Multi-Motor Valve Actuator with Plastic Gears and Universal Power
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Solution Overview
Problem
Existing valve actuators for domestic and industrial applications are heavy due to metal gears, lack position indication, have unreliable user interfaces, and require costly power supplies to accommodate various voltage standards, leading to inefficiencies and limited adaptability.
Innovation Solution
A valve actuator design utilizing multiple smaller electric motors with shared stators and rotors, reducing material usage and weight, incorporating a compact gear train made from plastics, and a universal power system with a local energy storage component for efficient operation across different voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a single electric motor with a metal gearbox is used to provide high torque, then the required torque is achieved, but the mass of the assembly increases significantly
Solution Approach 1:
The single motor system is divided into multiple smaller motors (at least two). Each motor drives its own separate gear train, eliminating the need for a single large metal gearbox. The segmentation of the drive system allows for lighter individual components while maintaining the required total torque output through combined operation of multiple motors.
Solution Approach 2:
Traditional metal/steel gearboxes are replaced with gear trains constructed from plastics material. This substitution reduces the mass of the gearing system significantly while maintaining the mechanical advantage needed to convert motor output to the correct torque and speed at the actuator output.
2Volume of moving object
If the drive motor is positioned between the output shaft and the housing for compactness, then space is optimized, but position indication becomes problematic as the indicator cannot be placed on the visible side
Solution Approach 1:
The drive system is segmented into multiple motors positioned around the periphery of the actuator rather than a single central motor. This peripheral arrangement creates space on the opposite side of the housing from the output shaft, allowing the position indicator to be clearly visible while the drive components remain compact.
3Adaptability or versatility
If a universal power supply is designed to handle all voltage standards (12V, 24V, 110V, 240V AC/DC), then global adaptability is achieved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
A single power supply unit is designed to accept multiple voltage inputs (12V, 24V, 110V, 240V AC and DC) and convert them to a standardized internal voltage for driving the motors. This universal power supply eliminates the need for separate power supplies for different markets while maintaining the ability to handle high current bursts required for valve actuation.
Solution Approach 2:
The power supply incorporates voltage detection and switching circuitry that automatically adjusts its operation based on the detected input voltage parameters. This allows the same hardware design to adapt to different voltage standards without requiring manual configuration or multiple specialized power supply units.
4Power
If a high current power supply is provided to deliver short bursts of high current for valve actuation, then the required power output is achieved, but the cost of the power supply increases
Solution Approach 1:
The power supply is designed to deliver high current in periodic bursts corresponding to the valve actuation cycles rather than continuous operation. Between actuation cycles, the power supply operates at low current to maintain readiness while consuming minimal power. This periodic high-current delivery pattern allows for more cost-effective power supply design compared to systems requiring continuous high current capability.
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 design achieves significant weight reduction, improved performance, energy efficiency, and adaptability to various power sources, enabling faster operation and longer motor life with reduced maintenance and operational costs.
Implementation Method 1
A valve actuator may comprise a plurality of electric motors
Data Source
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AI summary
The present invention provides a multi-motor system comprising a plurality of individual small electric motor rotors (102) which are driven via individual gear trains and their output summed at a primary output shaft (152).