Ball Valve Pulse Control for Lower Breakaway Torque
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Solution Overview
Problem
Ball valves experience sticking issues due to prolonged use, leading to increased resistance and higher breakaway torque requirements, which can exceed the capabilities of electronic actuators.
Innovation Solution
The implementation of a pulse control system that generates pulses with specific durations and polarities to rotate the ball valve slightly, reducing sticking and maintaining lower breakaway torque within the actuator's capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ball valve is used for prolonged use, then the valve provides reliable fluid control, but the resistance increases due to sticking issues
Solution Approach 1:
The patent applies periodic pulse signals to the actuator to rotate the ball valve slightly at intervals. This periodic action prevents the ball from sticking by continuously making small adjustments to its position, thereby maintaining low resistance while preserving reliable fluid control over prolonged use.
Solution Approach 2:
The system performs preliminary rotation of the ball valve using pulse signals before significant sticking occurs. By applying small rotational pulses in advance, the valve maintains its operational reliability without experiencing high resistance buildup during normal operation.
2Ease of operation
If the ball valve rotates to adjust position, then the valve changes flow control state, but the breakaway torque exceeds actuator capabilities
Solution Approach 1:
Instead of applying full rotation torque, the system uses partial rotation through pulse signals that move the ball valve only slightly at a time. This partial action approach keeps the required breakaway torque within actuator capabilities while still achieving the desired flow control adjustment over multiple pulses.
Solution Approach 2:
The patent segments the valve adjustment process into multiple small rotational steps using pulse signals, rather than requiring a single large rotation. This segmentation reduces the peak breakaway torque needed at any moment, making it compatible with limited actuator capabilities.
3Force
If pulse control is applied to reduce resistance, then the ball valve operates smoothly, but the valve may rotate when it should maintain position
Solution Approach 1:
The system uses feedback from sensors to detect the ball valve's position and determines whether pulse signals should be applied. This feedback mechanism ensures pulses are only sent when needed to reduce sticking, preventing unnecessary rotation that would compromise position stability.
Solution Approach 2:
The patent implements dynamic pulse control where the timing and application of pulses adapt based on valve conditions. The system dynamically adjusts when to apply pulses versus when to maintain position, balancing resistance reduction with position stability requirements.
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.