Condensate Valve Stepped Piston Pressure Reducer
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Solution Overview
Problem
Existing condensate drain systems for high- and medium-pressure compressors are inefficient due to pressure drops during condensate drainage, requiring additional control air, complex construction, and costly solenoid valves prone to contamination and clogging, leading to increased effort and costs.
Innovation Solution
A condensate drain system utilizing a solenoid valve with a stepped piston design that acts as a pressure reducer, allowing direct discharge of condensate into a collection tank without intermediate expansion tanks, simplifying construction and reducing costs by using low-pressure components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If condensate is discharged directly via solenoid valves with very small nominal diameter, then the valve is less sensitive to contamination, but the discharge volume is too large requiring additional relief tanks
Solution Approach 1:
The condensate discharge path is segmented into two distinct stages: first through a small-diameter solenoid valve (4) that provides contamination resistance, then through a separate pressure reducer (3) with a nozzle (5) that controls the discharge volume. This segmentation allows each component to optimize for its specific function without compromise.
Solution Approach 2:
The pressure reducer (3) acts as an intermediary component between the solenoid valve (4) and the condensate collection tank (6). It receives condensate from the solenoid valve, reduces its pressure, and controls the discharge volume through the nozzle, thereby mediating between the small valve diameter and the discharge volume requirement.
2Reliability
If condensate valve is arranged separately from oil/water separators, then direct attachment is avoided, but additional connecting lines are required making construction more complex
Solution Approach 1:
The pressure reducer (3) and solenoid valve (4) are merged into a single integrated assembly that can be directly mounted to the oil/water separator (1). This combination eliminates the need for separate condensate valves and multiple connecting lines, reducing construction complexity while maintaining the benefits of indirect condensate discharge.
3Stress or pressure
If additional control air is used to control condensate drain system, then system pressure is maintained, but additional lines are required increasing overall effort
Solution Approach 1:
The pressure reducer (3) is designed to automatically reduce condensate pressure through its nozzle (5) without requiring external control air or additional control lines. The system uses the inherent pressure differential and fluid dynamics to achieve automatic pressure reduction, making the system self-regulating and eliminating complex control infrastructure.
4Reliability
If solenoid valves with larger nominal diameter are used to avoid contamination, then discharge volume increases, but additional relief tanks are required
Solution Approach 1:
The discharge function is segmented between the solenoid valve (4) which handles contamination resistance with its smaller diameter, and the pressure reducer (3) with nozzle (5) which handles volume control. This segmentation allows using a smaller valve diameter without requiring large discharge volume, eliminating the need for additional relief tanks.
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 system effectively reduces pressure and eliminates the need for additional tanks or silencers, ensuring reliable and cost-effective condensate drainage without impairing compressor efficiency.
Implementation Method 1
the condensate valve through which the condensate flows is designed in such a way that it also forms a pressure reducer for reducing the pressure of the condensate flowing out
Implementation Method 2
a shut-off element, such as a solenoid valve, which serves to open and close a condensate valve arranged in the condensate drain system
Data Source
AI summary
The invention relates to a condensate valve (3) for at least one oil/ water separator (1) on a compressor. Said condensate valve can be connected to at least one oil/water separator (1) of a compressor (2) on the input side and the condensate can flow therethrough. The condensate valve (3) can be actuated via a shut-off member (A), for example a solenoid valve (4), for opening and closing. The outlet of the condensate valve (3) opens into a condensate collection container (6). The condensate valve (3) through which the condensate (3) flows is designed such that it also forms a pressure reducer for lowering the pressure of the condensate flowing out and allows for direct discharge to the condensate collection container (6) on the outlet side. The condensate valve (3) preferably comprises a moveable piston (10), which can be pressed against an opening (A1) having a small diameter of the valve seat (11) on the inlet side when the condenser valve is closed by means of the shut-off member (A). On the outlet side, the piston (10) comprises a piston surface (A2, A3) having a larger diameter or a large piston cross-sectional surface, to which the condensate is supplied via an overflow line when the condensate valve (3) is opened by means of the shut-off element (A). The overflow line can be formed by at least one through-channel (12) extending axially through the piston (10).