Electrically-driven flow rate control valve
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Solution Overview
Problem
Existing electrically-driven flow rate control valves require high electric power to maintain valve position due to direct pressure application on the sub valve body, leading to inefficiencies and increased power consumption.
Innovation Solution
The design incorporates a main valve body with a back pressure chamber and flow rate adjusting mechanisms that isolate high pressures from the sub valve body, allowing the electric motor to generate only the necessary driving force to move the sub valve body relative to the main valve body, with a switching mechanism to automatically select the high-pressure side and supply fluid to the back pressure chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the electric motor directly drives the main valve body against high fluid pressure, then the valve can be closed against high pressure, but the electric power consumption increases significantly
Solution Approach 1:
The valve body is divided into a main valve body and a sub valve body. The sub valve body with a smaller cross-sectional area is driven by the electric motor, while the main valve body is moved indirectly through pressure differential created in the back pressure chamber. This segmentation allows the motor to drive only a small component rather than the entire valve assembly against high pressure.
Solution Approach 2:
A back pressure chamber is introduced as an intermediary mechanism between the electric motor and the main valve body. The chamber accumulates pressure from fluid flow through communication passages, and this pressure differential is used to move the main valve body. The intermediary chamber transforms the direct high-pressure driving requirement into a low-power pressure accumulation process.
2Force
If a valve-closing spring is used to urge the valve body, then the valve can be closed against pressure, but the positional accuracy fluctuates due to hysteresis
Solution Approach 1:
The valve-closing spring is completely removed from the system. Instead of using elastic force from a spring, the invention uses pressure differential force generated by fluid flow through the communication passages into the back pressure chamber. This extraction eliminates the hysteresis and positional accuracy issues associated with spring mechanisms.
Solution Approach 2:
The mechanical spring-based urging mechanism is replaced with a fluid pressure-based urging mechanism. The back pressure chamber uses fluid pressure from the communication passages to provide the closing force, replacing the elastic mechanical system with a hydraulic/pneumatic system that offers more precise and hysteresis-free control.
3Ease of operation
If the pilot valve element is controlled by spring and actuator, then the valve can operate, but the positional accuracy fluctuates due to equipment hysteresis
Solution Approach 1:
The spring and actuator mechanism is replaced with a direct electric motor-driven system. The sub valve body is moved by the electric motor, and the main valve body is controlled through the pressure differential in the back pressure chamber. This substitution eliminates the hysteresis inherent in spring and actuator systems, providing more accurate positional control.
Solution Approach 2:
The control mechanism changes from indirect spring/actuator control to direct electric motor control with pressure differential actuation. By changing the control parameter from mechanical displacement through springs to electrical control of motor position, the system achieves better positional accuracy without hysteresis effects.
4Force
If high pressure acts directly on the pilot valve element, then the valve can be closed, but the actuator requires large driving force
Solution Approach 1:
The valve structure is segmented into a sub valve body with small cross-sectional area that is directly driven by the electric motor, and a main valve body with large cross-sectional area that is moved by pressure differential. This segmentation allows the motor to generate sufficient force on the small sub valve body without needing to directly overcome high pressure on the large main valve body.
Solution Approach 2:
The control approach moves from direct one-dimensional force application against high pressure to a two-dimensional pressure differential system. The back pressure chamber creates pressure differences that act on both the sub valve body and main valve body, utilizing pressure as a second dimension of control to reduce the direct force requirement on the motor.
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
This configuration enables precise control of the main valve body position with reduced electric power consumption, achieving energy savings and downsizing of the valve system while maintaining accurate fluid flow control in both directions.
Implementation Method 1
a sub valve body which is movable relatively to the main valve body between a sub valve body unblocking position and a sub valve body blocking position by receiving a driving force generated by the electric motor
Implementation Method 2
an urging mechanism which urges the main valve body toward the main valve body blocking position
Implementation Method 3
when a pressure of the fluid in the first fluid chamber is higher than a pressure of the fluid in the second fluid chamber... when a pressure of the fluid in the first fluid chamber is lower than a pressure of the fluid in the second fluid chamber
Data Source
AI summary
Provided is an electrically-driven flow rate control valve capable of controlling a flow rate of a fluid flowing between two inlet/outlet ports, restraining a high pressure of the fluid from being applied to a sub valve body connected to an electric motor. The flow rate control valve has a casing, a raising/lowering drive device, a supply-switching valve, a main valve body, a valve-closing spring. When the electric motor of the raising/lowering drive device moves the sub valve body upward, oil of a back pressure chamber is discharged from a discharge oil passage through a sub valve body communication port and a sub valve body oil passage to open the main valve body. When the main valve body is closed, a pressure of the back pressure chamber is inhibited from being directly applied to a lower end face of the sub valve body.