Controller Valve Actuator Connector Transverse Screw Alignment
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Solution Overview
Problem
Existing valve actuator controller mounting systems are prone to radial misalignment and lack a strong, secure connection, especially when installed in non-standard orientations, leading to reduced control accuracy and risk of damage during installation.
Innovation Solution
A connector design featuring screws with transverse screw axes to prevent radial shifts, combined with a locking mechanism that ensures proper alignment and a strong coupling between the controller and valve actuator, utilizing a base plate with apertures for the piston rod and knobs, and a locking system with protrusions and set screws for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws with radial orientation are used to attach the controller to the valve actuator, then the connection strength is improved, but radial misalignment occurs causing reduced control accuracy
Solution Approach 1:
The patent inverts the conventional radial screw orientation by using transverse screw axes that are perpendicular to the radial direction. This inversion prevents the controller from shifting radially toward the piston rod during tightening, thereby maintaining control accuracy while still achieving strong connection through the transverse locking mechanism
2Strength
If screws are tightened hard to ensure strong coupling, then connection strength is improved, but the controller may shift or break due to excessive force
Solution Approach 1:
The patent employs asymmetric locking features including a cam mechanism and unevenly distributed locking surfaces that distribute the tightening force non-uniformly. This asymmetric design allows the connection to achieve strong coupling through mechanical interlocking and cam action rather than uniform screw compression, thereby reducing the risk of controller damage while maintaining connection strength
3Adaptability or versatility
If the controller is mounted in non-standard orientations (horizontal or upside down), then installation flexibility is improved, but significant forces act on the connection causing potential damage
Solution Approach 1:
The patent incorporates counterbalancing features in the form of support surfaces and distributed mounting points that counteract gravitational forces when the controller is mounted in non-standard orientations. The transverse screw arrangement and locking mechanism work together to provide mechanical support that compensates for the weight-induced forces, enabling flexible installation orientations without compromising connection integrity
Data Source
Figure 1a~1c
Figure 2a~2b
Figure 3a~3d
AI summary
An assembly comprising a valve actuator and a controller for controlling the function of the valve actuator is disclosed. The valve actuator has a first knob and a piston rod that protrudes from the first support surface. The controller has a connector (26) with a base plate (28) having a first aperture (34), a second aperture (64) and a second support surface (36) that conforms to the first support surface. The first knob extends through the first aperture (34) and the piston rod extends through the second aperture (64). The connector also has a first lock (38) with a first screw (46) that engages the first knob (18), and wherein the first screw (46) has a first screw axle that is oriented at a right angle to a line between the piston rod and the first knob.