Hybrid Poppet Valve Assembly for Precise Low-Energy Flow Control
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Solution Overview
Problem
Existing control valve assemblies for process fluid flow in plants are complex, energy-intensive, and prone to faults, making them unsuitable for certain applications due to their large size, high energy consumption, and complex control systems.
Innovation Solution
A control valve assembly comprising a combination of fine-adjustment poppet valves with analogue drives and open/close poppet valves with digital actuators, connected in parallel, allowing for precise control of cumulative flow areas with reduced energy consumption and simplified maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple poppet valves with different sized opening diameters are used to achieve high control precision, then manufacturing precision is improved, but device complexity increases and energy consumption rises
Solution Approach 1:
The control valve assembly is segmented into multiple independent poppet valves (first poppet valve, second poppet valve, third poppet valve) with different flow areas. Each valve can be independently controlled by its own actuator, allowing precise control of total flow area through combinatorial opening/closing patterns. This segmentation enables high control precision while maintaining manageable device complexity through modular architecture.
Solution Approach 2:
The invention employs dynamically adjustable flow areas through multiple poppet valves that can be independently positioned between fully closed and fully open states. The total effective flow area is dynamically controlled by selecting which valves are open, enabling adaptive flow control that responds to varying process requirements without requiring complex mechanical linkages.
2Manufacturing precision
If multiple poppet valves are used to achieve high control precision, then manufacturing precision is improved, but energy consumption increases
Solution Approach 1:
The control system uses partial action by selectively opening only the necessary subset of poppet valves to achieve the desired flow rate, rather than using all valves simultaneously. This reduces the total work required from actuators and minimizes energy consumption while maintaining precise flow control through optimal valve selection based on current process demands.
Solution Approach 2:
The control system implements periodic assessment and adjustment of valve states based on flow requirements. Actuators engage only when flow area adjustments are needed, rather than continuous operation, reducing energy consumption through intermittent actuation cycles that maintain precise control while minimizing power usage during steady-state operation.
3Manufacturing precision
If a large number of poppet valves are used, then control precision is improved, but the assembly becomes large and heavy
Solution Approach 1:
The valve assembly is divided into multiple independent poppet valve units with different flow areas. This segmentation allows achieving high control precision through combinatorial control of fewer valves rather than using one large complex valve, reducing overall assembly weight while maintaining fine flow control capability through modular lightweight components.
Solution Approach 2:
Each poppet valve is designed with locally optimized flow area characteristics tailored to specific control ranges. The first, second, and third poppet valves have progressively different flow areas, allowing each component to be minimized in size for its specific function while collectively providing high-resolution flow control, reducing total assembly weight compared to a single large valve.
Data Source
AI summary
Control valve assembly for controlling a process fluid flow in a process engineering plant such as a power plant, a chemical plant, a food processing plant or the like, wherein at least one fine-adjustment poppet valve with a fine-adjustment drive for the fine adjustment of a fine-adjustment poppet valve flow area; and at least one open/close poppet valve having a discrete adjustment actuator for placing the open/close poppet valve either into an open position, in which a poppet valve flow area is completely open, or into a closed position, in which the poppet valve flow area is closed off, wherein a cumulative total flow area of the adjustment valve assembly is defined by the fine-adjustment poppet valve flow area of the at least one fine-adjustment poppet valve and by the poppet valve flow area of the at least one open/close poppet valve.