Butterfly Valve Flapper Rotation for Deposit Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Butterfly valves used in deposition systems face issues with deposit buildup due to condensation of vapors and gases, leading to reduced functionality and increased maintenance costs, as existing solutions like heating or high-torque purging are costly and complex.
Innovation Solution
A butterfly valve design allowing the flapper to rotate at least 180°, enabling it to move to multiple positions for effective cleaning by exposing edges and sides to cleaning fluids and alternating positions to dislodge deposits, reducing maintenance needs without added complexity or cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flapper is rotated 180° to expose all surfaces to cleaning fluid, then deposit removal effectiveness is improved, but the mechanical complexity and cost of the rotation mechanism increase
Solution Approach 1:
The flapper is segmented into multiple surfaces (front, back, and edges) that can be sequentially exposed to cleaning fluid through rotation. This segmentation allows comprehensive cleaning of all deposit-prone areas without requiring overly complex cleaning mechanisms, as each surface is addressed in sequence during the rotation cycle.
Solution Approach 2:
The flapper undergoes periodic rotation between operational positions and cleaning positions. During normal operation, the flapper remains in a stable position for flow control, then periodically rotates to expose different surfaces to cleaning fluid. This periodic action ensures deposits are removed at regular intervals without requiring continuous complex mechanisms.
2Reliability
If heaters are embedded in the flapper to prevent condensation, then deposit buildup is reduced, but power consumption and system complexity increase
Solution Approach 1:
The patent replaces the thermal field approach (heaters) with a mechanical field approach (rotation and fluid flow). Instead of using heat to prevent condensation, the system uses mechanical rotation to periodically expose all flapper surfaces to cleaning fluid, which physically removes deposits as they form. This substitution eliminates the need for continuous power consumption while maintaining deposit prevention effectiveness.
Solution Approach 2:
The cleaning system is self-service in that it uses the existing cleaning fluid flow already present in the system. By rotating the flapper to expose all surfaces to this existing fluid flow, the system utilizes available resources rather than requiring additional energy-intensive heating elements. The cleaning action is performed by the system's own operational fluid.
3Reliability
If high torque is applied to break up deposits during purging, then deposit removal is improved, but motor and gearbox cost increase
Solution Approach 1:
The patent uses hydraulic action of cleaning fluid flowing through the valve to remove deposits. The fluid flow, combined with the mechanical motion of rotating the flapper, creates effective cleaning force that dislodges deposits without requiring high-torque motors or complex gearboxes. The hydraulic force of the cleaning fluid itself performs the deposit removal function.
Solution Approach 2:
Instead of continuously applying high torque to break up deposits, the system uses periodic rotation during purging cycles. The flapper rotates to positions where cleaning fluid can access and flush away deposits from all surfaces. This periodic action with moderate torque is more cost-effective than continuous high-torque application, as it leverages fluid dynamics at specific moments in the rotation cycle.
Data Source
AI summary
A butterfly valve comprises: a body including a valve opening; and a flapper rotatably mounted about a rotation axis so as to be movable relative to the valve opening. The flapper is rotatable at least 180° about the rotation axis so that the flapper is movable to at least one fully opened position, at least one fully closed position 90° apart from the fully opened position, and a third position, either fully opened or fully closed, 180° from the other like position. In one embodiment the flapper is rotatable at least 360° about the rotation axis so that the flapper is movable to each of two opened positions 180° apart, and two closed positions 180° apart from each other and 90° and 270° apart from each of the fully opened positions. The valve can be easily calibrated and controlled, and cleaned to extend the useful service life between cleanings.