Cascaded Fluid Control Valve with Nested Plugs

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Solution Overview

Problem

Traditional fluid control valves struggle to meet requirements for high flow control range, especially when pressure drop is large at low flow and small at high flow, often necessitating larger valves with large port sizes that cannot control low or very low flows, or using two separate valves which increase cost and space requirements.

Innovation Solution

A cascaded controllable fluid control valve design featuring a first valve plug assembly and a second valve plug assembly within the first, allowing for precise control of both large and small fluid flows through a single, compact valve with a smaller port size, utilizing a spring-biased mechanism to maintain fluid isolation and reduce erosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a large fluid control valve is used to provide large flow control capacity, then the flow control range is improved, but the port size becomes large and the valve cannot control low or very low flow

Engineering Contradiction:

Improveflow control capacityVSAvoidflow control range

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The valve is divided into two separate valve plugs: a first valve plug for controlling large flows and a second valve plug for controlling low flows. Each valve plug operates independently within the same valve body, allowing the valve to handle a wide range of flow rates by switching between or combining the functions of both plugs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second valve plug assembly is nested within the first valve plug assembly. The second valve plug is positioned inside the axial bore of the first valve plug, creating a compact nested structure that allows both valve mechanisms to coexist in a single valve body without requiring excessive space.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If two separated valves are used to control different flow ranges, then the flow control range is improved, but the cost and space requirements increase

Engineering Contradiction:

Improveflow control rangeVSAvoidnumber of valves

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Two separate valve control functions are merged into a single integrated valve body. The first and second valve plugs are housed together in the same valve body with a common actuator system, eliminating the need for two separate valves while maintaining the ability to control both large and low flows.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single valve body is designed to perform multiple functions through its dual valve plug configuration. The same valve body can control both large flows (via the first valve plug) and low flows (via the second valve plug), making it a universal solution that replaces what would traditionally require two separate specialized valves.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If a large fluid control valve is used, then the flow control capacity is improved, but the port size becomes large causing high fluid velocity and erosion at low flow

Engineering Contradiction:

Improveflow control capacityVSAvoidfluid erosion

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

Different port sizes and flow paths are provided for different flow conditions. The first valve plug provides a larger port for high flow conditions, while the second valve plug provides a smaller port optimized for low flow conditions. This local differentiation of port characteristics ensures appropriate fluid velocity and erosion characteristics for each operating regime.

Inventive Principle:

Principle #3Local quality

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 design achieves accurate control of fluid flows across a wide range with smaller port sizes, reducing costs and space requirements while extending the service life of components by minimizing fluid velocity and erosion.

Implementation Method 1

utilizing a spring-biased mechanism to maintain fluid isolation

Methodology Applied

Scientific EffectSpring biasing mechanism: Spring

Data Source

PatentUS10598288B2Cascaded controllable fluid control valve and valve trim for a fluid control valve

Publication Date: 2020.03.24 EMERSON PROCESS MANAGEMENT TIANJIN VALVES

AI summary

A fluid control valve having a body, a seat ring, a valve cage adjacent the seat ring, a first valve plug assembly positioned within the valve cage, and a second valve plug assembly positioned within an axial bore of the first valve plug assembly. The first valve plug assembly has radial apertures in fluid communication with the axial bore and a first valve plug including the axial bore and a throttling port in fluid communication with the axial bore. The first valve plug assembly is movable between a closed position, in engagement with the seat ring, and an open position, spaced apart from the seat ring. The second valve plug assembly has a second valve plug that is movable between a closed position, in engagement with the first valve plug, and an open position, spaced apart from the first valve plug.