Ball Valve Pre-Assembled Insert Design to Reduce Assembly Time
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Solution Overview
Problem
Existing ball valves for refrigerant circuits are time-consuming to assemble due to complex configurations and multiple components, leading to inefficiencies in assembly and potential leaks.
Innovation Solution
A simplified ball valve design featuring a pre-assembled unit with a spherical control surface, pivot bearing, and shaft that can be easily inserted into the housing, reducing assembly time and eliminating leaks through a one-piece housing and integrated components like a sliding sleeve and pivot bearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional ball valve with separate components (housing, ball, shaft, closures) is used, then the valve can be assembled with individual parts, but the assembly process becomes time-consuming and complex
Solution Approach 1:
The patent combines the ball, shaft, and pivot bearing into a single integrated spherical control surface assembly that can be inserted as one pre-assembled unit through the connection opening. This merging of components directly reduces assembly steps and time while maintaining the functional separation of parts within the integrated unit.
Solution Approach 2:
The spherical control surface with shaft and pivot bearing is pre-assembled into a complete unit before insertion into the housing. This preliminary assembly allows the entire control mechanism to be installed in one operation rather than assembling individual components separately during final assembly, significantly reducing assembly time.
2Adaptability or versatility
If multiple separate components are used in the ball valve, then the valve can be manufactured with standardized parts, but the number of components increases leading to more assembly steps
Solution Approach 1:
The patent merges the ball, shaft, and pivot bearing into a single integrated assembly that functions as one component during installation. This reduces the number of separate parts that need to be handled and assembled while maintaining the functional modularity and adaptability of the valve system.
3Reliability
If traditional sealing arrangements with multiple closures are used, then the valve can seal in both directions, but the sealing complexity increases and potential leak paths multiply
Solution Approach 1:
The patent extracts the closure component from the sealing arrangement, allowing the spherical control surface itself to provide the sealing function. By removing the traditional closure and using the ball's spherical surface with integrated sealing elements, the design reduces sealing complexity while maintaining bidirectional sealing capability through the simplified spherical interface.
Data Source
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AI summary
The invention relates to a ball valve, in particular for use in a refrigerant circuit of a refrigeration system, comprising a housing (12) which includes at least one inlet opening (14) and at least one outlet opening (16), between which a control chamber (17) is provided, with a valve (19) arranged in the control chamber (17), which comprises at least one spherical control surface (20) with at least one passage (24) connecting an inlet opening (22) with an outlet opening (23) of the valve (19), with a connection opening (18) in the housing (12) which opens into the control chamber (17), into which a connection housing (34) can be inserted, wherein at least one seal (43) is provided between the connection housing (34) and the connection opening (18), and the connection housing (34) comprises a shaft passage (36) with a shaft (33) mounted therein, through which the valve (19) can be actuated.wherein the valve (19) with the at least one spherical control orifice (20) can be inserted into the regulating chamber (17) through the connection orifice (18). (See Figure 4)