3D Flow-Path Pressure Reduction for Low-Noise Control Valves
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Solution Overview
Problem
Conventional fluid pressure reduction devices in process control systems often lead to increased noise and vibration, and are costly and inefficient to manufacture.
Innovation Solution
The use of additive manufacturing techniques, such as 3D printing, to custom manufacture fluid pressure reduction devices with complex and customizable flow paths that maximize pressure reduction while being easier and less costly to produce.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional flow restriction devices (stacked disks, valves, diffusers) are used to reduce fluid pressure, then pressure reduction is achieved, but noise and vibration levels increase
Solution Approach 1:
The flow path is divided into multiple segments or stages, with each segment contributing to gradual pressure reduction. This segmentation allows the fluid to lose pressure incrementally through controlled flow restrictions at different stages, rather than a single abrupt restriction, thereby reducing noise and vibration generation.
Solution Approach 2:
The invention transitions from conventional two-dimensional flow paths to a three-dimensional complex flow path structure. By utilizing three-dimensional spatial arrangement of flow channels, the device achieves more effective pressure reduction while controlling noise and vibration through optimized fluid flow distribution in multiple dimensions.
2Stress or pressure
If conventional manufacturing methods (laser cutting, stacking disks) are used to create pressure reduction devices, then pressure reduction functionality is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
Multiple separate components (disks, flow path elements, restrictions) are merged into a single integrated three-dimensional structure. This consolidation eliminates the need for assembly of multiple parts, reducing manufacturing complexity and cost while maintaining the pressure reduction functionality through the integrated complex flow path.
Solution Approach 2:
The invention changes the manufacturing approach from conventional subtractive methods (laser cutting, machining) to additive manufacturing (3D printing). This parameter change in the manufacturing process enables direct creation of complex three-dimensional flow paths that would be difficult or expensive to manufacture using traditional methods, thereby reducing manufacturing cost and complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces fluid pressure with minimized noise and vibration, and is more efficient and cost-effective than traditional methods, allowing for tailored designs that enhance pressure reduction capabilities.
Implementation Method 1
The use of additive manufacturing techniques, such as 3D printing, to custom manufacture fluid pressure reduction devices
Implementation Method 2
a plurality of flow paths (208) formed in the unitary body (204) in a manner that maximizes pressure reduction
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A method of custom manufacturing a fluid pressure reduction device (300) for use in a process control valve. The method includes creating the fluid pressure reduction device using an additive manufacturing technique, which generally includes forming a body (304) and forming a plurality of flow paths (308) in the body. The body has an inner wall (220) and an outer wall (224) spaced radially outward of the inner wall. The flow paths are formed in the body between the inner wall and the outer wall of the body. Each of the flow paths includes an inlet section (312) formed in one of the inner and outer walls, a curved intermediate section (320), and an outlet section (316) formed in the other of the inner and outer walls.