Butterfly Valve Feedback Actuator for Compressor Inlet Stability
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Solution Overview
Problem
Air compressor inlet valves are unstable at low flow rates or low opening points, making them unsuitable for efficient operation.
Innovation Solution
A system and method involving a butterfly valve with an actuator and feedback actuator that applies a variable secondary force to stabilize the valve position, using a spool within a cylinder to direct control fluid and provide feedback force proportional to the valve's position, ensuring balanced forces for stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional inlet valve is used to control air flow into the compressor, then the valve can regulate flow quantity, but the valve becomes unstable at low flow rates or low opening points
Solution Approach 1:
The patent implements a feedback mechanism where the downstream side of the butterfly valve is connected to the third portion of the actuator cylinder. This creates a feedback force that varies with valve position, providing stabilizing influence at low opening points and low flow rates where conventional valves become unstable.
Solution Approach 2:
The patent changes the pressure parameter by connecting the downstream side (higher pressure) to the third portion of the cylinder, creating a feedback force that counteracts instability. This parameter change transforms the pressure differential into a stabilizing feedback mechanism that improves valve stability across the full range of opening positions.
2Loss of energy
If the butterfly valve is positioned at low opening points for reduced flow, then energy consumption is reduced, but the valve operation becomes unstable and hunting occurs
Solution Approach 1:
The feedback connection between the downstream side and the third portion of the cylinder provides a stabilizing force that prevents hunting and instability at low opening positions, enabling energy-efficient operation at reduced flow rates without sacrificing valve stability.
Solution Approach 2:
The feedback force acts as a counterbalancing mechanism that offsets the inherent instability of the valve at low opening points. By providing an opposing force through the pressure differential, the system counteracts the tendency toward hunting and enables stable operation across the full range of positions.
3Ease of operation
If the actuator applies force to move the butterfly valve to desired position, then flow control is achieved, but the system lacks stability due to unbalanced forces
Solution Approach 1:
The feedback mechanism provides a stabilizing force that balances the actuator force across the full range of valve positions. This feedback force, generated by the pressure differential between upstream and downstream sides, ensures stable equilibrium at any desired position and prevents oscillations or hunting.
Solution Approach 2:
By utilizing the pressure parameter difference between upstream and downstream sides, the system creates a feedback force that varies with valve position. This parameter change transforms the pressure differential into a position-dependent stabilizing force that maintains force balance and improves overall system stability.
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 stabilizes the air compressor operation by linearizing the relationship between regulation pressure and mass flow, reducing hunting and instability, and allowing precise control of the valve position for efficient compressor operation.
Implementation Method 1
A feedback actuator is coupled to the actuator and is operable to apply a variable secondary force to the butterfly valve in opposition to the actuator force, the secondary force varying in response to the position of the butterfly valve
Implementation Method 2
A spool is disposed within the cylinder. The spool defines a first portion, a second portion, and a third portion. A control fluid inlet is formed in the cylinder and is positioned to direct control fluid to the second portion
Data Source
AI summary
An air compressor system includes a housing defining an inlet and an outlet, a butterfly valve coupled to the inlet and movable between a closed position and an open position, and an actuator coupled to the butterfly valve and operable to apply an actuator force to the butterfly valve to move the actuator and the butterfly valve to a desired position between the closed position and the open position. A feedback actuator is coupled to the actuator and is operable to apply a variable secondary force to the butterfly valve in opposition to the actuator force, the secondary force varying in response to the position of the butterfly valve.