Compact Electric Valve Design for Variable Refrigerant Flow Systems
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Solution Overview
Problem
Conventional direct-acting electric valves used in variable refrigerant flow commercial air-conditioning systems are too large due to the need for a large driving force, which is not compatible with the limited refrigerant charge and size constraints, especially with the use of flammable and explosive new refrigerants like R290 and R32.
Innovation Solution
The electric valve design is optimized with a compact structure featuring a valve body, valve cover, valve core, and valve seat components, where the valve seat core is sleeved outside the valve port jacket, improving position accuracy and reliability, and the manufacturing process involves forming the valve body by drawing or pressing metal sheets/tubes to reduce size and increase precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large valve port area is used to meet the flow control requirements of commercial air conditioners, then the flow capacity is increased, but the driving force requirement increases and the valve size becomes larger
Solution Approach 1:
The patent replaces the conventional direct-acting mechanical driving system with an electromagnetic driving system. The electromagnetic coil generates a magnetic field that directly actuates the valve core, eliminating the need for large mechanical levers and springs. This substitution allows achieving the required driving force for large valve ports without proportionally increasing the overall valve size, as electromagnetic actuators can generate high force in a compact form factor.
Solution Approach 2:
The patent changes the material properties and structural parameters of the valve components. By using optimized magnetic circuit designs, high-permeability magnetic materials, and precise dimensional parameters for the electromagnetic coil and valve core, the system achieves efficient force transmission. This allows the valve to maintain large flow capacity while keeping the actuator size compact through optimized parameter selection rather than simply scaling up all dimensions.
2Volume of stationary object
If the valve size is reduced to meet refrigerant charge limitations with flammable refrigerants, then the refrigerant charge volume is controlled, but the driving force may be insufficient
Solution Approach 1:
The electromagnetic actuation system replaces conventional mechanical spring-lever mechanisms that would require large physical dimensions to generate sufficient force. The electromagnetic coil can generate concentrated magnetic force in a small volume, allowing the valve to be compact while maintaining adequate driving force to overcome refrigerant pressure and achieve precise flow control.
Solution Approach 2:
The patent employs composite structural designs combining magnetic materials, magnetic conductive materials, and non-magnetic materials in the electromagnetic actuator assembly. This composite approach optimizes the magnetic circuit efficiency and force generation density, enabling high driving force in a reduced size package that is suitable for applications with strict volume constraints.
3Volume of stationary object
If a compact structure is adopted to reduce valve size, then the refrigerant charge volume is reduced, but the position accuracy between functional parts becomes difficult to guarantee
Solution Approach 1:
The patent adopts a nested structural arrangement where the valve core is positioned within the valve body, and the electromagnetic coil is integrated around the magnetic circuit components. This nested design allows multiple functional parts to be arranged in three-dimensional space efficiently, maintaining precise relative positions while minimizing the overall valve envelope. The concentric arrangement of components ensures accurate positioning without requiring excessive manufacturing tolerances.
Solution Approach 2:
The valve is divided into modular components (valve body, valve core, electromagnetic coil assembly, magnetic circuit parts) that can be manufactured separately with controlled precision and then assembled. This segmentation allows each component to be optimized and manufactured independently, making it easier to guarantee position accuracy through precision machining and standardized interfaces, rather than attempting to machine the entire assembly as a single piece.
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 optimized design results in a compact, reliable, and cost-effective electric valve that meets the requirements of variable refrigerant flow systems, reducing overall size while ensuring stable operation and precise control of refrigerant flow.
Implementation Method 1
an electromagnetic coil, arranged outside the valve cover and corresponding to the magnetic rotor; wherein the magnetic rotor is arranged inside the valve cover and connected with the screw rod
Data Source
AI summary
An electrical valve, comprising: a valve body component, the valve body component comprising a valve body and a valve cover body, the valve cover body being fixedly connected to the valve body; a valve seat component, the valve seat component comprising a valve seat body and a valve seat core, the valve seat body being fixedly connected to the valve body, the valve seat core being sleeved with a valve port protective sleeve. Due to a structurally optimised design, the electrical valve has a compact overall structure and a small size, and the positional accuracy between various functional parts is easily ensured, thereby increasing the reliability of the valve seat core.