Geared Ball Plug Valve for Low-Noise Purge Flow Control
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Solution Overview
Problem
Existing motorized valves for fuel vapor canister purge systems suffer from issues such as sensitivity to particles, clogging, noise generation, limited flow rate, increased electrical consumption, and lack of direct diagnosis, particularly due to their design and reliance on solenoid actuators.
Innovation Solution
A motorized valve with a geared motor and reduction gear train is integrated into a single-piece housing, featuring a ball valve for progressive opening, which minimizes seals, reduces noise, and includes a position sensor for precise control and self-cleaning, while consuming electricity only during movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solenoid actuator with needle valve is used, then the valve can be controlled to open and close, but the valve becomes sensitive to particles from activated carbon tank causing leakage risk
Solution Approach 1:
The invention extracts the problematic needle-seal interface from the system by replacing it with a ball valve mechanism. The ball valve's spherical geometry and radial sealing contact eliminate the linear sliding interface that is vulnerable to particle contamination, thereby removing the sensitivity to activated carbon particles while maintaining sealing reliability.
Solution Approach 2:
The invention changes the geometric parameters of the sealing interface from a linear needle-to-seat contact to a spherical ball-to-seat contact. This parameter change transforms the sealing mechanism from one vulnerable to particle interference to one where particles cannot interfere with the radial sealing contact, thus resolving the particle sensitivity issue.
2Speed
If a solenoid actuator is used for valve control, then the response time is fast, but the valve generates significant audible clicking noise
Solution Approach 1:
The invention uses periodic PWM (pulse width modulation) control of the solenoid actuator to achieve progressive valve opening. By cycling the solenoid on and off at controlled intervals, the valve opens gradually rather than instantaneously, which reduces the clicking noise while maintaining fast response capability through the underlying solenoid mechanism.
3Reliability
If the valve is normally closed with needle pressed against seal, then the valve can seal tightly, but the seal experiences creep due to continuous pressing force
Solution Approach 1:
The invention inverts the normal valve design philosophy by using a ball valve where the sealing force is applied perpendicular to the flow direction rather than parallel. The ball's weight and spring force create a radial sealing contact that is self-adjusting and does not suffer from creep in the same way linear seals do, thereby improving both sealing reliability and seal durability over time.
4Productivity
If the solenoid size is increased to allow larger opening diameter, then the flow rate increases, but the device complexity and size increase significantly
Solution Approach 1:
The invention uses a spherical ball valve geometry to achieve a larger effective opening diameter without proportionally increasing the actuator size. The ball's rotational movement creates a variable opening from fully closed to fully open positions, allowing large flow capacity through a compact spherical mechanism rather than requiring a large linear solenoid stroke.
5Measurement precision
If PWM control is used to regulate valve opening, then the flow control precision is improved, but the electrical consumption increases as actuator constantly consumes current
Solution Approach 1:
The invention uses periodic PWM control to achieve progressive valve opening with precise flow regulation. The solenoid is switched on and off in pulses rather than remaining continuously energized, allowing the valve to maintain position through mechanical damping and spring forces between pulses. This reduces electrical consumption while maintaining flow control precision through the cumulative effect of pulsed actuation.
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 provides a compact, low-noise, self-cleaning valve with minimized electrical consumption and enhanced flow capacity, enabling precise control and direct diagnostic capabilities.
Implementation Method 1
a motorized regulation system comprising a ball valve connecting said intake and exhaust ducts, a geared motor comprising an electric motor and a reduction gear train
Implementation Method 2
a geared motor comprising an electric motor and a reduction gear train, said gear train comprising an output wheel rotating the ball of said valve
Data Source
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AI summary
The present invention relates to a motorised valve comprising a body (10) with at least one intake duct (8a) and one outlet duct (8b), a plugging member movably mounted in the body (10) to plug or release a passage between said intake duct (8a) and said outlet duct (8b), and a motorised control system for controlling the movement of the plugging member, said motorised control system comprising a plug valve connecting said intake (8a) and outlet (8b) ducts, a gear motor comprising an electric motor and a reduction gear train, said gear train comprising an exit wheel rotating the plug of said valve so as to allow progressive opening of the valve, characterised in that said gear motor is formed by a casing (1) comprising said electric motor and reduction gear train, the valve body (10) being integrally formed with the casing (1).