Check Valve Reinforcement Mechanism to Prevent Disk Sticking

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Solution Overview

Problem

Check valves in oil production systems often fail due to debris lodging between the check disk and the valve components, leading to frequent maintenance and increased costs, as they are not tolerant of harsh environments with fluid mixtures containing oil, water, gas, and contaminants.

Innovation Solution

A valve unit with a reinforcement mechanism that restricts lateral movement of the check disk, combined with integrated sensors to monitor the valve's position and fluid parameters, preventing sticking and enhancing operational reliability and reducing maintenance needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a check valve is used in a harsh environment with debris-containing fluid mixtures, then the valve can perform its basic function of preventing backflow, but the valve frequently fails due to debris lodging between the check disk and valve components

Engineering Contradiction:

Improvevalve operational reliabilityVSAvoiddebris lodging and sticking

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A reinforcement mechanism is introduced as an intermediary element between the check disk and the valve body. This mechanism includes a reinforcement member extending through the check disk that prevents lateral movement and eliminates sticking caused by debris accumulation, thereby resolving the contradiction between maintaining valve function and preventing debris-related failures

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The check disk is segmented into multiple components: the check disk proper and a reinforcement member. This segmentation allows the reinforcement member to specifically address the sticking problem by preventing lateral movement, while the check disk maintains its sealing function, thus improving reliability without compromising the basic valve function

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the valve is designed to tolerate debris in the fluid mixture, then the valve can operate in harsh environments, but the valve requires frequent maintenance and replacement

Engineering Contradiction:

Improvetolerance to harsh environmentsVSAvoidmaintenance frequency

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The reinforcement mechanism acts as a mediator that enables the valve to tolerate harsh environments by preventing debris from causing sticking. This eliminates the need for frequent maintenance while maintaining adaptability to harsh conditions, as the reinforcement member continuously prevents debris-related failures during operation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The reinforcement mechanism provides beforehand protection by preventing lateral movement of the check disk before debris can cause sticking. This proactive measure eliminates the need for reactive maintenance and replacement, reducing maintenance frequency while maintaining environmental adaptability

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Measurement precision

If sensors are integrated into the valve to monitor position and fluid parameters, then accurate data on fluid flow can be provided, but the device complexity increases

Engineering Contradiction:

Improvefluid flow parameter measurement accuracyVSAvoidvalve structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Sensors are merged with the valve body and reinforcement mechanism, allowing the sensors to be positioned along the reinforcement member to detect check disk position and fluid parameters. This integration provides accurate measurement data while minimizing additional complexity by utilizing existing structural elements as sensor mounting platforms

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11781668B2Valve unit including a reinforcement mechanism with optional sensor assembly

Publication Date: 2023.10.10 BLACK HAWK TECH LLC

AI summary

A valve unit may include a valve and a sensor assembly coupled to the valve. The valve may include a check disk configured to move along a pre-determined path to contact a valve seat in a closed state and configured to decouple from the valve seat in an open state. The valve may also include a mechanism to restrain lateral movement of the check disk to prevent the check disk from sticking. The sensor assembly may include a position sensor configured to generate a first electrical signal related to movement of the check disk and may include circuitry coupled to the position sensor. The position sensor assembly may generate a reference signal to eliminate noise within the first electrical signal. The circuitry may determine fluid flow parameters including flow volume of liquid components and of gas components of the fluid mixture based on frequency components within the first electrical signal.