Modular Valve Plug Segments for Flexible Control Valve Sizing

Solution Overview

Problem

Existing control valves require unique manufacturing processes and tooling for each valve plug configuration, leading to increased manufacturing and inventory costs due to fixed designs that cannot be easily adapted for different sizes and configurations.

Innovation Solution

A modular valve plug apparatus comprising interchangeable plug segments that can be stacked or removed to adjust the overall length and diameter of the valve plug, allowing for various configurations and pressure-balancing options, reducing manufacturing complexity and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If unique manufacturing processes and tooling are used for each valve plug configuration, then manufacturing precision and reliability are improved, but manufacturing costs and device complexity increase

Engineering Contradiction:

Improvevalve plug performanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The valve plug is divided into multiple interchangeable segments that can be assembled in different configurations. Each segment is manufactured using standardized processes, eliminating the need for unique tooling for each valve plug design while maintaining precision through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A set of universal plug segments is designed to work across multiple valve configurations. These segments can be combined in various ways to create different valve plug geometries, allowing a single manufacturing process to produce multiple valve plug types for different flow requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If fixed valve plug designs are used, then manufacturing precision is improved, but adaptability to different sizes and configurations deteriorates

Engineering Contradiction:

Improvevalve plug dimensionsVSAvoidvalve plug configuration flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The valve plug is divided into multiple interchangeable segments that can be assembled in different configurations. Each segment is manufactured using standardized processes, eliminating the need for unique tooling for each valve plug design while maintaining precision through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The valve plug design transitions from a static, fixed configuration to a dynamic, reconfigurable structure. Plug segments can be added or removed to adapt the valve plug to different valve sizes and flow requirements, allowing the same manufacturing process to serve multiple applications.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If standardized plug segments are used, then ease of manufacture and productivity are improved, but manufacturing precision may deteriorate

Engineering Contradiction:

Improvevalve plug assemblyVSAvoidvalve plug fit and function

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The valve plug is divided into multiple interchangeable segments that can be assembled in different configurations. Each segment is manufactured using standardized processes, eliminating the need for unique tooling for each valve plug design while maintaining precision through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Connection features and sealing elements act as intermediaries between plug segments, ensuring precise alignment and proper sealing. These standardized connection mechanisms maintain manufacturing precision while enabling easy assembly and disassembly of the modular segments.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11649897B1Valve plug apparatus for use with control valves

Publication Date: 2023.05.16 FISHER CONTROLS INT LLC

AI summary

Methods, apparatus, systems, and articles of manufacture are disclosed for a valve plug apparatus for use with control valves. An example valve plug apparatus disclosed herein an upper plug segment, a middle plug segment, and a lower plug segment, the middle plug segment positioned between the upper plug segment and the lower plug segment, the upper plug segment, the middle plug segment and the lower plug segment defining an overall length of the valve plug, the middle plug segment removably coupled to the upper plug segment and the lower plug segment.