Modular Valve Manifold Assembly for Reconfigurable Fluid Control
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Solution Overview
Problem
Existing manifold systems for fluid flow control are often custom-designed and not easily adaptable for different applications, leading to issues with power consumption, heat generation, and valve reliability, especially when frequently changing states.
Innovation Solution
A modular manifold assembly with standardized modules that can be easily concatenated and re-purposed, featuring standardized dimensions, inputs, outputs, and valve assemblies, along with an on-board controller for programmable functions and pressure measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manifold systems are custom-designed for specific applications, then the system can be optimized for that particular application, but the system cannot be easily re-purposed for other applications
Solution Approach 1:
The manifold system is divided into separate, interchangeable modules including valve assemblies, manifold bodies, and controller units. Each module can be independently selected and combined to create different configurations for various applications, enabling easy re-purposing without redesigning the entire system.
Solution Approach 2:
The manifold modules are designed with standardized interfaces and universal connection mechanisms that allow the same basic modules to serve multiple functions across different applications. The standardized valve assemblies and controller mounting interfaces enable a single module type to be used in various fluid flow control scenarios.
2Productivity
If traditional manifold valves frequently change states, then the system can respond to dynamic fluid flow requirements, but power consumption increases and heat generation occurs
Solution Approach 1:
The system employs periodic pulsing of pneumatic actuators to achieve valve state changes rather than continuous electrical actuation. By using intermittent pneumatic pulses synchronized with the fluid flow cycle, the system maintains rapid response capability while significantly reducing average power consumption compared to continuously energized electromagnetic valves.
3Productivity
If traditional manifold valves frequently change states, then the system can adapt to dynamic requirements, but valve reliability decreases
Solution Approach 1:
The system replaces electromagnetic valve actuation with pneumatic actuation using compressed gas or vacuum sources. Pneumatic actuators provide cleaner operation without electrical contacts that wear or overheat, enabling frequent state changes while maintaining higher reliability. The pneumatic system uses diaphragms and springs that have longer operational lifetimes compared to electromagnetic coil assemblies.
4Productivity
If manifold valves frequently change states, then the system can meet dynamic fluid control demands, but heat generation increases
Solution Approach 1:
By substituting pneumatic actuation for electromagnetic actuation, the system eliminates the primary heat generation source in traditional valves. Pneumatic systems operate isothermally or with minimal temperature rise, allowing frequent cycling without the heat accumulation problems that limit electromagnetic valve operation. The pneumatic actuators transfer energy through gas compression/expansion rather than resistive heating.
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 allows for rapid reconfiguration and reduced power consumption, heat generation, and improved valve reliability, enabling efficient and flexible fluid flow control across various applications.
Implementation Method 1
The controller can be used to measure the amount of pressure delivered to or present in the liquid flow control apparatus
Implementation Method 2
The control board having one or more electrical output connectors for connection to an electromagnetic coil to actuate the valve assembly
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.