Ball Valve Pulse Actuation for Sticking and Breakaway Torque
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Solution Overview
Problem
Ball valves experience sticking issues due to long-term use, leading to increased resistance and breakaway torque requirements, which can exceed the capabilities of electronic actuators, especially when handling certain fluids that cause calcification, resulting in inefficiencies and potential failure to rotate.
Innovation Solution
Applying controlled electric pulses to the ball valve actuator to slightly rotate the ball, reducing sticking by maintaining lower breakaway torque requirements and preventing fluid stagnation, which can be generated locally or remotely and tailored for specific valve configurations and fluid types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ball valves are used for long-term fluid control, then reliability of fluid control is improved, but resistance and breakaway torque increase due to sticking
Solution Approach 1:
The patent applies periodic pulsing action to the ball valve mechanism. A controller delivers periodic pulses to an actuator that applies controlled forces to the ball, creating periodic movement that prevents the ball from sticking in one position. This periodic action maintains reliable fluid control while preventing excessive breakaway torque buildup.
Solution Approach 2:
The patent changes the operational parameters of the ball valve by applying variable force magnitudes and durations through pulsed actuation. The controller adjusts pulse width, frequency, and amplitude to optimize ball movement, preventing sticking while managing breakaway torque requirements within actuator capabilities.
2Ease of operation
If electronic actuators are used to control ball valves, then ease of operation is improved, but capability is insufficient when breakaway torque exceeds actuator limits
Solution Approach 1:
The electronic actuator receives periodic control pulses that create intermittent force application to the ball. This periodic actuation allows the actuator to overcome sticking conditions through repeated small movements rather than requiring a single large torque output, enabling reliable rotation even when breakaway torque exceeds continuous actuator limits.
Solution Approach 2:
The controller applies partial rotations through pulsed actuation rather than requiring full continuous rotation. By applying multiple small rotational increments through periodic pulses, the system achieves full valve operation capability without requiring the actuator to generate excessive continuous torque.
3Reliability
If pulses are applied to rotate the ball, then sticking is reduced, but fluid flow may be interrupted if valve state changes
Solution Approach 1:
The patent applies localized small-angle rotations to specific portions of the ball's rotational range rather than full rotations. By applying pulses that create only minimal angular displacements (local quality changes), the ball moves enough to prevent sticking but remains in the same functional position, maintaining fluid flow continuity while improving valve reliability.
Solution Approach 2:
The periodic pulsing maintains continuous useful action by preventing sticking throughout the valve's operational life. The repeated small movements ensure the ball never becomes fully stuck, maintaining continuous fluid flow capability without interrupting the valve's functional state or requiring full rotation cycles.
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 pulse control system effectively reduces sticking, maintains efficient operation by preventing fluid stagnation, and ensures the ball valve remains functional within the actuator's torque range, preventing freezing and bacterial growth, while allowing for customizable pulse durations and intervals based on valve position and fluid type.
Implementation Method 1
A ball valve controls the flow of a fluid, such as a liquid or a gas, through the use of a rotary ball having a bore through the ball. In one position of the ball, the bore is aligned with the pipe or tubing, which allows for fluid to flow through the valve. When the ball is turned 90 degrees (e.g., a quarter turn), flow of the fluid through the valve is blocked.
Implementation Method 2
Ball valves experience sticking issues due to long-term use, leading to increased resistance and breakaway torque requirements, which can exceed the capabilities of electronic actuators
Data Source
AI summary
Aspects of the disclosure relate to providing a pulse control to a ball valve to reduce the amount of torque required to adjust the position of the ball valve. In an aspect, the technology relates to a method for reducing resistance of a ball valve. The method includes generating a pulse having a duration and a polarity; providing the pulse to an actuator configured to rotate a ball of the ball valve; and rotating, by the actuator, the ball of the ball valve by an amount based on the duration of the pulse and a direction based on the polarity of the pulse, wherein the ball valve does not change state after rotation of the ball.