Electric Fail-Safe Valve Actuator With Local Pneumatic Accumulator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric and pneumatic actuators face issues such as lack of reliability, high maintenance requirements, and inefficiencies in large-scale applications, including line leakage and responsiveness problems due to their design and operation in hazardous locations like power plants and refineries.
Innovation Solution
The development of an electric power actuator system that converts a pneumatic actuator to an electric actuator, utilizing a closed system configuration to eliminate the need for air filters, reduce leaks, and enhance responsiveness and repeatability by using a directional control valve and a pneumatic accumulator to store pressurized gas, allowing for efficient operation and simplified integration in industrial settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pneumatic actuators are used in large-scale applications with networked pipes, then they can control system components, but line leakage and downstream pressure loss occur causing inefficiency
Solution Approach 1:
The patent divides the centralized pneumatic system into distributed modular units. Each actuator contains its own integrated compressor and accumulator, eliminating the need for extensive pipeline networks. This segmentation isolates each control point as an independent unit, preventing leakage in one location from affecting the entire system and eliminating downstream pressure loss.
Solution Approach 2:
The patent introduces an intermediate energy storage component (accumulator) between the compressor and actuator mechanisms. This accumulator stores pressurized gas locally at each actuator unit, serving as a buffer that eliminates the need for continuous compressed air supply through pipelines, thereby preventing leakage losses and pressure drops over distance.
2Adaptability or versatility
If pneumatic actuators are located at large distances from the fluid supply source, then they can operate in remote locations, but responsiveness and repeatability deteriorate due to pressure loss
Solution Approach 1:
The patent implements segmentation by placing complete pneumatic systems (compressor + accumulator + actuator) at each remote location rather than relying on centralized supply. This allows actuators to be positioned anywhere without compromising responsiveness, as each unit has immediate access to pressurized gas through its local accumulator.
Solution Approach 2:
The patent applies preliminary action by pre-storing pressurized gas in local accumulators at each actuator location before operation is needed. This eliminates the time delay associated with transporting compressed air through long pipelines, ensuring immediate responsiveness regardless of distance from any central source.
3Ease of operation
If conventional pneumatic systems are used, then they can operate actuators, but maintenance requirements increase due to air filters and line leakage
Solution Approach 1:
The patent segments the pneumatic system into isolated modular units with no interconnecting pipelines. Each unit contains its own compressor and accumulator, eliminating the extensive network of pipes and fittings that require maintenance. This modular approach simplifies both operation and repair, as each unit can be serviced independently without affecting the entire system.
Solution Approach 2:
The patent extracts and eliminates the external pipeline network and associated components (filters, valves, fittings) from the system by integrating all necessary pneumatic functions within each actuator unit. This removal of external infrastructure dramatically reduces maintenance requirements while preserving operational simplicity.
4Reliability
If electric actuators are designed to be fail-safe with stored potential energy, then they can provide safety upon power loss, but unit size and weight increase significantly
Solution Approach 1:
The patent employs pneumatic principles by using compressible gas stored in accumulators as the energy storage mechanism for fail-safe operation. This replaces the traditional mechanical spring or heavy battery systems with a much lighter gas-based system, achieving fail-safe capability without significant weight penalty.
Solution Approach 2:
The patent changes the physical state and storage parameters of the energy source by using compressed gas instead of solid mechanical springs or electrochemical batteries. This parameter change (from solid/liquid storage to gaseous storage under pressure) dramatically reduces the weight and volume required for fail-safe energy storage while maintaining the necessary force output.
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 electric power actuator system improves efficiency, reduces maintenance needs, and increases responsiveness and repeatability by acting as a self-contained fluid supply, reducing line pressure loss and enabling higher torque outputs, thus addressing the deficiencies of existing systems.
Implementation Method 1
a pneumatic accumulator to store pressurized gas
Implementation Method 2
a directional control valve and a pneumatic accumulator to store pressurized gas, allowing for efficient operation
Data Source
AI summary
An electric-powered fail-safe actuator for use with a valve, where the actuator stores potential energy for conversion to kinetic energy to close or open the valve to the fail-safe position.