Drain Valve Actuator Energy Reduction via Periodic Motor Control
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Solution Overview
Problem
Existing drain valve actuators in industrial washing machines consume continuous electrical energy to maintain the valve closed and lack efficient control mechanisms, leading to unnecessary power usage and mechanical limitations.
Innovation Solution
A valve actuator system utilizing a permanent magnet DC motor with a gear train and a controller that provides power only when needed to open and close the valve, incorporating a signal reducer to manage power usage and prevent continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the AC shaded pole geared motor is used to close the drain valve against coil spring tension, then the valve can be reliably closed, but the motor consumes continuous electrical energy even when the valve is already closed
Solution Approach 1:
The motor operates periodically rather than continuously - it runs only during the brief periods needed to transition the valve between open and closed positions, then stops. This periodic operation dramatically reduces energy consumption while maintaining the reliability of valve closure through the gear train's mechanical advantage and the spring's holding force.
Solution Approach 2:
The coil spring serves a dual function: it provides the closing force when the motor operates, and then maintains the valve in the closed position without requiring continuous motor power. The spring essentially 'services' itself by maintaining valve position passively after the motor has done its work.
2Reliability
If the motor runs continuously to maintain the valve closed, then the valve remains reliably sealed, but unnecessary electrical power is consumed
Solution Approach 1:
The coil spring maintains the valve in the closed position without requiring continuous motor power. Once the motor closes the valve, the spring takes over the holding function, allowing the motor to stop and eliminating unnecessary energy consumption while maintaining valve reliability.
Solution Approach 2:
The function of maintaining valve position is extracted from the motor and transferred to the coil spring. The motor's role is limited to transitioning the valve between positions, while the spring handles the continuous holding function, separating these two functions to reduce energy loss.
3Measurement precision
If hard mechanical stops are used at both end positions, then the valve reaches precise open and closed positions, but the system lacks smooth control and creates mechanical stress
Solution Approach 1:
The gear train acts as a cushioning mechanism that gradually reduces the motor's driving force as the valve approaches its end positions. This prevents sudden impacts with the mechanical stops, reducing mechanical stress while still achieving precise positioning through the combination of controlled deceleration and defined stop points.
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 reduces electrical energy consumption and prevents motor damage by selectively powering the motor during valve movements, conserving energy and ensuring precise control of the valve positions.
Implementation Method 1
a permanent magnet DC (PMDC) motor which drives a gear train
Implementation Method 2
the coil spring forces the drain valve open until the moving valve hits a hard mechanical stop... The locked rotor torque of the geared motor is enough to overcome the coil spring tension... When the AC voltage is removed from the motor terminals the coil spring recoils and the mechanical energy stored in the spring transfers to a rotary motion which opens the valve
Data Source
AI summary
A valve actuator operates a valve, such as a drain valve of an industrial washing machine. The valve actuator has a permanent magnet DC motor which drives a gear train which rotatably drives an output shaft. The output shaft is engaged with the drain valve and moves the drain valve to open and closed positions as desired. The valve actuator also has a controller which controls operation of the valve actuator. The controller provides power to the motor only when needed to open and close the drain valve. The controller does not provide power to the motor when the drain valve is in the open and closed positions.