Integrated Valve Body Trim to Reduce Leakage and Assembly Complexity
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Solution Overview
Problem
Control valves in process control systems, such as those used in oil production and power generation, face manufacturing complexities and increased costs due to intricate designs of trim components like cages and posts, which also lead to difficulties in assembly and repair.
Innovation Solution
The integration of fluid ducts and a cage within the valve body, with openings to fluidly couple the ducts and a plug seat, reduces the number of trim components and eliminates the need for additional gaskets, allowing for reduced manufacturing costs and minimized fluid leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate trim components (cage, post, seat) are used in control valves, then the valve can be assembled with modular parts, but the manufacturing complexity and cost increase due to intricate designs and multiple assembly steps
Solution Approach 1:
The patent combines multiple separate trim components (cage, post, and seat) into a single integrated trim assembly. The cage forms the main structural body, the post is integrally formed as part of the cage structure, and the seat is incorporated into the cage wall. This merging eliminates the need for separate manufacturing and assembly of these components, thereby reducing manufacturing complexity and cost while maintaining functional performance
2Ease of operation
If multiple separate trim components are used, then each component can be manufactured independently, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
By integrating the cage, post, and seat into a single trim assembly, the patent eliminates multiple assembly steps. The integrated design allows the entire trim assembly to be installed as one unit into the valve body, significantly reducing assembly time and simplifying the assembly process compared to traditional separate component assembly
3Reliability
If traditional designs with separate components and gaskets are used, then sealing can be achieved between components, but fluid leakage increases due to multiple gasket interfaces
Solution Approach 1:
The integrated trim assembly eliminates multiple gasket interfaces by combining the cage, post, and seat into a single monolithic structure. This reduces the number of potential leakage paths and gasket failure points, thereby improving sealing reliability and minimizing fluid leakage compared to traditional designs with multiple separate components requiring multiple gaskets
Data Source
AI summary
Valve bodies and methods of manufacturing the same are disclosed. An example method of manufacturing a valve body includes forming a first duct extending from a first side of the valve body, forming a first wall in the valve body at least partially protruding from a surface of the first duct, the first wall defining a chamber, forming one or more openings in the first wall to fluidly couple the chamber to the first duct, and forming a second duct extending from a second side of the valve body opposite the first, the second duct fluidly coupled to the chamber.