Gate Valve Coating Process Using Reference Structures
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Solution Overview
Problem
Conventional gate-manufacturing techniques require sequential coating and grinding of gate faces, leading to increased costs and time due to the need for shipping between coating and grinding vendors, and result in high friction and leaks under high-pressure conditions.
Innovation Solution
The process involves coating both faces of the gate before grinding, using uncoated reference structures to planarize the surfaces, allowing for simultaneous coating and subsequent grinding without the need for multiple shipments, thereby reducing costs and improving surface smoothness for better sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sequential coating and grinding is performed with multiple vendors, then manufacturing specialization is improved, but shipping time and cost increase
Solution Approach 1:
The patent combines coating and grinding operations into a single facility, eliminating the need for shipping the gate between vendors. The coating vendor performs both coating and grinding in sequence, merging what were previously separate manufacturing steps into one location, thereby reducing shipping time and cost while maintaining specialized manufacturing capabilities.
2Ease of manufacture
If sequential coating and grinding is performed with multiple vendors, then manufacturing specialization is improved, but number of shipments increases
Solution Approach 1:
The patent merges coating and grinding operations into a single facility, reducing the number of shipments from two (gate shipped to coating vendor, then to grinding vendor) to zero (both operations performed at coating vendor). This simplifies the manufacturing process while maintaining specialized capabilities.
3Productivity
If both faces are coated before grinding, then manufacturing time is reduced, but reference structure planning is required
Solution Approach 1:
The patent applies preliminary action by coating both faces of the gate before grinding, rather than coating and grinding one face at a time. This allows both coating operations to be performed in sequence without intermediate shipping, reducing manufacturing time. The reference structures are planned in advance to enable proper alignment during the subsequent grinding process.
Data Source
AI summary
An apparatus that includes a body of a gate configured to seal a gate valve. In certain embodiments, the body has a first face with a first coating disposed thereon, and a second face opposite the first face and having a second coating disposed thereon. The body also may include a flow bore that extends from the first face, through the body of the gate, to the second face and a reference structure that does not have either the first coating or the second coating disposed thereon. In some embodiments, the reference structure is configured to define a plane on the first face, the second face, or both during a planarization process.