of solenoid valves is their dependence on electrical energy. Failure of the system to operate in the case of a power outage poses a risk, especially in terms of safety, and disrupts business continuity. In addition, the fact that solenoid valves only have an electrical control mechanism is insufficient in cases where manual intervention is required. Manually controlled alternatives are needed, especially in field conditions or in environments where there is no power.

[0007] In the existing system, there are patent / utility model applications and articles on the subject. In the article “Dynamic Characteristics of Pilot-Operated 2 / 2-Way SolenoidPoppet Valves”, which is in the known state of the art, the dynamic characteristics of high flow and high-pressure pilot controlled 2 / 2-way solenoid poppet valves are analyzed. However, the system does not have the possibility of manual control and becomes inoperable in cases such as power failure.

[0008] In the article “Design and Implementation of an Intelligent Gas Cylinder Valve Regulating System using Solenoid”, which is in the known state of the art, the control of gas cylinders with intelligent systems via solenoid valves is discussed. In this system, sensors and electrical control are at the forefront, but the valve cannot be controlled in case of power failure. Furthermore, the fact that the system only has an electrical control mechanism is a major drawback when manual intervention is required. In addition, such systems usually only work with certain types of gas (e.g. dry air).

[0009] The patent application numbered “CN109128816A” in the state of the art, discloses a device for performing automatic assembly of two-position two-way threaded cartridge valves. The device has holding plates located on the table support for holding components such as valve bushings, tapered valve elements, small springs, pilot valve elements, main springs, moving irons and flux flow sleeves. There is also a first holding device to hold and position the components in order and left and right holding mechanisms located on the left and right sides of the table support.

[0010] In existing systems, high-pressure gas valves usually only have an electrical control mechanism, and the option of manual operation is limited. Although there are systems that use magnets for manual operation, the coil must be removed in the said structures.

[0011] In existing systems, these valves are developed for dry air or water applications. Although some manufacturers have water-operated solutions in their systems, these products do not have the possibility of manual control. In addition, most existing products are not compatible with different gases such as nitrogen. The inability to use such gas valves in the absence of electric power poses a significant technical problem.

[0012] As a result, due to the negativities described above and the inadequacy of existing solutions on the subject, there is a need for a gas valve that offers manual control without being dependent on electrical energy, can work with different gas types (dry air, oily air, and nitrogen), and provides safe and fast gas evacuation in high-pressure gas applications.Brief Description and Aims of the Invention

[0013] The invention is related to a manually controllable valve developed for use in high-pressure pneumatic systems, which meets all the above-mentioned requirements and eliminates the negativities and disadvantages in the existing system.

[0014] The aim of the present invention is to develop a valve that can be controlled both electrically and manually in high-pressure gas applications, providing a fast and safe gas transfer. The valve provides business continuity by allowing manual control, especially in environments with power outages.

[0015] The valve developed with the invention is compatible with different gases such as dry air, oily air, and nitrogen. In this way, it offers a wider usage area compared to existing technologies. Made of stainless-steel material, the valve provides a long-lasting solution by showing high durability in harsh environmental conditions.

[0016] By means of the valve, the pressurized gas in the system is transferred to the desired environment at high flow rate. Since it has been developed for use in gas applications, the main body is sealed with high-strength polyurethane and polyacetal materials suitable for valve geometry, and a valve for manual control is integrated. It is used in high-pressure gas applications with and without electricity.

[0017] Figures

[0018] Figure- 1 : Sectional view of the gas valve subject to invention.

[0019] Figure-2: View of the gas outlet connected to the gas valve with the connector.

[0020] References

[0021] In order to better explain the valve developed with the present invention, the parts and elements in the figures are numbered and the equivalent of each number is given below:

[0022] 1. Body

[0023] 2. Coil

[0024] 3. Core

[0025] 4. Poppet

[0026] 5. Sealing element

[0027] 6. Control valve

[0028] 7. Connector8. Socket

[0029] 9. Coil spring

[0030] 10. Orifice

[0031] Detailed Description of the Invention

[0032] The invention is related to a valve which can safely maintain pressurized gas in high-pressure gas applications, and which can be operated by electric power if required, or manually in the absence of electricity. Said gas outlet and gas inlet of the valve are on different surfaces. The different surfaces are more suitable for the installation of the system than the existing system and this geometry increases the flow rate of the valve. It is also easier to produce in this way than the existing system.

[0033] The gas valve subject to invention, as shown in figure-1 and figure-2, controls the flow of gas and allows both electrical and manual operation. The body (1) is made of stainless steel, high-strength polyurethane or polyateal to ensure containment of the gas in a sealed way and mechanical integrity of the valve. On the body (1), there are gas inlet channels that allow the gas to enter the system and gas outlet channels that allow the gas to exit. In addition, there are inlets on the body (1) that allow the connection of manual control valve (6) and pneumatic connectors (7).

[0034] Solenoid coil (2) is structured to move the core (3) with magnetic force by taking the current coming from the energy source through the electrical socket (8) and open the gas outlet by triggering the poppet (4) with this magnetic force in case the valve is controlled by electrical energy. It ensures the system to be controlled with electrical energy. It operates with 24 Volt DC (18 W) energy and moves the core (3) mechanism by means of magnetic force. When the solenoid coil (2) is de-energized, the magnetic force disappears, and the core (3) returns to its original position and stops the gas flow.

[0035] The core (3), which is a cylindrical part moved by the solenoid coil (2), is structured to open the hole on the orifice (10) by retracting by means of the energy coming from the coil (2) or when the control valve (6) is opened by the user and allow the gas passing through this hole to open the gas outlet of the poppet (4) by triggering the poppet (4) and the gas to be discharged from the gas outlet. When the solenoid coil (2) is energized, the core (3) opens the opening on the orifice (10), allowing the gas to pressurize the poppet (4). Whende-energized, the core (3) returns to its original position and closes the orifice (10) and the gas ceases to act on the poppet.

[0036] The poppet (4), which is the moving mechanism that manages the gas inlet and gas outlet and opens and closes the shortest path between the gas inlet and gas outlet, is triggered via the core (3) and orifice (10) to provide gas flow. As specified, the poppet moves up or down under the influence of gas pressure or coil spring force to open or close the gas path.

[0037] Sealing element (5) made of rubber material is used to prevent gas leakage. The sealing element (5) is positioned on and in front of the poppet (4) and prevents the gas from mixing or escaping in the desired lines.

[0038] The control valve (6) allows the valve to be operated manually in the absence of electric power. The control valve (6) is mounted on the body (1) with a connector (7), and in the absence of electrical energy, ensures that the valve is operated manually by allowing the core (3) to retract, the gas to pass through the hole in the orifice (10), the gas to trigger the poppet (4) to open the gas outlet line and the gas to be discharged, respectively, upon opening by the user.

[0039] When the control valve (6) is opened by the user, the core (3) is released without magnetic force and opens the hole on the orifice (10). This allows the gas to build up pressure on the poppet (4) and gas is released. When the manual control valve (6) is closed, the system returns to its original position and the gas outlet is closed.

[0040] Unlike the sealing element (5), the connector (7) (such as elbow and reducer) in the pneumatic structure is made of stainless steel and has its own sealing properties. The connector (7) provides a sealed connection between the manual control valve (6) and the body (1). Connectors (7) are used to prevent gas leaks that may occur at the connection points and ensure reliable operation of the system.

[0041] The gas outlet in the gas valve can be directly on the valve as shown in figure- 1 or it can be connected to the valve with a connector (7) as shown in figure-2. In case the gas outlet is connected with a connector (7) as shown in figure-2, the gas inlet is positioned directly opposite to it according to figure-1.The electrical socket (8) provides the electrical connection of the solenoid coil (2) and transfers the current from the energy source to the solenoid coil (2) and enables the coil to operate.

[0042] The coil spring (9) closes the poppet (4) when the valve is de-energized and ends the gas outlet. Orifice (10), on the other hand, activates the poppet (4) thanks to the gas pressure triggered by the separation of the sealing element (5) in the core (3), which moves thanks to electrical energy.

[0043] In said system, gas enters the body (1) via the gas inlet. When the solenoid coil (2) is not energized or the manual control valve (6) is not opened, the gas remains static in the system. When the solenoid coil (2) is energized (24 Volt DC, 18 W) or the manual control valve (6) is opened manually, the core (3) retracts and opens the hole on the orifice (10). The gas pressure passing through this hole triggers the poppet (4) to open the gas outlet line. Thus, the gas is discharged with high-pressure and high flow rate.

[0044] When the electric power is cut off or the manual control valve (6) is closed, the coil spring (9) is activated and pushes the poppet (4) to close the gas outlet line again. This operating principle offers high reliability and flexibility, allowing the system to operate with both electrical and manual control.

[0045] The properties of the sealing element (5) and the surface quality of the contact surfaces of the sealing element (5) have been improved and made suitable for gases. In this way, unlike hydraulic systems, it is compatible with different gases such as dry nitrogen, oily air, or nitrogen gas. This feature enables the valve to be used in many different industries such as industrial automation, energy, defense, aerospace and medical. In high-pressure gas applications, this valve provides fast and safe gas evacuation and offers a great advantage especially in situations where electricity is not available thanks to the manual control valve (6).

[0046] The gas valve developed with this invention provides continuity in the system thanks to its ability to be used manually in the absence of electric power. In addition, thanks to its stainless-steel body (1), it is resistant to harsh environmental conditions and offers a long service life. The valve operates safely under high-pressure, allowing the gas to be discharged in a fast way. Thanks to its structure that can operate with different gases, it can be used in a wide range of industrial applications and provides energy efficiency.Developed for use in high-pressure pneumatic systems, the valve has a temperature range of -20°C to +50°C. This enables the valve to operate reliably at low temperatures (-20°C) and high temperatures (+50°C). Preparations for the low temperature environmental conditions test started with connecting and fixing the unit to the test device, followed by the application of seals and treatment with Teflon tape. Pressurized tanks were filled, and the pressure and temperature values were checked for compliance. The units were pressurized on the test table with equipment suitable for occupational safety. The unit was dried and cleaned before being placed in the environmental conditions chamber. The unit was placed in the environmental conditions test device, the test program was applied, and the image was processed. The unit was placed in the environmental conditions device, the test was performed, and the image was taken. At the end of the test, the environmental conditions device was turned off and the image of the unit was processed. Finally, the unit was prepared for further processing.

[0047] Within the scope of temperature tests, the solenoid valves were taken into the test chamber to evaluate their performance under specified environmental conditions. The valves were pressurized to 130 ± 5 bar and tested according to the requirements of Method 502.5, Procedure II of the MIL-STD-810G standard. The test chamber was programmed to provide a temperature drop of 10°C every 1 minute and when the temperature reached -20°C, the valves were kept at this temperature for 120 minutes. During the test, it was observed that the pressure in the solenoid valves decreased as the temperature dropped. When the valves were pressurized above 130 bar, some valves failed to open. The valves were then re-tested at a pressure of 130 ± 2 bar and removed from the chamber after the test period was completed. The chamber temperature was verified as -20°C, and measurements with a laser thermometer showed that the valve and coil temperature reached the same value. Finally, the valves were tested by applying 24V power and it was recorded that all valves successfully opened under 130 bar pressure. These results show that the valves can operate reliably under high-pressure in low temperature conditions.

[0048] Preparations for the high temperature environmental conditions test started with the connection and fixing of the unit to the test device. Sealing elements were applied and the process was completed with Teflon tape. Pressurized tanks were filled, and the compatibility of pressure and temperature values was checked. The units were pressurized on the test table with equipment suitable for occupational safety. The unit was dried andcleaned before being placed in the environmental conditions chamber. The test program was applied and visualized in the environmental conditions tester. The unit was placed in the environmental conditions tester and the test was performed, followed by visual recording. At the end of the test, the environmental conditions tester was switched off and the unit was visualized. Finally, the unit was removed from the test apparatus and visually and dimensionally checked.

[0049] Within the scope of high temperature tests, the solenoid valves were placed in the test chamber to be evaluated under specified environmental conditions. The valves were pressurized to 130 ± 5 bar and kept for 4 hours, during which time the pressure values were checked, and no leakage was observed. Then, the valves were subjected to environmental conditions test under 120 ± 5 bar pressure. According to the requirements of Method 501.5, Procedure II of the MIL-STD-810G standard, the test chamber was programmed to provide a temperature increase of 10°C every 1 minute and the valves were held for 3 minutes at each temperature increase. When the chamber temperature reached +50°C, the valves were held at this temperature for 120 minutes and the test was completed.

[0050] During the test, it was determined that the internal pressure of the solenoid valves increased due to the increase in temperature. The valves with a maximum operating pressure of 130 bar were adjusted to 130 ± 2 bar at the end of the test and removed from the test chamber. In the opening tests using a multimeter with 24V power application, it was confirmed that all of the valves successfully opened. These results show that the valves can operate reliably under high-pressure under high-temperature conditions. The test procedures were recorded, and the results were verified.

Claims

CLAIMS1. A valve for use in high-pressure systems, characterized in comprising;• A solenoid coil (2) structured to move the core (3) with magnetic force by taking the current coming from energy source through electrical socket (8) and open gas outlet by triggering the poppet (4) with this magnetic force in case the valve is controlled by electrical energy,• A core (3) structured to open the hole on the orifice (10) by retracting by means of the energy coming from the coil (2) or when the control valve (6) is opened by the user and allow the gas passing through this hole to open the gas outlet of the poppet (4) by triggering the poppet (4) and the gas to be discharged from the gas outlet, • A control valve (6) mounted on a body (1) with a connector (7), which, in the absence of electrical energy, ensures that the valve is operated manually by allowing the core (3) to retract, the gas to pass through the hole in the orifice (10), the gas to trigger the poppet (4) to open the gas outlet line and the gas to be discharged, respectively, upon opening by the user.

2. The valve according to claim 1, characterized in that the body (1) provides gas containment and mechanical integrity of the valve.

3. The valve according to claim 2, wherein said body (1) is made of polyurethane, polyateal or stainless steel.

4. The valve according to claim 3, characterized in comprising inlets for connecting a gas inlet allowing gas to enter the valve, a gas outlet allowing gas to exit the valve, the control valve (6) and the connector (7) on said body (1).

5. The valve according to claim 4, wherein said gas outlet is connected to the body (1) by a connector (7).

6. The valve according to claim 5, wherein said connector (7) made of stainless steel.

7. The valve according to claim 1, characterized in comprising a sealing element (5) positioned on and in front of the poppet (4) to prevent the gas from escaping.

8. The valve according to claim 7, wherein said sealing element (5) is made of rubber material.

9. The valve according to claim 1, characterized in comprising a coil spring (9) which closes the gas outlet by pushing the poppet (4) when the electric power is cut off or the control valve (6) is closed.

10. The valve according to claim 1, wherein operating temperature of said valve is between -20°C and +50°C.

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