Compact Valve Actuator Layout for Narrow-Space Retrofit
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Solution Overview
Problem
Conventional valve actuators for motorizing manual valves in ships increase the size of the valve significantly, making them difficult to install in narrow spaces and requiring complex procedures, often necessitating the replacement of manual valves with motorized ones, leading to increased costs.
Innovation Solution
A compact valve actuator design featuring a motor with a rotary shaft, pulley system, worm reduction gear, and a bracket part that can be easily attached to existing manual valves, allowing for high torque output and precise control while reducing the overall size of the actuator, enabling it to fit in narrow spaces and simplify the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a conventional valve actuator is attached to a manual valve, then the valve can be motorized, but the size of the valve is significantly increased, making it difficult to install in narrow spaces
Solution Approach 1:
The actuator is nested around the existing valve stem, with the motor, pulley system, and worm gear arranged in a compact cylindrical configuration that fits over the valve body without requiring additional lateral space. The bracket part integrates the valve attachment mechanism into the actuator housing itself
Solution Approach 2:
The actuator utilizes the vertical dimension by extending upward from the valve body rather than expanding horizontally. The pulley system and belt arrangement are configured to transmit power in a vertical orientation, allowing the actuator to fit within the limited horizontal space while maintaining sufficient vertical clearance
2Extent of automation
If a conventional valve actuator is attached to a manual valve, then the valve can be motorized, but the attachment process becomes complicated and requires tools such as spanners
Solution Approach 1:
The bracket part incorporates a self-aligning attachment mechanism that automatically positions the actuator relative to the valve stem. The valve attachment part includes integrated fastening features that engage with the valve body without requiring external tools, allowing the actuator to be installed by simply sliding it onto the valve and securing it with hand-operated clips or snap-fit mechanisms
Solution Approach 2:
The actuator is divided into modular components: the motor assembly, the pulley system, the worm gear, and the bracket part. This segmentation allows each component to be independently manufactured and assembled, simplifying the overall attachment process and enabling easy replacement or maintenance of individual parts
3Extent of automation
If a conventional valve actuator is attached to a manual valve, then the valve can be motorized, but the size increase makes it difficult to work in narrow spaces with tools
Solution Approach 1:
The actuator components are nested within a compact cylindrical housing that fits over the valve body, creating a space-efficient assembly that can be serviced in tight quarters. The pulley and belt system are enclosed within the actuator housing, protecting them from damage while allowing access to critical components through removable panels or openings
Solution Approach 2:
The actuator incorporates self-diagnostic and self-adjustment features that reduce the need for manual intervention. Sensors detect valve position and actuator status, automatically adjusting operational parameters to optimize performance and prevent malfunctions, thereby reducing maintenance requirements in difficult-to-access locations
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 compact and easily attachable valve actuator effectively motorizes manual valves without increasing the valve's size, allowing for precise control and efficient power transmission, reducing installation complexity and costs by enabling direct attachment to existing valves.
Implementation Method 1
a belt that is stretched between the first pulley and the second pulley to connect the first pulley to the second pulley in order to rotate the first pulley and the second pulley in the same direction
Implementation Method 2
a worm reduction gear that has a worm portion and a worm wheel such that the second pulley is attached to the worm portion and a worm wheel is orthogonally engaged with the worm portion in order for the worm portion to orthogonally drive the worm wheel by meshing of gears between the worm portion and the worm wheel
Data Source
AI summary
A valve actuator has an actuator body and a valve attachment part. Further, the actuator body has a case, a motor, a belt transmission part, and a worm reduction gear. Further, the actuator body has a bracket part.