Integrated Actuating Key for Pipeline Valve Torque Management
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Solution Overview
Problem
Existing actuation keys for adjusting underground pipeline shut-off valves require significant manual effort, energy consumption, and complex installation due to the need for a frame to absorb torque, making them cumbersome and potentially dangerous to handle.
Innovation Solution
The drive is integrated into a housing within the key rod, with a linkage section on both sides, allowing for direct and efficient torque transmission to the coupling sleeve, enabling the use of a rechargeable battery and eliminating the need for a frame, and incorporating an anti-twist device and monitoring units for safety and documentation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the drive is positioned at a distance from the coupling sleeve (e.g., at waist height of operators), then the drive can be operated with sufficient leverage, but the energy requirement increases considerably and the device becomes cumbersome
Solution Approach 1:
The key rod is divided into distinct segments: the drive housing containing the motor, the drive shaft, and the coupling sleeve. This segmentation allows the drive to be positioned close to the coupling sleeve while maintaining operational efficiency, eliminating the need for long linkage arms and reducing energy consumption.
Solution Approach 2:
The drive shaft is nested within the drive housing, and the coupling sleeve is integrated with the key rod structure. This nesting arrangement minimizes the overall length of the linkage while maintaining the functional integrity of the drive mechanism, thereby reducing the energy required to operate the valve.
2Power
If a frame is used to absorb the torque from the drive, then the drive can be operated effectively, but the installation becomes complex, cumbersome and dangerous
Solution Approach 1:
The drive housing is merged with the key rod structure, forming an integrated assembly. The drive shaft connects directly to the coupling sleeve, which is part of the key rod. This merging eliminates the need for a separate frame to absorb torque, simplifying the overall structure and making installation straightforward and safe.
3Device complexity
If the drive is integrated into the key rod with housing, then the structure becomes compact and energy consumption reduces, but the drive must be precisely positioned and integrated
Solution Approach 1:
The integrated structure is manufactured as segmented components (drive housing, drive shaft, coupling sleeve) that are designed to fit together with precise tolerances. This segmentation allows for easier manufacturing of individual parts while achieving the desired compact integrated structure when assembled.
Solution Approach 2:
The drive shaft serves as an intermediary component that connects the drive housing to the coupling sleeve. This intermediary element facilitates the precise positioning and integration of the drive components, enabling compact structure manufacturing while maintaining ease of assembly through standardized connection interfaces.
4Power
If mains voltage connection is required for the drive, then sufficient power is available, but the device becomes less portable and requires infrastructure
Solution Approach 1:
The mechanical system is replaced with an electric drive system that can operate on portable power sources. The drive housing contains an electric motor that can be powered by rechargeable batteries instead of requiring mains voltage connection, thereby maintaining sufficient power availability while significantly improving portability and ease of operation in remote locations.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The key has a drive, and a key bar (12) that is provided with a boom (2). A coupling sleeve (3) is provided underside (5) of key bar, for connection to the shut-off valve. An integrated housing (4) is arranged in the key bar. A motor, control unit and/or power supply are housed in the housing. The housing is detachably connected with the key bar and/or coupling sleeve.