Diaphragm-Suspended Flow Divider for Non-Hydraulic Fluids
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Solution Overview
Problem
Existing flow dividers are primarily designed for hydraulic systems with lubricating fluids and high pressures, and they struggle to maintain consistent flow division with non-hydraulic fluids, especially those with lower viscosity or adhesive properties, and are prone to mechanical sticking and high manufacturing costs due to precision requirements.
Innovation Solution
A flow divider design using diaphragms instead of sliding contacts, with a spool suspended by diaphragms, allowing movement without lubrication, and featuring larger diaphragms with a low durometer rating and screw connections for sealing, enabling reliable operation across a range of fluid viscosities and pressures, and accommodating lower flow rates and corrosive fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precision machined sliding spool is used in hydraulic systems, then flow division consistency is maintained under high pressure, but mechanical sticking occurs with non-hydraulic fluids and manufacturing costs increase
Solution Approach 1:
The patent replaces the traditional sliding spool mechanism with a ball valve mechanism. Instead of a spool that slides within a body requiring precision machining and lubrication, a ball with a through-hole rotates within a valve seat. This substitution eliminates the sliding contact that causes mechanical sticking with non-hydraulic fluids, while maintaining flow division functionality through rotational movement of the ball.
Solution Approach 2:
The patent changes the movement parameter from linear sliding motion to rotational motion. The ball rotates about its diameter to control flow division, eliminating the need for precision sliding surfaces. This parameter change allows the valve to operate reliably with non-lubricating fluids by replacing the sliding interface with a rotating interface that does not require the same level of precision or lubrication.
2Reliability
If precision machined parts are used for flow division, then flow consistency is maintained, but manufacturing costs increase
Solution Approach 1:
The sliding spool mechanism requiring precision machining of sliding surfaces is replaced with a ball valve mechanism. The ball and valve seat can be manufactured with less stringent tolerances compared to precision sliding surfaces, reducing manufacturing complexity and cost while maintaining functional performance.
Solution Approach 2:
The ball valve components can be manufactured as simpler, more robust parts compared to precision sliding spools. The design allows for easier manufacturing and potential replacement, reducing overall system cost while maintaining reliability.
3Reliability
If sliding spool is used with lubricating hydraulic fluids, then flow division is maintained, but the system fails with non-lubricating or low viscosity fluids
Solution Approach 1:
The sliding spool system that depends on lubrication is replaced with a ball valve system that does not rely on fluid lubrication for its operation. The rotational movement of the ball within the valve seat functions effectively with non-lubricating and low viscosity fluids, significantly expanding fluid compatibility.
Solution Approach 2:
The invention changes the operational parameter from sliding friction-dependent movement to rotation-based movement. This parameter change allows the valve to function across a wide range of fluid viscosities and lubricity characteristics, making it adaptable to hydraulic, pneumatic, and other non-lubricating fluid systems.
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 design effectively maintains proportional flow division even with backpressure and a wide range of fluid viscosities, reduces manufacturing costs, and prevents mechanical sticking, while providing a strong seal and increased movement range without precision issues.
Implementation Method 1
the diaphragm is movable in response to pressure differences to selectively provide fluid communication between the central chamber and the first and second chambers
Data Source
AI summary
Described herein is a flow divider that has two chambers defined by two diaphragms and a spool disposed through the diaphragms. The spool has two tapered nozzles that extend into outlets from each chamber. Within the spool are orifices for providing fluid communication from an inlet to each chamber and dividing the flow. The flow divider generally maintains consistent flow to each outlet even when there is downstream backpressure by being able to move away from the outlet with the increased pressure to further drive the opposite nozzle into the other outlet to reduce the flow at the other outlet to balance the pressure at each outlet.