Adjustable valve core
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Solution Overview
Problem
Check valves in air conditioning systems face challenges in precise calibration and adjustment to manage fluid flow effectively, particularly in regulating one-directional flow of refrigerant, which affects system efficiency and reliability.
Innovation Solution
The introduction of a valve core with a calibration plunger and spring system, where the calibration plunger is secured via an interference fit and can be adjusted to alter spring compression, and a set screw with a calibration nut allows for pre-installation calibration and post-installation adjustment, enabling precise control of fluid flow by modifying the pressure differential required to open the valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a traditional spring-loaded valve pin is used, then the valve can prevent backward flow of refrigerant, but the valve lacks precise calibration and adjustment capability
Solution Approach 1:
The valve core is divided into separate functional components: a valve pin, a calibration plunger, and a spring assembly. The calibration plunger can be independently adjusted relative to the valve pin, allowing precise calibration without redesigning the entire valve structure. This segmentation enables independent optimization of each component's function.
Solution Approach 2:
The calibration plunger is designed to be pre-calibrated to specific positions before assembly with the valve pin. This preliminary positioning allows the valve to be precisely calibrated during manufacturing, and the calibrated position is maintained through the interference fit connection between components, eliminating the need for complex adjustment mechanisms during operation.
2Ease of manufacture
If the valve structure is simplified for ease of manufacture, then manufacturing cost decreases, but calibration and adjustment capability is lost
Solution Approach 1:
The valve core incorporates adjustable components that allow the valve to adapt to different calibration requirements. The calibration plunger can be positioned at different depths relative to the valve pin, and the spring compression can be adjusted, enabling the same basic valve structure to serve multiple calibration needs without requiring different valve designs.
Solution Approach 2:
The calibration plunger acts as an intermediary element between the valve pin and the spring assembly. It provides a simple mechanical interface that enables precise calibration adjustment through interference fit connections, while maintaining ease of manufacture through standard machining operations. The plunger translates small positional adjustments into precise calibration changes.
3Ease of repair
If the valve pin is fixed in position, then the valve structure is simple, but the valve cannot be calibrated or adjusted after installation
Solution Approach 1:
The valve core is designed with self-calibrating features through the interference fit connections between the calibration plunger, valve pin, and spring assembly. The components are designed to maintain their calibrated positions through precise dimensional tolerances and interference fits, allowing the valve to self-maintain its calibration without requiring external adjustment mechanisms or complex locking systems.
Solution Approach 2:
The calibration plunger is nested within the valve core structure, with the spring assembly nested around the plunger. This nested arrangement allows for compact design while maintaining adjustability. The plunger can be independently positioned within the nested structure, enabling calibration adjustment without increasing the overall valve size or requiring additional external components.
4Manufacturing precision
If interference fit is used to secure the calibration plunger, then calibration precision is improved, but assembly complexity increases
Solution Approach 1:
The interference fit connection utilizes controlled dimensional parameters and material properties to achieve precise positioning. By carefully selecting the interference fit tolerance ranges and material elastic moduli, the design achieves high positioning precision through standard machining and assembly processes, avoiding the need for specialized assembly equipment or complex multi-step procedures.
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
This solution enhances the precision and reliability of fluid flow regulation, simplifies the calibration process, and allows for adjustments during maintenance, thereby improving the overall efficiency and longevity of the air conditioning system.
Implementation Method 1
the calibration plunger is secured via an interference fit
Implementation Method 2
a spring having a first end that is fixed relative to the valve pin
Data Source
AI summary
A valve may include a valve body forming a central passage extending from a first side of the valve body to a second side of the valve body. A valve pin may be located within the central passage, where the valve pin includes a sealing head that selectively contacts a valve seat of the valve body to control flow of a fluid through the central passage. A spring may have a first end that is fixed relative to the valve pin. A spring seat may be fixed relative to a second end of the spring, where the spring is fixed relative to a calibration plunger, and where the calibration plunger is secured to a threadless calibration wall of the valve body via an interference fit.