Flush Valve Stepper Plunger Control Mechanism
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Solution Overview
Problem
Existing flush valves in pump stations operate on every pump cycle, consuming energy without performing useful pumping work and leading to accumulation of solid matter and grease, which causes issues like bad smells and corrosion.
Innovation Solution
A flush valve with a control mechanism comprising a stepper and plunger, biased by pressure differences, that only engages to enable fluid circulation on specific pump cycles, saving energy by adapting to operational conditions through a timing mechanism and stepper position changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flush valve operates on every pump cycle, then the mixing/circulation function is continuously maintained, but energy is consumed without performing useful pumping work
Solution Approach 1:
The flush valve is designed to operate periodically rather than continuously, activating only on specific pump cycles when mixing is actually needed. The control mechanism uses a stepper and plunger system that enables the valve to skip certain cycles, thereby maintaining the mixing function while eliminating energy waste during cycles when mixing is unnecessary.
2Reliability
If the flush valve operates on every pump cycle, then sedimentation and accumulation are prevented, but the pump time is reduced due to frequent valve activation
Solution Approach 1:
The system implements periodic activation of the flush valve based on actual mixing needs rather than continuous operation. By using a control mechanism with stepper and plunger that can skip cycles, the valve maintains effective mixing and prevents sedimentation while allowing longer continuous pumping periods, thus improving overall productivity.
3Use of energy by moving object
If the flush valve is adapted to operational conditions, then energy efficiency is improved, but the device complexity increases
Solution Approach 1:
The control mechanism is designed to automatically detect and respond to operational conditions without external control systems. The stepper and plunger mechanism self-regulates valve activation based on pressure differentials and cycle counters, enabling the system to adapt to operational conditions and improve energy efficiency while avoiding the complexity of electronic controls or external monitoring systems.
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 reduces energy consumption by only activating the flush valve when necessary, effectively preventing sedimentation and accumulation of solid matter and grease, thereby improving operational efficiency and reducing maintenance issues.
Implementation Method 1
the plunger being biased towards said inactive position and being displaced towards said active position by means of the pressure [P2] in the second chamber when the pressure [P2] in the second chamber is greater than a threshold value [PT]
Data Source
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AI summary
In a fist aspect the invention relates to a flush valve comprising an inlet (13), an outlet (14) and a valve arrangement (15), wherein the valve arrangement (15) comprises a first chamber (17), a second chamber (18) that is partly delimited by a diaphragm (21), and a conduit (19) extending between and connecting the first chamber (17) and the second chamber (18), a third chamber (22) that connects the inlet (13) and the outlet (14) of the flush valve (12) and that is partly delimited by said diaphragm (21), the third chamber (22) comprising a valve member (23) configured to control a fluid flow from the inlet (13) to the outlet (14) based on the position of said diaphragm (21), and a control mechanism arranged in said conduit (19). The flush valve is characterized in that the control mechanism comprises a stepper (25) and a plunger (26), the plunger (26) being biased towards an inactive position and being displaced towards an active position by means of the second pressure [P2] in the second chamber (18) when said second pressure [P2] in the second chamber (18) is greater than a threshold value [PT], the plunger (26) being configured to engage the stepper (25) when the plunger (26), wherein the stepper (25), each time the plunger (26) engages the stepper (25), changes position once in a repeated set of positions and wherein the stepper (25) in at least one position enables fluid communication between the first chamber (17) and the second chamber (18) via said conduit (19). In a second aspect the invention also relates to a pump station comprising such a flush valve.