Flow Control Valve Assembly With Pre-Assembled Motorized Frame
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Solution Overview
Problem
Existing flow control valve assembly methods are cumbersome and difficult to manage, especially in confined spaces, due to the need for multiple parts to be assembled sequentially at the operating site, increasing the risk of errors and reducing efficiency.
Innovation Solution
A method for assembling a flow control valve that involves attaching a first and second housing part directly to form a substantially closed housing, with a frame part, spindle, and stepper motor mounted on the second housing part, allowing for pre-assembly of the valve element, spindle, and motor at a manufacturing site, reducing the complexity of the final assembly step to just attaching the two housing parts at the operating site.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate parts are assembled sequentially at the operating site, then the flow control valve can be constructed with modular components, but the assembly process becomes cumbersome and difficult to manage
Solution Approach 1:
The flow control valve is divided into two main housing parts (first housing part and second housing part) that can be separately manufactured and assembled. The valve unit is further segmented into a valve body and a movable valve element, allowing for modular construction while maintaining ease of assembly through the integrated frame part design.
Solution Approach 2:
The frame part integrates multiple components including the lead nut, spindle accommodation, and valve element mounting into a single structural unit. This merging reduces the number of separate parts that need to be assembled at the operating site, transforming a complex multi-part assembly into a simpler two-part assembly (first housing part and second housing part).
2Ease of manufacture
If multiple separate parts are assembled at the operating site, then the valve can be constructed from standardized components, but the assembly becomes time-consuming and error-prone
Solution Approach 1:
The frame part, lead nut, spindle, and valve element are pre-assembled into the second housing part at the manufacturing site before final assembly. This preliminary action ensures that standardized components are correctly positioned and secured beforehand, reducing assembly time and minimizing errors at the operating site where only the final attachment of the two housing parts is required.
3Reliability
If a complex multi-part assembly is performed at the operating site, then all components can be installed in their final positions, but the complexity increases and efficiency decreases
Solution Approach 1:
The frame part serves as an integrated structure that combines the lead nut, spindle mounting, and valve element positioning into a single component. This merging reduces assembly complexity by eliminating the need to separately install and align multiple small components at the operating site, while ensuring reliable positioning through the pre-integrated frame structure.
Solution Approach 2:
The complex positioning and alignment of the lead nut, spindle, and valve element are performed in advance during the pre-assembly of the second housing part. This preliminary action transfers the complexity from the operating site to the manufacturing site, where controlled conditions can ensure high reliability of component positioning without increasing the complexity of field assembly.
4Adaptability or versatility
If sequential assembly of multiple parts is performed, then each component can be individually adjusted, but the overall assembly process becomes cumbersome
Solution Approach 1:
The valve is segmented into adjustable components (valve body, movable valve element, spindle) that can be individually adjusted for flow control, while the integrated frame part maintains assembly simplicity. The segmentation allows functional adjustability without requiring complex assembly procedures at the operating site.
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 approach simplifies the assembly process, reduces the risk of errors, and makes it more cost-effective by allowing the majority of the assembly to occur in a controlled environment, minimizing the number of steps and parts required at the operating site.
Implementation Method 1
a spindle threadedly connected to the lead nut and for moving the lead nut and the valve element
Implementation Method 2
a stepper motor connected to the spindle for operating the spindle
Data Source
Figure 1
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AI summary
A flow control valve (1) and a method for assembling a flow control valve (1) are disclosed. The flow control valve (1) comprises a first housing part (2) and a second housing part (3) attached directly to each other, in such a manner that the first housing part (2) and the second housing part (3) form a substantially closed housing. The first housing part (2) defines a first flow section (4), a second flow section (5), a connecting port (6) fluidly interconnecting the first flow section (4) and the second flow section (5), and a valve seat (7) arranged at the connecting port (6). The flow control valve (1) further comprises a frame part (9) arranged in an interior part of the housing formed by the first housing part (2) and the second housing part (3), the frame part (9) having mounted thereon a valve element (10, 13) arranged movably relative to the valve seat (7), a moving mechanism, e.g. including a spindle (12), for moving the valve element (10, 13), and an actuating mechanism, e.g. a stepper motor (14), for operating the moving mechanism. The frame part (9) is attached directly to the first housing part (2) or to the second housing part (3).