Float Valve Pilot Tank Segmentation for Wave Interference
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Solution Overview
Problem
Float valves in fluid tanks experience unwanted switching operations due to rapid fluid level changes, leading to unnecessary opening and closing of the main valve, especially when waves or similar phenomena occur, causing the float to move without significant level changes.
Innovation Solution
The float is arranged in a separate pilot tank, which is open at the bottom and top, with an orifice plate to adjust the inflow and a guide surface for defined movements, and the pilot valve is connected to the main valve via a flexible pilot line, allowing for controlled switching and preventing backflow through mechanical means or air separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the float is positioned directly in the fluid tank to detect fluid level, then the float valve can respond to fluid level changes, but wave movements cause the float to move unnecessarily leading to unwanted switching operations
Solution Approach 1:
The system is divided into two separate tanks: the fluid tank containing the fluid and the pilot tank containing the float. This segmentation isolates the float from direct exposure to wave movements in the fluid tank, allowing the float to detect only genuine fluid level changes transmitted through the connecting passage rather than being disturbed by surface waves.
Solution Approach 2:
The pilot tank acts as an intermediary between the fluid tank and the pilot valve. It transmits fluid level information from the fluid tank to the pilot valve while filtering out harmful wave movements. The connecting passage serves as the intermediary channel that allows fluid communication but prevents direct wave action on the float.
2Ease of operation
If the pilot tank is open at both bottom and top with an orifice, then fluid can enter and air can escape, but the opening cross-section must be precisely controlled to prevent unwanted switching
Solution Approach 1:
The orifice cross-section is made adjustable through the rotatable perforated discs mechanism. This dynamic adjustment capability allows the opening cross-section to be optimized for different operating conditions and fluid flow rates, ensuring reliable operation without requiring extremely precise fixed manufacturing tolerances. The adjustable nature compensates for manufacturing variations.
3Speed
If the pilot valve and float are closely coupled, then switching response is fast, but the system is more sensitive to float movements caused by waves
Solution Approach 1:
By separating the float (in the pilot tank) from the main fluid tank, the system maintains a responsive coupling between float and pilot valve while physically isolating the float from wave disturbances. The segmentation allows the float to respond quickly to genuine level changes transmitted through the connecting passage without being triggered by surface waves in the fluid tank.
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 arrangement minimizes unwanted switching of the main valve, reducing operational errors and preventing contamination by ensuring the main valve only opens when the fluid level genuinely requires it, thus enhancing the reliability and hygiene of the fluid tank system.
Implementation Method 1
a float (7) which is arranged in a pilot tank (4) and serves to open and close the valve seat (3.1) of the pilot valve (3)
Implementation Method 2
Fluid from the fluid tank can enter the pilot tank through an opening at the bottom
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a float valve (1) with a main valve (2) that can be controlled via a pilot valve (3) and a float (7) for actuating the pilot valve (3), in which the float (7) is arranged in a pilot tank (4).