Wall-Mounted Boiler Hydraulic Valve Layout With Fast-Coupled Sub-Assemblies
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Solution Overview
Problem
Current hydraulic assemblies for wall-mounted boilers are non-rational in their component arrangements, leading to inefficiencies in compactness and cost reduction, with complex installations and numerous connections compromising reliability and cost-effectiveness.
Innovation Solution
A compact hydraulic valve assembly with a rational arrangement of components, utilizing three sub-assemblies connected via fast-coupling means, made from composite materials, and a 'zero balance' water crossing device to optimize space and reduce components, allowing for a single enbloc assembly with reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional hydraulic valve assembly configurations are used, then all hydraulic functions are integrated, but the overall dimensions and production costs cannot be significantly reduced
Solution Approach 1:
The hydraulic valve assembly is divided into three distinct sub-assemblies (first, second, and third sub-assemblies), each containing specific functional elements. This segmentation allows for optimized spatial arrangement and reduces the overall dimensions by organizing components into modular units that can be efficiently packed within the housing.
Solution Approach 2:
Multiple functional elements are merged into integrated sub-assemblies. For example, the first sub-assembly combines the pump, three-way valve, and associated piping into a single unit. This merging reduces the number of separate connection elements needed and simplifies the overall structure, thereby reducing both dimensions and production costs.
2Reliability
If numerous connection elements are used between components, then all hydraulic functions can be implemented, but reliability decreases and production costs increase
Solution Approach 1:
The patent integrates multiple components into sub-assemblies with internal connections, reducing the number of external connection elements. For instance, the pump, three-way valve, and piping are combined into the first sub-assembly, eliminating the need for numerous separate connection elements between these components and thereby improving reliability.
Solution Approach 2:
The housing serves multiple functions: it contains the sub-assemblies, provides structural support, and acts as part of the hydraulic circuit. This multi-functionality reduces the need for additional connection elements and components, simplifying the assembly and improving reliability.
3Ease of manufacture
If non-rational arrangement of functional elements is used, then installation may be simpler, but overall dimensions and production costs cannot be reduced
Solution Approach 1:
By segmenting the assembly into three sub-assemblies with rational spatial arrangement, the patent achieves compact dimensions while maintaining ease of manufacture. Each sub-assembly is designed as a modular unit that can be efficiently produced and assembled, reducing both overall dimensions and production costs.
Solution Approach 2:
The patent utilizes three-dimensional spatial optimization by arranging sub-assemblies in specific orientations within the housing. The rational arrangement in multiple dimensions allows for compact packaging of all functional elements, reducing the overall footprint while maintaining manufacturability.
4Ease of manufacture
If composite materials are used instead of brass, then production costs are reduced, but the assembly of components becomes more challenging
Solution Approach 1:
By merging multiple components into integrated sub-assemblies manufactured as single pieces or pre-assembled units, the patent reduces the number of assembly steps required. This approach mitigates the challenges of assembling composite material components while maintaining the cost advantages of using composite materials instead of brass.
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 achieves a significant reduction in overall dimensions and production costs while ensuring intuitive installation and enhanced reliability through a rational layout and use of composite materials, improving the compactness and efficiency of the hydraulic valve assembly.
Implementation Method 1
in the secondary heat exchanger 20 a heat exchange occurs between the hot water coming from the first heat exchanger 16 and the sanitary cold water (FS) coming from the water mains
Implementation Method 2
a pump 26 for recirculation into the main circuit (C1)
Implementation Method 3
the three-way valve 24 is used for activating a secondary circuit (C2) (for the sanitary water)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A hydraulic valve assembly (13*) for wall-mounted boilers (11), wherein a secondary heat exchanger (20) represents an assemblage plate, mounted on which are, by means of fast-coupling mechanical devices ((SHR1), (SHR2)): - a first, central, sub-assembly (STG1) basically comprising a pump (26); - a second, lateral, sub-assembly (STG2) comprising some elements belonging to a secondary circuit (C2) for the distribution of sanitary water; and - a third, lateral, sub-assembly (STG3) comprising some elements belonging to a primary circuit (C1) for distribution of heating water in premises.