Backflow Prevention Assembly With Spool Spacer Footprint Matching
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Solution Overview
Problem
The existing backflow prevention assemblies require certification from certifying authorities, but manufacturers do not produce replacement valves to standard lengths or footprints, leading to inefficiencies in installation as contractors must retrofit new assemblies to fit existing fluid lines, potentially voiding certification.
Innovation Solution
A method of manufacturing a replacement backflow prevention assembly that includes a spool spacer to match the length and footprint of the existing assembly, allowing for certification before installation, comprising a replacement valve, spool spacer, inlet shut-off valve, and outlet shut-off valve, which are shipped as a pre-assembled unit to ensure proper fit and compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If contractors use non-standard replacement valves to match existing footprints, then installation compatibility is improved, but certification validity deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-assembling the spool spacer with the replacement valve at the manufacturing stage to create a pre-configured assembly that matches the footprint of existing valves. This allows the assembly to be certified in advance with certifying authorities, eliminating the need for on-site modifications that would void certification. The spool spacer is precisely dimensioned to achieve the required footprint match while maintaining certification validity.
2Adaptability or versatility
If contractors retrofit assemblies on-site to match footprints, then installation compatibility is improved, but installation time increases
Solution Approach 1:
The spool spacer is pre-manufactured with precise dimensions to match the footprint of existing valves, and is assembled with the replacement valve before shipment to the job site. This eliminates on-site machining and fitting operations, reducing installation time while maintaining compatibility with existing valve footprints.
Solution Approach 2:
The spool spacer acts as an intermediary component that bridges the dimensional gap between standard replacement valves and existing valve footprints. By introducing this intermediate element with precisely controlled dimensions, the system achieves compatibility without requiring custom fabrication or modification of the main replacement valve.
3Adaptability or versatility
If contractors machine spools on-site to compensate for length differences, then footprint compatibility is improved, but machining time and complexity increase
Solution Approach 1:
The spool spacer is pre-machined to exact specifications at the manufacturing facility using precision equipment, rather than being machined on-site. This transfers the complex machining operation to a controlled manufacturing environment where it can be performed efficiently and accurately, eliminating the need for on-site machining operations.
Solution Approach 2:
The complex machining operation is extracted from the on-site installation process and relocated to the manufacturing process. The spool spacer is completely pre-fabricated with all necessary dimensional adjustments made at the factory, removing the machining step from the field installation sequence and simplifying the on-site operation to basic assembly tasks.
Data Source
AI summary
A backflow prevention assembly is disclosed including a backflow prevention valve having a valve housing including a valve inlet end and a valve outlet end; a spool spacer of predetermined length having a first end and a second end; an inlet shut-off valve; and an outlet shut-off valve, wherein the spool spacer extends between the backflow prevention valve and one of the inlet shut-off valve and the outlet shut-off valve. The entire assembly, including the backflow prevention valve, the spool spacer, the inlet shut-off valve, and the outlet shut-off valve, is a certified assembly, certified by a certifying authority prior to installation. Methods of manufacturing a backflow prevention assembly and replacing a backflow prevention assembly are also disclosed.