Control Valve Coaxial Cylinder Shells Pressure Relief
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Solution Overview
Problem
Control valves face high raw material costs due to the use of copper-rich brass alloys and require extensive machining, leading to material wastage and diaphragm overload from constant pressure, which weakens the material.
Innovation Solution
The control valve design reduces material usage by using coaxial cylinder shell faces with a smaller diameter and axial movement for flow reduction, incorporating a capillary channel for pressure relief, and integrating the pressure maintaining and amount control arrangements in a single opening, allowing for simpler machining and reduced material consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If copper-rich brass alloys are used for control valve components, then strength and durability are improved, but raw material costs and machining complexity increase
Solution Approach 1:
The control valve is divided into modular components (valve body, diaphragm, throttle member, spindle) that can be manufactured separately and assembled. This segmentation allows each part to be optimized for its specific function and manufacturing process, reducing overall machining complexity while maintaining strength requirements for critical components.
Solution Approach 2:
The patent modifies material parameters by using brass alloy with reduced copper content and optimized mechanical properties. This parameter change lowers raw material costs and improves machinability while maintaining sufficient strength for valve components through careful selection of alloy composition and heat treatment parameters.
2Manufacturing precision
If extensive machining is performed on brass components, then manufacturing precision is improved, but material wastage increases
Solution Approach 1:
The valve body and internal passages are designed to be cast or molded with near-net-shape geometry, performing preliminary forming before final machining. This preliminary action removes the need for extensive material removal, reducing copper wastage while maintaining the precision required for flow control passages and sealing surfaces.
Solution Approach 2:
The patent changes the manufacturing approach by adopting casting or molding processes with optimized parameters to achieve near-net-shape components. This parameter change in the manufacturing process significantly reduces material wastage while maintaining or improving manufacturing precision through better dimensional control during forming.
3Reliability
If the rolling diaphragm is subjected to constant inlet pressure, then pressure maintaining function is improved, but diaphragm material weakening occurs
Solution Approach 1:
The harmful constant pressure load is extracted from the diaphragm by providing a pressure relief passage that redirects excess inlet pressure away from the diaphragm. This separation allows the diaphragm to maintain its pressure-sensing function while being protected from damaging constant high-pressure exposure that would weaken the material over time.
Solution Approach 2:
A pressure relief passage acts as an intermediary element between the inlet pressure source and the diaphragm. This mediator selectively allows pressure to reach the diaphragm when needed for function while providing a relief path when pressure becomes excessive, thereby protecting the diaphragm from strength-degrading constant high-pressure exposure.
4Reliability
If multiple separate components are used for pressure maintaining and amount control, then functional reliability is improved, but device complexity and material cost increase
Solution Approach 1:
The pressure maintaining arrangement and amount control arrangement are merged into a single integrated control valve assembly. The valve body incorporates both the differential pressure governor mechanism and the adjustable orifice within one unified structure, reducing the number of separate components and connections while maintaining the functional reliability of both pressure maintenance and flow control functions.
Solution Approach 2:
The control valve assembly is designed as a multi-functional device that simultaneously performs pressure maintenance, flow control, and adjustable rate setting. This universal design consolidates multiple functions into one device, reducing overall system complexity and material requirements compared to using separate components for each function.
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 design results in a more cost-effective, durable, and functionally reliable control valve with reduced material wastage and enhanced diaphragm protection from pressure overload, enabling precise adjustment and effective flow control.
Implementation Method 1
a rolling diaphragm and a throttle member which sets itself in a balance between the inlet pressure and the outlet pressure
Implementation Method 2
incorporating a capillary channel for pressure relief
Data Source
AI summary
A control valve comprises a valve housing (1) having an inlet side (17) and an outlet side (18). The control valve also has a pressure maintaining arrangement for maintaining a constant differential pressure between the inlet and outlet sides, as well as an amount control arrangement for setting the maximum flow through the valve. A pair of cylinder shells located in the flow path have cooperating recesses which provide an uncovered area forming an opening (25). One cylinder shell is rotatable relative to the other cylinder shell by a rotatable handle (13), whereby a larger or smaller opening (25) between the cooperating cylinder shells may be provided. Both cylinder shells are axially displaceable within a seat hole (8), resulting in an increase or a decrease of the opening (25).