Float-Actuated Rotary Valve for Tank Overfill Shut-Off
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Solution Overview
Problem
Existing liquid storage systems lack reliable automatic shut-off mechanisms to prevent overfilling, especially in unpredictable liquid input scenarios like rainwater harvesting, which can lead to property damage if not addressed effectively.
Innovation Solution
A rotary shut-off valve with a float assembly that controls a plug valve to automatically open or close based on liquid levels, using a shaft and plug mechanism to engage or disengage with openings in a body divider, ensuring reliable liquid flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rotary valve with plug mechanism is used to control liquid flow, then the reliability of automatic shut-off is improved, but the device complexity increases due to multiple components (plugs, openings, shaft, float assembly)
Solution Approach 1:
The valve body is divided into multiple sections with a body portion divider that includes a set of openings. The plug valve portion includes multiple plugs that can independently engage with these openings. This segmentation allows the valve to control multiple flow paths simultaneously while maintaining a modular structure that is easier to manufacture and assemble.
Solution Approach 2:
The float assembly is positioned within the housing component, and the plug valve portion rotates within the body portion divider. The shaft portion extends through the housing component to connect the float assembly with the plug valve portion. This nested arrangement allows multiple functional components to be integrated in a compact space, reducing overall device complexity while maintaining reliability.
2Extent of automation
If the plug valve portion is controlled by float assembly movement, then the automation level is improved, but the manufacturing precision requirements increase to ensure proper engagement of plugs with openings
Solution Approach 1:
The plugs include sealing portions made of waterproof and flexible materials, which are differentiated from the rigid body of the plugs. This local quality variation allows the sealing portions to deform and adapt to the openings during engagement, compensating for manufacturing tolerances and ensuring reliable sealing without requiring extremely tight manufacturing precision.
Solution Approach 2:
The spring portions apply continuous force to the plugs to maintain engagement with the openings. The spring force can be adjusted to account for variations in manufacturing precision, ensuring that the plugs remain properly seated against the openings throughout operation. This parameter adjustment capability allows for compensation of manufacturing tolerances.
3Ease of operation
If the float assembly is designed with arms connected to the shaft, then the ease of operation is improved, but the device complexity increases due to additional connection components
Solution Approach 1:
The float arms are directly connected to the shaft portion, merging the float assembly function with the actuation mechanism. This integration eliminates the need for separate linkages or transmission components, reducing device complexity while maintaining ease of operation. The float arms directly transfer the buoyant force to rotate the shaft and actuate the plug valve portion.
4Adaptability or versatility
If multiple body cavity wall portions are used to form a housing, then the adaptability is improved for different applications, but the ease of manufacture decreases due to assembly requirements
Solution Approach 1:
The housing component is divided into multiple body cavity wall portions that can be manufactured separately and then assembled. This segmentation allows each wall portion to be optimized for its specific function and manufactured using the most appropriate process, while the modular design simplifies assembly through standardized connection interfaces.
Solution Approach 2:
The body cavity wall portions are designed with standardized features that allow them to be used in different configurations for various applications. The same basic wall portion design can be adapted for different tank sizes, liquid types, and operational requirements, providing universality that reduces manufacturing complexity across product lines.
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 provides a reliable and automatic means to prevent overfilling by effectively controlling liquid flow into storage containers, protecting against property damage and ensuring consistent operation even with unpredictable liquid inputs.
Implementation Method 1
a float assembly portion, the float assembly portion including a float portion and a pair of float arms connected to, and extending from, the float portion
Data Source
AI summary
A rotary valve and float assembly for controlling a flow of liquid into a container including a plug valve portion and a divider portion. The plug valve portion including a set of plugs that seal against a set of openings in the divider portion when the rotary valve is in a closed position. Movement of the rotary valve between open and closed positions is controlled by the movement of the float assembly in the container. The float assembly typically moves according to a liquid level within the container.