Additive-Manufactured Compressor Valve Body for Uniform Piston Pressure

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Solution Overview

Problem

Existing reciprocating compressor valves experience uneven pressure distribution across pistons due to the radial hydraulic duct design, leading to inefficient fluid passage control and increased complexity in production, which affects operational life and production costs.

Innovation Solution

The integration of a hydraulic circuit with radially arranged radial ducts and a distributing duct, designed using additive manufacturing technology, ensures equal pressure across each piston, allowing for precise shaping and reduced production complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a radial hydraulic duct design is used, then the hydraulic circuit can be integrated in the valve body, but the pressure distribution across pistons becomes uneven

Engineering Contradiction:

Improvehydraulic circuit integrationVSAvoidpressure distribution uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The hydraulic circuit is divided into multiple independent ducts (first hydraulic duct, second hydraulic duct, etc.), each serving specific pistons. This segmentation allows independent pressure control and flow optimization for different piston groups, resolving the uneven pressure distribution issue while maintaining integration in the valve body.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different duct configurations are designed for different regions of the valve body. The first hydraulic duct serves pistons in a first group with specific flow characteristics, while the second hydraulic duct serves pistons in a second group with different requirements. This local optimization ensures uniform pressure distribution across all pistons while keeping the overall system integrated.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If conventional manufacturing methods are used, then production processes are well-established, but the hydraulic circuit design becomes complex and time-consuming

Engineering Contradiction:

Improveproduction process maturityVSAvoidhydraulic circuit design complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The hydraulic circuit is merged with the valve body structure itself, with ducts integrated directly into the seat and guard components. This eliminates the need for separate hydraulic components and reduces assembly steps, simplifying the overall manufacturing process while maintaining functional complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The valve body serves multiple functions: it acts as both the structural component housing the pistons and the hydraulic circuit integration platform. The seat and guard components simultaneously provide mechanical support and hydraulic flow paths, reducing the total number of parts and simplifying manufacturing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If the hydraulic circuit is integrated in the seat and guard, then production costs can be reduced, but the design requires significant time and skilled work

Engineering Contradiction:

Improveproduction costVSAvoiddesign and production time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The hydraulic ducts are designed and positioned during the initial valve body manufacturing process rather than being added later. The additive manufacturing approach allows the complex duct geometries to be created directly during production, eliminating time-consuming post-processing operations and reducing the need for skilled manual work.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Traditional mechanical machining and assembly processes are replaced with additive manufacturing technology. This enables the complex integrated hydraulic circuit to be produced directly from digital designs, significantly reducing production time and the skill level required while maintaining cost efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This solution enables homogeneous movement of pistons and shutter elements, enhancing operational life and reducing production costs by allowing for customizable and precise hydraulic circuit designs within the valve body.

Implementation Method 1

a hydraulic apparatus for moving a shutter element at least between an open position and a closed position, comprising pistons and a hydraulic circuit

Methodology Applied

Scientific EffectHydraulic pressure: Hydraulic Press

Data Source

PatentUS11009017B2Reciprocating compressor valve body made by additive manufacturing

Publication Date: 2021.05.18 NUOVO PIGNONE TECH SRL

AI summary

It is disclosed a valve (1) for a reciprocating compressor, comprising a valve body (2) which comprises a seat (3) and a guard (4), the seat (3) and the guard (4) developing substantially parallel to a valve plane (A). The valve (1) also comprises a hydraulic apparatus (7) with pistons (9) and a hydraulic circuit (8) provided with a first portion (8a) which is made by additive manufacturing technology according to digital 3D design data.