3D-Printed Flow Path Pressure Reduction for Low-Noise 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, limiting their effectiveness in reducing fluid pressure.
Innovation Solution
The use of additive manufacturing techniques to create a custom fluid pressure reduction device with a unitary body and multiple flow paths, including inlet, curved intermediate, and outlet sections, which are designed to maximize pressure reduction while minimizing manufacturing costs and noise, using techniques like 3D printing to create complex and customizable flow paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional flow restriction devices 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 including inlet section, curved intermediate section, and outlet section. This segmentation allows progressive pressure reduction through controlled flow direction changes, reducing turbulence and associated noise/vibration compared to single-stage restriction devices
Solution Approach 2:
The flow path includes a curved intermediate section that smoothly transitions fluid flow from inlet to outlet direction. This curvature design reduces flow separation and turbulence, thereby minimizing noise and vibration generation while maintaining pressure reduction effectiveness
2Reliability
If conventional manufacturing methods are used for pressure reduction devices, then device functionality is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The device combines multiple functional elements (inlet section, curved intermediate section, outlet section, and multiple flow paths) into a single unitary body. This integration eliminates the need for assembling multiple separate components, reducing manufacturing complexity and cost while maintaining reliable pressure reduction functionality
Solution Approach 2:
The invention utilizes three-dimensional additive manufacturing to create complex internal flow paths that would be difficult or impossible to achieve with conventional two-dimensional machining methods. This dimensional approach allows optimized pressure reduction geometry to be manufactured as a single integrated component
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 reduced noise and vibration, while being easier and less costly to manufacture than conventional devices, allowing for customizable and efficient pressure reduction in process control systems.
Implementation Method 1
Each of the first flow paths includes an inlet section, an outlet section, and a curved intermediate section between the inlet and outlet sections, wherein the inlet section of each of the first flow paths is oriented along a first inlet axis
Data Source
AI summary
A method of custom manufacturing a fluid pressure reduction device 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 and forming a plurality of flow paths in the body. The body has an inner wall and an outer wall 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 formed in one of the inner and outer walls, a curved intermediate section, and an outlet section formed in the other of the inner and outer walls.