Butterfly Valve Disc with Arcuate Shape for Granular Flow
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Solution Overview
Problem
Butterfly valves used in unloading granular materials from tank trailers and railway cars face issues with slow unloading times and noise generation, along with potential clogging and abrasive wear due to existing disc designs that obstruct flow and increase wear points.
Innovation Solution
A uniquely designed disc for butterfly valves with a reduced pivot mount size, a thin arcuate shape, and a stepped connection between the disc and stem, which increases the open cross-sectional area and reduces noise by minimizing structural obstructions and surface area, allowing for smoother flow and reduced noise during unloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional butterfly valve disc design is used, then the valve structure is simple and easy to manufacture, but the unloading speed is slow and flow acceleration is insufficient
Solution Approach 1:
The disc is designed with an arcuate curved shape instead of a flat configuration. This curvature creates a streamlined profile that accelerates granular material flow through the valve, increasing unloading speed by reducing flow resistance and promoting smoother material movement through the valve body.
Solution Approach 2:
The disc structure is segmented into distinct functional zones including a thin central portion for flow acceleration and thicker peripheral sections for structural support. This segmentation allows the disc to simultaneously achieve flow optimization and mechanical strength without requiring complete structural redesign.
2Object-affected harmful factors
If a traditional disc design with larger pivot mounts is used, then the valve has sufficient structural strength, but noise levels increase during operation
Solution Approach 1:
The disc employs a thin film-like central portion that minimizes surface area and structural obstructions in the flow path. This thin configuration reduces turbulence and noise generation while maintaining sufficient strength through strategic thickness distribution and material selection.
Solution Approach 2:
The disc features asymmetric thickness distribution with a thin central section for noise reduction and thicker peripheral sections for structural support. This asymmetric design allows the disc to reduce noise during operation while maintaining the structural strength needed for reliable valve operation.
3Reliability
If a traditional disc design is used, then the valve provides adequate flow area, but granular material binding and clogging occur
Solution Approach 1:
The arcuate curved shape of the disc creates a streamlined flow path that prevents granular material from binding or clogging. The curved profile promotes continuous material movement through the valve by eliminating dead zones and sharp edges where material could become trapped, ensuring reliable flow continuity.
4Ease of operation
If a heavy disc material is used, then the valve has sufficient durability, but installation and handling become difficult
Solution Approach 1:
The thin film-like central portion of the disc reduces overall weight while maintaining structural integrity through strategic thickness distribution. This weight reduction facilitates easier installation and handling during maintenance operations.
Solution Approach 2:
The disc utilizes composite construction with varying material properties across different sections - lighter materials in the central flow area and stronger materials at the periphery. This composite approach maintains valve durability while reducing overall weight for easier handling.
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 design accelerates the flow of granular materials by providing up to 24.3% more open area and reduces noise levels, enhancing unloading efficiency and reducing wear, while also being lightweight for easier installation and handling.
Implementation Method 1
manufacturing the butterfly valve disc of an arcuate shape enhances the flow of granular material therepast, under Bernoulli's principle
Data Source
AI summary
An improved disc for a butterfly valve having reduced structure within the bore of the valve, so as to minimize obstruction to the flow of granular material therethrough. Accelerated flow of granular material through the valve is obtained because of the thin dimensions of the butterfly valve. The modified disc includes upper and lower sockets, most of its structure is outside the perimeter of the disc. The disc may be of arcuate shape.