Flow Control Regulator Valve With Low Activation Pressure Range
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flow control valves in heating and cooling systems have limited functional pressure ranges, require high activation pressure, and result in uneven water distribution across branches in closed-loop systems, leading to inefficiencies and increased costs due to the need for larger pumps and more expensive valves and piping.
Innovation Solution
A flow control valve design featuring a hollow shaft, three-legged shaft holder, and mushroom-shaped metering disk with a tapered passageway, which reduces activation pressure, allows for a broader operating range, and provides consistent flow rates across the control range, enhancing the distribution of heated or cooled water to all branches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional flow control valves are used in multi-branch closed loop systems, then flow distribution can be controlled, but activation pressure is high and functional pressure range is limited
Solution Approach 1:
The valve is divided into distinct functional segments: a hollow shaft providing activation pressure relief, a metering disk for flow control, and a shaft holder with flow passages. This segmentation allows each component to address specific pressure control needs, reducing overall activation pressure while extending functional range
Solution Approach 2:
The hollow shaft is nested within the shaft holder, and the metering disk is positioned within the hollow shaft structure. This nested arrangement allows fluid to flow through multiple paths (including through the hollow shaft), reducing the pressure required to activate the valve while maintaining control capability across a broader pressure range
2Power
If larger pumps are used to overcome high activation pressure, then flow can be maintained, but system cost and energy consumption increase
Solution Approach 1:
The valve design allows fluid flow itself to contribute to activation through the hollow shaft structure, reducing the external power needed from the pump. The system uses its own operating fluid to assist in valve activation, thereby reducing overall power requirements while maintaining ease of operation
3Productivity
If conventional valve designs are used, then flow control is achieved, but flow distribution among branches is uneven
Solution Approach 1:
The valve incorporates a tapered seat and specifically shaped metering disk edge that create a precise local flow control zone. This localized geometric design ensures consistent flow characteristics and equitable distribution among branches, improving flow control efficiency while maintaining manufacturability
4Ease of manufacture
If smaller valves and piping are used to reduce cost, then installation expense decreases, but activation pressure requirements increase
Solution Approach 1:
The hollow shaft introduces an additional dimensional element (internal flow passage) to the valve structure. This allows smaller external valve dimensions while providing internal flow paths that reduce activation pressure, achieving cost reduction without sacrificing pressure performance
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 new valve design achieves a lower activation pressure, reduces the size and cost of required pumps, ensures more uniform flow distribution, and extends the operating range of valves, making them more cost-effective and efficient by allowing smaller, less expensive valves and piping to achieve the same functionality as larger ones.
Implementation Method 1
a compression spring that normally biases the metering disk in the rest position and that provides resistance to movement of the metering disk to the flow restricting position
Implementation Method 2
axially moveable under the influence of fluid pressure from a rest position to a flow restricting position
Data Source
AI summary
A flow control valve includes a body portion including a first end, a second end and an axially extending passageway. A metering valve is included that is axially moveable under the influence of fluid pressure from a rest position to a flow restricting position. In the flow restricting position, the metering valve can restrict the flow of fluid through the axially extending passageway. The metering valve includes an upstream portion and a downstream portion. The upstream portion has a flattened top spherical shape. A biasing device is provided that normally biases the metering valve in the rest position, and for provides resistance to movement of the metering valve to the flow restricting position.