Dual-Piston Valve Actuator Assembly for Fail-Open Flow Control
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Solution Overview
Problem
Flow valves are limited in operation due to obstructions like sand, which restrict full opening or closing, leading to limited operational flow rates and modularity, and inability to handle various fluids effectively.
Innovation Solution
The implementation of fail open or fail close actuator assemblies with an outer housing, fluid openings, ambient openings, and pistons that allow for pressurized fluid release and supply to move the valve stem to open or closed positions, ensuring operation even during failures or obstructions, using a controller to manage fluid flow through hydraulic lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional valve actuator is used, then the structure is simple, but the valve cannot fully open or close when obstructions like sand are present, limiting operational flow rates
Solution Approach 1:
The actuator is divided into two independent pistons (first piston and second piston) that can operate separately. The first piston controls the valve stem movement while the second piston provides backup force. This segmentation allows the system to maintain functionality even when one piston is obstructed, ensuring both reliability and flow rate performance.
Solution Approach 2:
The actuator assembly pre-configures two pistons with separate fluid supply paths before any failure occurs. The controller is programmed to switch between pistons based on detected conditions. This preliminary preparation ensures that when sand or obstructions block one piston, the system can immediately switch to the other piston without loss of reliability or flow rate.
2Adaptability or versatility
If a single-piston actuator is used, then the device complexity is low, but the modularity and adaptability to different fluids are limited
Solution Approach 1:
The dual-piston actuator design provides multi-functionality by enabling the same actuator assembly to handle different fluid types and operational conditions. Each piston can be independently controlled to suit different fluid characteristics, making the actuator universally adaptable to various applications while maintaining a standardized structure that doesn't excessively increase complexity.
Solution Approach 2:
The actuator employs dynamic control where the controller can switch between the first and second pistons based on real-time operational conditions and fluid characteristics. This dynamic adaptability allows the system to optimize performance for different fluid types without requiring multiple specialized actuators, balancing versatility with manageable complexity.
3Stability of the object's composition
If pressurized fluid is continuously supplied to maintain valve position, then the valve position stability is high, but the energy consumption increases
Solution Approach 1:
Instead of continuous pressurized fluid supply, the system uses periodic action where the controller activates the first or second piston only when position adjustment is needed. The pistons are engaged intermittently to maintain or adjust valve position, rather than requiring constant fluid pressure. This periodic operation maintains valve position stability while significantly reducing energy consumption compared to continuous supply 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
Enhances operational reliability, achieves consistent flow rates, and supports modularity and variance in fluids, ensuring valves can fully open or close despite failures or obstructions, reducing resource expenditure and enhancing efficiency.
Implementation Method 1
The releasing of the first pressurized fluid includes pressurizing a second side of the first piston relative to a first side of the first piston using an ambient pressure through one or more ambient openings formed in the outer housing
Implementation Method 2
The supplying of the second pressurized fluid includes moving the second piston to stop the second piston against the first piston
Data Source
AI summary
Aspects of the present disclosure relate to fail open or fail close actuator assemblies and related methods for valve systems. In one implementation, an actuator assembly for valves includes an outer housing that includes an inner surface at least partially defining an internal volume. The actuator assembly includes one or more first fluid openings formed in the outer housing, one or more second fluid openings formed in the outer housing, and one or more ambient openings formed in the outer housing. The actuator assembly includes a valve stem disposed at least partially in the internal volume, and a first piston disposed in the internal volume and coupled to the valve stem. The actuator assembly includes a second piston disposed in the internal volume and disposed about the valve stem.