Control Valve Linear Motor Actuation for Rapid Air Flow
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Solution Overview
Problem
Contemporary starter air valves that can accommodate high flow rates are not very responsive, requiring anticipation of system events rather than real-time response, which is risky in transient systems, and valves that are responsive cannot handle high flow rates effectively.
Innovation Solution
A control valve assembly with a linear motor and a permanent magnet-electromagnetic coil system that allows the valve body to move between open and closed positions in less than 30 ms, enabling rapid modulation of high flow rates up to 1700 scfm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a starter air valve is designed to accommodate high flow rates (e.g., 1700 scfm), then the flow capacity is improved, but the response time becomes slow (more than one second to fully open)
Solution Approach 1:
The valve is segmented into a body portion and a movable valve member that can be independently controlled. The valve member includes a head and shaft that can be rapidly positioned by the linear motor, separating the flow control function from the actuation mechanism. This allows the valve body to be optimized for high flow capacity while the valve member is optimized for rapid response.
Solution Approach 2:
The patent replaces traditional pneumatic actuators with a linear motor that uses electromagnetic fields to directly drive the valve member. This substitution of mechanical/pneumatic actuation with electromagnetic actuation enables much faster response times (30 ms or less) while maintaining the ability to handle high flow rates through proper valve design.
2Loss of time
If a starter air valve is designed to be very responsive (less than 100 ms opening time), then the response time is improved, but the flow capacity is limited (only 300 scfm)
Solution Approach 1:
The valve design separates the actuation mechanism (linear motor driving valve member) from the flow path (body portion with inlet/outlet ports). This segmentation allows the valve member to be small and lightweight for fast response, while the body portion is designed with large passages to accommodate high flow rates up to 1700 scfm.
Solution Approach 2:
The patent changes the actuation mechanism from traditional pneumatic actuators to a linear motor with electromagnetic coils and permanent magnets. This parameter change in the actuation system enables rapid valve opening (30 ms or less) without compromising flow capacity, as the electromagnetic force can quickly overcome the spring biasing force regardless of the valve size.
3Device complexity
If a traditional pneumatic actuator is used to open the valve, then the system is simpler, but the response time is slow and anticipation of system events is required
Solution Approach 1:
The patent substitutes traditional pneumatic actuators with a linear motor that uses electromagnetic fields for actuation. This replacement eliminates the need for complex pneumatic control systems and auxiliary power units, while achieving dramatically faster response times (30 ms or less) that enable real-time control without anticipating system events.
Solution Approach 2:
The linear motor is directly coupled to the valve member, eliminating the need for intermediate pneumatic components, hoses, and actuators. The electromagnetic coil and permanent magnet system provides direct force to the valve shaft, simplifying the overall system while enabling rapid response through direct electromagnetic actuation.
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 solution provides a fast response time, allowing real-time control of air flow, preventing engine damage during slow starting and accommodating high flow rates without the need for internal feedback, resulting in a more reliable and cost-effective system.
Implementation Method 1
an electromagnetic coil circumscribing the shaft, wherein when electricity is passed through the electromagnetic coil it generates a magnetic field that interacts with the permanent magnet to apply a force to the shaft
Implementation Method 2
a biasing element applying a biasing force to the piston to urge the piston to the closed position
Data Source
AI summary
A control valve and an air starting system for an engine having a pressurized air source, an air starter, and a control valve. The control valve having a housing defining a flow passage with an inlet port fluidly coupled to the pressurized air source and an outlet port fluidly coupled to the air starter, a valve body movable between an opened and closed positions to selectively open and close one of the inlet and outlet ports, resulting in a corresponding opening and closing of the control valve, and a linear motor operably coupled to the valve body to move the valve body between the opened and closed positions.