Fully Welded Ball Valve Assembly Jig for Contact Pressure Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fully welded ball valves face challenges in achieving consistent contact surface pressure due to dimensional and assembly tolerances, leading to potential leakage or operational difficulties during opening and closing operations.
Innovation Solution
A jig with a pressurizing device, load cell, and controller is used to precisely adjust the contact surface pressure between the ball and seat by inserting an insertion pipe through the valve body and end piece pipes, allowing for stable assembly and adjustment of the contact pressure, ensuring consistent assembly regardless of dimensional and assembly tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If end piece pipes are welded to valve body while being pushed to ball to achieve proper contact surface pressure, then sealing capability is improved, but manufacturing precision deteriorates due to dimensional and assembly tolerances
Solution Approach 1:
The patent applies preliminary action by pre-assembling the end piece pipes to the valve body at predetermined positions before welding, using positioning structures (such as positioning pins or fixtures) to ensure accurate alignment and consistent contact surface pressure. This preliminary positioning eliminates the need for forceful pushing during final assembly, thereby maintaining manufacturing precision while achieving reliable sealing.
2Reliability
If contact surface pressure is increased to prevent leakage, then sealing capability is improved, but ease of operation deteriorates due to difficulty in ball rotation
Solution Approach 1:
The patent applies parameter changes by optimizing the contact surface pressure within a specific range rather than maximizing it. By carefully controlling the compression spring force and end piece pipe positioning, the design achieves adequate sealing capability while maintaining ball rotation smoothness. This balanced parameter selection prevents excessive friction that would hinder operation.
3Device complexity
If conventional assembly method is used without precise pressure control, then device complexity is reduced, but manufacturing precision deteriorates due to tolerance accumulation
Solution Approach 1:
The patent introduces intermediary elements such as compression springs and positioning fixtures that mediate between the end piece pipes and the valve body. These intermediaries absorb dimensional tolerances and ensure consistent contact surface pressure without requiring complex measurement and adjustment equipment, thus maintaining manufacturing precision while avoiding excessive device 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 enables the production of fully welded ball valves with a consistent contact surface pressure, reducing leakage risks and improving operational smoothness by allowing for precise adjustment and automation of the assembly process.
Implementation Method 1
A compression spring 141 is placed between the stepped surface 132 and the annular seat 140, giving a predetermined contact surface pressure between the ball 120 and the seat 140.
Data Source
AI summary
According to an embodiment of the disclosure, a jig for assembling a fully welded ball valve includes a fastening end having a projecting insertion pipe inserted through the first end piece pipe to an inside of the second end piece pipe and configured to support the first end piece pipe to stably maintain a state of the first and second end piece pipes being inserted through the insertion holes of the valve body, a pressurizing plate configured to pressurize the second end piece pipe to the first end piece pipe, a pressurizing device configured to press the pressurizing plate to pressurize the second end piece pipe, a load cell configured to measure a pressure applied by the pressurizing device, and a controller configured to output the pressure measured by the load cell.