Process Valve Tensioning Assembly With Gear-Driven Diaphragm Clamping
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Solution Overview
Problem
Current process valve technologies face challenges in achieving tool-free, automated, and efficient membrane tensioning, which affects cleanability, service processes, and membrane lifespan, particularly under varying operating pressures.
Innovation Solution
A clamping assembly with a gearbox that converts rotational movement into translational movement for the clamping element, enabling uniform membrane tension and self-retarding transmission, combined with a sensor unit for automatic tension and relaxation, allowing for tool-free and partially automated membrane operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a spring-loaded system is used for membrane tensioning, then the membrane is automatically tensioned, but the tension cannot be precisely adjusted to different operating pressures
Solution Approach 1:
The system transitions from a static spring-loaded tensioning mechanism to a dynamic gear-driven system with a drive rod that can be precisely positioned. The gear mechanism allows for controlled, incremental adjustment of the drive rod position, enabling precise tension settings that adapt to different operating pressures while maintaining manufacturing precision.
Solution Approach 2:
The invention changes the tensioning parameter control from passive spring force to active mechanical positioning via the drive rod. By controlling the position of the drive rod through the gear mechanism, the tension applied to the membrane can be precisely adjusted to match different operating pressure requirements, overcoming the fixed tension characteristic of spring-loaded systems.
2Productivity
If manual tensioning tools are used, then the membrane can be tensioned, but the service process is time-consuming and requires additional tools
Solution Approach 1:
The system incorporates a self-contained drive mechanism with a gear and drive rod that can be actuated directly by the valve actuator. This eliminates the need for external manual tensioning tools, as the system performs its own tensioning operation through the integrated mechanical components already present in the valve assembly.
Solution Approach 2:
The tensioning function is merged with the existing valve actuation system. The drive rod is integrated into the valve body structure, and the gear mechanism is combined with the actuator mounting, allowing the same actuator that operates the valve to also perform membrane tensioning without requiring separate tools.
3Reliability
If the clamping assembly is rigidly connected to the valve body, then the connection is stable, but the cleanability of the process valve is reduced
Solution Approach 1:
The clamping assembly is designed as a segmented, modular component that can be detached from the valve body. The interface between the clamping assembly and valve body is designed to allow separation, enabling the clamping assembly to be removed for cleaning or replacement without damaging the valve body, thus maintaining connection stability during operation while improving cleanability during maintenance.
4Ease of operation
If the drive rod is directly connected to the actuator, then the actuation is simple, but the membrane cannot be uniformly tensioned
Solution Approach 1:
The gear mechanism serves as an intermediary between the actuator and the drive rod. It translates the rotational motion of the actuator into controlled linear motion of the drive rod through gear engagement, ensuring uniform force distribution and precise, uniform tensioning of the membrane while maintaining the simplicity of actuation through the existing valve actuator.
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 solution improves cleanability, simplifies and accelerates service processes, extends membrane lifespan, and allows for adaptive tensioning under different pressures, ensuring safe operation and reducing the need for additional tools, especially in industries like pharmaceuticals and food.
Implementation Method 1
a gear (116) supported on the housing (110) and designed to convert a rotary movement of a drive (112) into a translatory movement of the clamping element (114) oriented along an adjusting axis (122)
Implementation Method 2
The gear (116) is designed to be self-locking. This ensures that a set tension is maintained on the outer collar (120) of the diaphragm (106) without a permanent control of the drive (112)
Data Source
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AI summary
A clamping assembly (108) for a process valve (100) is provided, comprising: a housing (110) with an interface (109) for rigid connection with a valve body (104), an actuator (112) fixed to the housing (110), a gearbox (116) supported on the housing (110) and driven by the actuator (112), and a clamping element (114) arranged on the output of the gearbox (116), wherein the clamping element (114) comprises a contact surface (119) designed to clamp a lateral outer flange (120) of a diaphragm (106) of the process valve (100) between the clamping element (114) and the valve body (104). A switchable clutch (400) selectively transmits a torque applied to the clutch (400) either to a drive rod (126) or to the gearbox (116).