Integrated Ball Valve Insert for Low-Weld Pressure Resistance
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Solution Overview
Problem
Conventional ball valve manufacturing processes are inefficient due to multiple assembly parts, high welding requirements, and potential weak areas, leading to increased production time and cost, as well as reduced resistance to internal pressure.
Innovation Solution
The ball valve is constructed using two valve part units with insert elements that are connected and fixed together, forming a ball cartridge, which is then inserted into a tube with a pre-shaped section, reducing assembly parts and welding needs, and allowing for easier leakage testing and replacement of malfunctioning parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional ball valve manufacturing uses multiple assembly parts with high welding requirements, then the valve can be assembled with traditional methods, but production time and cost increase, and resistance to internal pressure decreases
Solution Approach 1:
The patent combines multiple assembly parts (insert elements, supporting shapes, sealing elements) into an integrated valve part unit where the insert element is received within a tube forming a unified structure. This merging reduces the number of separate components requiring assembly and welding, thereby decreasing production time while maintaining or enhancing structural strength and resistance to internal pressure through the integrated design.
Solution Approach 2:
The patent segments the ball valve into a modular valve part unit that can be manufactured separately and then installed as a complete assembly. The valve part unit includes the insert element, supporting shapes, and sealing elements pre-positioned within the tube, allowing for efficient manufacturing and testing before final installation, thus reducing overall production time without compromising strength.
2Ease of manufacture
If conventional ball valve manufacturing uses multiple assembly parts, then the valve can be assembled with traditional methods, but production costs increase
Solution Approach 1:
The patent merges multiple assembly parts into a integrated valve part unit structure where the insert element is received within a tube with pre-positioned supporting shapes and sealing elements. This reduces the number of discrete parts that need to be managed, stored, and assembled, simplifying the manufacturing process and reducing costs associated with handling multiple components.
Solution Approach 2:
The patent applies preliminary action by pre-positioning the supporting shapes and sealing elements within the tube before the insert element is installed, and pre-testing the valve part unit for leakage. This preliminary preparation simplifies the final assembly process and reduces the complexity of on-site manufacturing operations, thereby easing manufacture and reducing costs.
3Reliability
If conventional ball valve manufacturing uses high welding requirements, then traditional assembly methods can be used, but weak areas are created in the structure
Solution Approach 1:
The patent merges components into an integrated valve part unit where the insert element is received within the tube forming a unified structure with pre-positioned supporting shapes. This integration reduces the number of weld joints required, eliminating potential weak areas while maintaining structural integrity. The design allows for mechanical assembly and leakage testing before installation, improving reliability without requiring extensive welding operations.
4Strength
If conventional ball valve manufacturing uses multiple assembly parts, then traditional assembly can be used, but assembly parts create potential weak areas
Solution Approach 1:
The patent combines multiple assembly parts (insert elements, supporting shapes, sealing elements) into a unified valve part unit where components are pre-positioned and integrated within the tube structure. This merging reduces the number of separate parts and their associated connection points, thereby eliminating potential weak areas while maintaining or enhancing resistance to internal pressure through the integrated design.
Solution Approach 2:
The patent applies preliminary action by pre-assembling and pre-testing the valve part unit for leakage before final installation. This preliminary validation ensures that the integrated structure performs correctly under pressure without the weaknesses that would arise from multiple separate assembly parts, thereby improving strength while managing device complexity.
Data Source
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AI summary
The present invention relates to an insert element (30a) for a ball valve being a combined biasing and supporting insert element formed in one piece comprising - an inlet section (31a) in fluid connection to an outlet section (31b) by an inner flow path, - a supporting shape (32) towards the outlet shaped to support a sealing element, and - a biasing section (33) of the insert element intermediate between an inlet and the supporting shape. The present invention further relates to methods to manufacture ball valves by such insert elements.