Modular Pneumatic Valve Assembly With Switchable Dead Volume
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Solution Overview
Problem
Pneumatically driven process valves require different drive units for shut-off and control applications, leading to a high variety of parts and increased manufacturing and storage costs due to the need for different dead volumes.
Innovation Solution
A modular system for manufacturing valves of different types, utilizing a valve basic unit with a pneumatic drive unit and adjustable dead volume through the use of closure members to seal or leave open passage openings between the pressure chamber and dead space chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different drive units are used for shut-off valves and control valves, then the valve performance is optimized for specific applications, but the part variety increases and manufacturing costs rise
Solution Approach 1:
The drive unit is segmented into a standardized base component and interchangeable dead volume chambers. The base component contains the piston, spindle, and control elements, while separate dead volume chambers can be attached or removed to configure the unit for either shut-off or control valve applications.
Solution Approach 2:
A universal drive unit design is created that can function as either a shut-off valve actuator or a control valve actuator by changing the dead volume chamber configuration. The same basic unit serves multiple functions through optional attachments, eliminating the need for completely different drive units.
2Speed
If the dead volume is minimized for shut-off valves, then switching time and air consumption are reduced, but control precision for partial opening positions deteriorates
Solution Approach 1:
The dead volume chamber configuration is made dynamic and adjustable. For shut-off valve applications, the dead volume chamber is minimized or removed to achieve fast switching. For control valve applications, the dead volume chamber is attached to provide larger volume for precise partial opening control. The same base unit adapts to different requirements.
3Measurement precision
If the dead volume is maximized for control valves, then control linearity and precision are improved, but switching time and air consumption increase
Solution Approach 1:
The dead volume management is segmented into an optional attachable chamber. When not needed for control precision, the chamber can be removed or disconnected, allowing the system to achieve fast switching characteristics. When control precision is required, the chamber is attached to provide the necessary volume.
Data Source
AI summary
A modular system having an assembly for manufacturing valves of two different valve types including a valve basic unit having a housing, an actuator base, and a piston/spindle unit with a piston displaceable in the housing. An end face of the piston and an end face of the actuator base define a pressure chamber. The actuator base and the housing delimit a dead space chamber on a side of the actuator base facing away from the piston. The actuator base includes at least one passage opening between the dead space chamber and the pressure chamber. Closure members for manufacturing a first valve type are each inserted into one of the passage openings to seal it in a gas-tight manner and to permanently disconnect the dead space chamber from the pressure chamber in terms of flow. For manufacturing a second valve type, the passage openings are left open.