Jump Valve Assembly for Accurate Low-Flow Metering
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Solution Overview
Problem
Existing fluid control valves struggle with accurately measuring low flow rates, as they often allow undesired low flows that cannot be registered by measurement elements, leading to revenue loss and inefficiency, particularly in applications like utility companies monitoring fluid consumption.
Innovation Solution
A mechanical valve assembly that prevents low flow rates until a predefined threshold is reached, allowing the flow to 'jump' to a higher, more accurately measurable rate, featuring a poppet element and sealing/dampening mechanisms to control fluid flow and ensure accurate metering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional check valve is used to control fluid flow, then the valve allows flow in forward direction, but at low flow rates the valve remains partially open causing unmeasured flow that cannot be registered by flow meters
Solution Approach 1:
The valve travel is segmented into distinct zones: a first zone from closed position to an intermediate position where flow is blocked, and a second zone from intermediate position to fully open where flow is permitted. This segmentation prevents the valve from remaining partially open at low flow rates, ensuring that only measurable flow rates pass through the valve.
Solution Approach 2:
The valve is designed to require a predefined minimum upstream pressure (cracking pressure) to be reached before the valve begins to open. This preliminary pressure threshold ensures that flow only occurs when sufficient pressure differential exists to activate the flow meter's measurement elements, preventing unmeasured low flow rates.
2Quantity of substance
If the valve opens partially at low flow rates, then some fluid can pass through, but the flow rate is insufficient to move the flow meter's measurement elements resulting in revenue loss
Solution Approach 1:
The invention extracts and eliminates the problematic intermediate partial-flow state by designing a valve that transitions from completely closed to fully open, bypassing the partially open condition that causes unmeasured flow. The valve travel mechanism ensures that the valve either blocks flow completely or opens sufficiently to allow measurable flow rates.
Solution Approach 2:
The valve changes its flow control parameter from continuous partial opening to discrete states (closed or open) by modifying the relationship between valve travel and flow rate. This parameter change ensures that flow rates below the meter's measurement threshold are completely blocked, while flows above the threshold are permitted to pass.
3Extent of automation
If a spring-loaded check valve is used, then the valve provides automatic check valve operation, but the spring force creates opposing forces that affect the cracking pressure and flow characteristics
Solution Approach 1:
The spring force acts as a counterweight or opposing force that must be overcome by the upstream pressure to open the valve. This spring opposition is deliberately designed to create a predictable cracking pressure threshold, ensuring that the valve only opens when sufficient pressure differential exists to both overcome the spring force and activate the flow meter's measurement elements.
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 enhances flow meter accuracy by preventing low flow rates and ensuring that fluid flow is delivered in measurable bursts, improving measurement reliability and reducing revenue loss.
Implementation Method 1
a resilient element configured to bias the poppet element to the closed position
Implementation Method 2
the actuation of the valve is controlled by forward and reverse opposing forces. Forward forces may include upstream pressure
Data Source
AI summary
The invention relates to a mechanical valve assembly used to control a fluid (e.g., gas, liquid, etc.) to provide at least one of a check valve control feature and flow range control feature. When unwanted low flows are present, the valve remains closed and jumps open only at higher desired flow rates. The valve then closes when the forces at the input and output equalize, and the process repeats. Such allows fluid delivered to a flow meter in larger segregated bursts, rather than steady low flows that cause metering errors.