Cushioned Relief Valve for Hydraulic Shock Mitigation
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Solution Overview
Problem
Conventional systems face challenges in mitigating hydraulic shock in piping systems, which can cause unwanted acoustic noise, vibration, and mechanical stress due to sudden changes in fluid flow velocity, particularly when pumps stop or valves close, leading to potential pipe damage.
Innovation Solution
A cushioned relief valve comprising a housing, piston, cylinder cover, and flexible diaphragm that absorbs pressure changes by allowing fluid to flow through a compressible gas volume, reducing the impact of hydraulic shock without adding mechanical components to the fluid flow system, and is adjustable for various fluid flow velocities and pipe diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional valves or pumps are abruptly closed or shut off to control fluid flow, then flow control is achieved, but hydraulic shock and extreme pressure gradients are generated causing mechanical stress and noise
Solution Approach 1:
The patent applies beforehand cushioning by incorporating a compressible gas cushion within the valve structure that activates during abrupt flow changes. The gas cushion is pre-positioned to absorb shockwave energy when hydraulic shock occurs, cushioning the impact on valve gates and piping structures before the full force of the shockwave can cause damage.
Solution Approach 2:
The compressible gas acts as an intermediary substance between the fluid system and the valve structure. When hydraulic shock occurs, the gas mediates the energy transfer by compressing and expanding, thereby absorbing shockwave energy and preventing direct transmission of extreme pressure gradients to the valve gates and piping.
2Reliability
If check valves are used to prevent retrograde fluid flow when pumps are turned off, then flow reversal is prevented, but significant hydraulic shock is generated due to sudden valve closing
Solution Approach 1:
The compressible gas cushion is pre-positioned within the valve structure to activate when the check valve closes during pump shutdown. The gas cushion absorbs the shockwave energy generated by the sudden valve closing, cushioning the impact and preventing hydraulic shock while maintaining the check valve's flow direction control function.
Solution Approach 2:
The patent converts the harmful shockwave energy from check valve closing into beneficial compressed gas energy. The compressible gas absorbs the shockwave energy that would otherwise cause hydraulic shock, transforming the harmful abrupt pressure gradient into useful compression and expansion cycles of the gas cushion.
3Object-affected harmful factors
If water towers or buffers are added to provide alternative energy absorbing pathways, then shockwave energy is absorbed, but system complexity and cost increase
Solution Approach 1:
The patent merges the shockwave energy absorption function with the existing valve structure by incorporating the compressible gas cushion directly within the valve body. This integration combines the flow control function of the valve with the energy absorption function of the gas cushion, eliminating the need for separate water towers or buffer tanks while maintaining shockwave energy absorption capability.
Solution Approach 2:
The valve structure is designed to perform multiple functions simultaneously: flow control through the valve mechanism and shockwave energy absorption through the integrated compressible gas cushion. This multi-functionality allows the single component to replace what would traditionally require separate dedicated shock absorption devices like water towers or external buffers.
4Object-affected harmful factors
If valve closing rates are reduced to minimize hydraulic shock, then shockwave energy is minimized, but flow control efficiency decreases
Solution Approach 1:
The compressible gas cushion is pre-positioned to activate during rapid flow changes, allowing the valve to maintain its rapid closing capability for efficient flow control. The gas cushion absorbs the shockwave energy that would result from rapid closing, enabling the valve to close quickly without generating excessive hydraulic shock, thus maintaining both productivity and shock mitigation.
Solution Approach 2:
The compressible gas acts as an intermediary that decouples the relationship between rapid valve closing and shockwave generation. By introducing this intermediate cushioning layer, the valve can close rapidly for efficient flow control while the gas mediates the energy transfer, absorbing the shockwave energy and preventing its transmission to the piping system.
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
Effectively reduces pressure fluctuations during hydraulic shock events, minimizing mechanical stress and noise, and is adaptable to different fluid types and system configurations without affecting flow rates, thus preventing pipe damage and maintaining system efficiency.
Implementation Method 1
Buffers, such as tanks filled with a compressible gas, may also be incorporated in fluid systems to absorb shockwave energy and pressure, and reduce or eliminate hydraulic shock. Retrograde flow redirected toward the tank increases the fluid pressure in the tank, which in turn compresses the compressible gas, and shockwave energy is thus absorbed and then fed back into the fluid system by the initial compression and subsequent expansion of the gas after the fluid system returns to nominal operating pressures.
Implementation Method 2
shockwave energy is thus absorbed and then fed back into the fluid system by the initial compression and subsequent expansion of the gas after the fluid system returns to nominal operating pressures
Implementation Method 3
The flexible diaphragm separates the compressible gas volume of the cylinder cover from the second end of the hollow cylinder, the diaphragm being biased toward the first end of the hollow cylinder
Data Source
AI summary
A cushioned relief valve includes a housing, a piston, a cylinder cover, and a flexible diaphragm. The housing has an inlet, an interior, an outlet channel, and an outlet, the interior being a hollow cylinder in fluid communication with the inlet and the outlet channel, the outlet channel extending from a cylindrical side of the hollow cylinder to the outlet, the outlet opening outside the housing. The piston is located within the hollow cylinder and is slidable between a first position blocking the inlet and the outlet channel, and a second position opening a path for fluid flow between the inlet and the outlet channel. The cylinder cover defines a compressible gas volume in fluid communication with the second end of the hollow cylinder. The flexible diaphragm separates the compressible gas volume of the cylinder cover from the second end of the hollow cylinder.