Modulating Valve Throttle Design for Minimum Flow Rate Control
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Solution Overview
Problem
Conventional modulating valves in heating systems face challenges in achieving a minimum fluid flow rate below 100 liters per hour to maintain constant temperature without excessive fluctuations or increased heating costs, and they are often complex, costly, and require modifications to existing valve bodies.
Innovation Solution
A modulating valve design featuring a conical throttle mechanism with a cylindrical cartridge and actuator system that allows for precise control of fluid flow through calibrated openings, enabling flow rates as low as 5-20 liters per hour, while being simple to operate and compatible with existing valve bodies, and produced using conventional techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional on-off valves are used to control fluid flow in heating systems, then the valve structure is simple and easy to manufacture, but the minimum flow rate cannot be reduced below approximately 100 liters per hour, which is excessive for maintaining constant temperature
Solution Approach 1:
The valve is divided into a body and a separate movable cartridge assembly. The cartridge contains the throttle mechanism and can be independently removed and replaced, allowing precise flow control without complicating the overall valve structure. This segmentation enables the complex throttle function to be isolated in a modular component.
Solution Approach 2:
The throttle is made movable relative to the outlet opening through the cartridge mechanism. By dynamically adjusting the throttle position along the axis, the valve can precisely control the minimum flow rate to very low values (5-20 liters per hour) while maintaining simple manufacturing of individual components.
2Loss of energy
If the minimum flow rate is reduced to maintain constant temperature, then heating costs are reduced, but the valve becomes more complex and costly to produce
Solution Approach 1:
The movable cartridge serves multiple functions: it provides the throttle mechanism for flow control, acts as a seal against the outlet opening, and can be easily removed for maintenance or replacement. This multi-functionality reduces the need for additional components, keeping production costs low while enabling precise minimum flow rate control.
Solution Approach 2:
The cartridge is designed to be easily removable and replaceable by the user without special tools or complex disassembly procedures. This self-service feature reduces maintenance costs and simplifies operation, offsetting the slightly increased manufacturing complexity by eliminating the need for expensive service interventions.
3Measurement precision
If a new valve design is created to achieve low minimum flow rates, then flow control precision is improved, but the valve body requires modifications that increase installation complexity
Solution Approach 1:
The complex throttle and flow control mechanism is extracted from the valve body and placed in a separate movable cartridge. This allows the cartridge to be inserted into existing valve bodies without modifying the body itself, maintaining compatibility while achieving precise flow control through the removable cartridge component.
Solution Approach 2:
The throttle mechanism is nested within the movable cartridge, which itself is inserted into the valve body. This nested structure allows the complex flow control system to be contained within a compact cartridge that fits into standard valve bodies, preserving adaptability while enabling precise minimum flow rate control.
Data Source
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AI summary
A modulating valve, for example an on-off valve (1) which can be inserted in a valve body (2) placed in the interior of a hydraulic plant for heating a dwelling, comprises a structure (7) which is hollow in the interior, and has at least one intake opening (9) and one outlet opening (8) for a fluid, at the outlet opening (8) there being placed a throttle (30) which is associated with a thrust unit (23) actuated longitudinally within said structure (7) by an actuator unit (21) which is connected to an end of said structure (7), said throttle (30) being movable together with said thrust unit (23) under the action of said actuator (21), and being displaced within said outlet opening (8) such as to regulate the flow of fluid through said outlet opening (8). According to one embodiment, the throttle (30) has a form which is at least partly conical, and has a widened end (55) which, during closure, can cooperate with said outlet opening (8) such as to close it, in said end (55) there being provided at least one longitudinal perimeter surface opening (57) which can permit the flow of a reduced quantity of fluid through said outlet opening (8) further to a limited displacement of said end (55) from said outlet opening.