Multi-Stage Control Valve Trim for Noise and Cavitation Reduction
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Solution Overview
Problem
Conventional control valve cages with drilled holes are cumbersome, costly, and difficult to manufacture, especially when producing complex geometries like non-linear flow paths or varying cross-sectional diameters, which exacerbates noise and cavitation issues, and limits the design's efficiency in reducing pressure recovery and minimizing damage from cavitation.
Innovation Solution
The use of additive manufacturing techniques to create control valve cages with multi-directional throttling passageways, including vena contracta and pressure recovery chambers, which form multiple pressure reducing stages, allowing for complex geometries and shapes that minimize axial and radial dimensions, and enhance noise reduction and cavitation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If drilled holes are used to form passages in the cage wall, then noise is reduced, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The cage wall is designed with a porous structure containing multiple passages formed by additive manufacturing. This porous configuration allows fluid to pass through while reducing noise, and the additive manufacturing process enables creation of complex porous geometries that would be impossible with traditional drilling methods.
Solution Approach 2:
The mechanical drilling process is replaced with additive manufacturing technology. Instead of using drill bits to create passages, the cage is built layer-by-layer with integrated passages, eliminating the need for post-manufacturing drilling operations and associated complexity.
2Object-affected harmful factors
If drilled holes are used to form passages in the cage wall, then noise is reduced, but manufacturing time and cost increase
Solution Approach 1:
The passages are pre-formed during the additive manufacturing process itself, rather than being created as a separate post-processing step. The cage is manufactured with integrated passages built-in from the start, eliminating time-consuming drilling operations afterward.
Solution Approach 2:
Additive manufacturing replaces traditional subtractive drilling methods, enabling simultaneous creation of the cage structure and its internal passages in a single manufacturing operation, significantly reducing production time and cost.
3Object-affected harmful factors
If complex geometries like non-linear flow paths are created, then pressure recovery is reduced and cavitation is minimized, but manufacturing difficulty increases
Solution Approach 1:
The passage geometry parameters are optimized to create non-linear flow paths with varying cross-sectional areas. The passages include constricted sections and expansion zones that control fluid velocity and pressure distribution, reducing cavitation while the additive manufacturing process enables these complex geometries.
Solution Approach 2:
The passages transition from simple linear holes to three-dimensional complex geometries with non-linear paths and varying cross-sections. Additive manufacturing enables this dimensional complexity, allowing passages to curve, expand, and contract in ways impossible with traditional drilling.
4Volume of moving object
If the cage dimensions are minimized, then the control valve becomes more compact, but the complexity of creating multi-directional throttling passageways increases
Solution Approach 1:
The passages are designed to extend in multiple directions (radial, axial, and angular) rather than simple linear paths. This multi-directional configuration allows effective throttling within a compact volume, and additive manufacturing enables the complex multi-axis geometries.
Solution Approach 2:
Multiple throttling stages are nested within the compact cage structure. The passages contain sequential constrictions and expansions that create multiple pressure reduction stages within a small volume, maximizing functionality while minimizing overall dimensions.
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 approach enables the production of compact, efficient control valve cages that effectively reduce noise and cavitation, minimize material usage, and optimize fluid flow, while being more cost-effective and less prone to manufacturing complexities compared to traditional methods.
Implementation Method 1
The passageway includes a plurality of vena contracta and a plurality of pressure recovery chambers, which form a plurality of pressure reducing stages
Implementation Method 2
The passageway includes a plurality of vena contracta and a plurality of pressure recovery chambers, which form a plurality of pressure reducing stages
Implementation Method 3
In some liquid applications conditions can occur that will produce a condition where the liquid cavitates, which can cause damage to components of the control valve 10
Implementation Method 4
The passageway includes a plurality of vena contracta and a plurality of pressure recovery chambers, which form a plurality of pressure reducing stages
Implementation Method 5
The passages 20 are spaced such that jets of fluid that are produced as the fluid exits the passages 20 do not converge to produce noise
Data Source
AI summary
A control valve a body having a fluid inlet and a fluid outlet and a valve seat between the fluid inlet and the fluid outlet. A valve plug is positioned within the body and movable between a closed position, in which the valve plug sealingly engages the valve seat, and an open position, in which the valve plug is spaced away from the valve seat. A cage is disposed within the body adjacent the valve seat. The cage includes a cage wall having a throttling inlet and a throttling outlet, which are connected by a throttling passageway. The throttling passageway has a radial direction, an axial direction, and an angular direction between the throttling inlet and the throttling outlet. The passageway includes a plurality of vena contracta and a plurality of pressure recovery chambers, which form a plurality of pressure reducing stages.