Modular Valve Manifold With Bistable Control for Lower Power Use
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Solution Overview
Problem
Existing fluid flow control systems, particularly manifold valves, face challenges with power consumption, heat generation, and complexity in integrating bistable valve assemblies, limiting their adaptability and efficiency in changing applications.
Innovation Solution
A modular manifold system with standardized modules and an on-board controller that allows for programmable functions, accommodating bistable valve sets to reduce power consumption and heat generation, and enabling easy replacement of valve assemblies, while allowing for re-purposing and efficient fluid pressure management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manifold valves are used to control fluid flow, then the system can maintain a particular position or state, but the valves require a constant source of current which increases power consumption and heat generation
Solution Approach 1:
The patent replaces traditional electromagnetic valves that require continuous electrical current with bistable valves that use magnetic fields and mechanical spring forces to maintain stable positions. The bistable valve uses a magnet, spring, and valve body configuration where the magnet can be positioned in two stable locations by applying magnetic force through a coil only during state transitions, eliminating the need for continuous power consumption to maintain position.
2Adaptability or versatility
If manifold valves frequently change states to control fluid flow dynamically, then the system becomes more adaptable, but power consumption and heat generation increase significantly
Solution Approach 1:
The bistable valve operates by applying magnetic force periodically only when state transitions are needed, rather than continuously. The coil is energized briefly to move the magnet between two stable positions, then left unenergized while the magnetic and mechanical forces maintain the valve in its current state, creating an energy-efficient periodic action pattern that enables dynamic control without continuous energy input.
3Manufacturing precision
If custom-designed manifold assemblies are created for specific liquid flow control apparatus, then the system can be optimized for that application, but the manifold cannot be re-purposed for other applications
Solution Approach 1:
The manifold assembly is divided into separate, interchangeable components including the valve body, magnet assembly, spring, and housing that can be disassembled and reconfigured. This segmentation allows the same basic components to be arranged differently for various applications, enabling the system to maintain application-specific optimization while gaining the ability to be re-purposed for different liquid flow control needs.
4Use of energy by moving object
If bistable valve assemblies are integrated into the pressure distribution manifold system, then power consumption is reduced, but the system complexity and cost increase
Solution Approach 1:
The patent combines multiple functions into the single valve body component, which serves as both the valve mechanism and the housing for the magnet and spring assembly. This merging eliminates the need for separate actuator housings, mounting brackets, and external control mechanisms, thereby reducing overall system complexity while maintaining the power-saving benefits of the bistable design.
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
The modular system enhances adaptability, reduces power consumption and heat generation, and improves the efficiency of fluid flow control by enabling programmable and specialized functions, facilitating easy integration and reconfiguration for various applications.
Implementation Method 1
A coil is provided in communication with the valve body and the magnet is movable between a first stable position and a second stable position in response to a magnetic force generated by the coil
Implementation Method 2
A spring is provided in communication with the valve body and having a first end and a second end, the second end being in communication with the magnet
Data Source
AI summary
A valved manifold module is disclosed, constructed and arranged to be readily connected in a chain with similar modules to form a manifold assembly. The modular manifolds allows for expansion or modification of the manifold assembly to control a group of pneumatically or hydraulically driven pumps, valves or combinations thereof in a liquid flow control apparatus. The valved manifold module can be configured to accept a group of four substantially identical valve assemblies, and can be controlled by a local controller mounted to the manifold module, thus forming an independently programmable valved manifold module. The resulting modular system is expandable to allow for coordinated operations of a liquid flow control system, using substantially independent controller functions originating at the manifold assembly level.