Multi-part Valve Assembly Using Inertia Welding

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Solution Overview

Problem

Conventional valve assemblies for reciprocating, positive displacement pumps, such as fracking pumps, are costly due to the use of expensive materials and manufacturing processes, and often require complex assembly and heat treatment, which increases production costs and waste.

Innovation Solution

A multi-part valve assembly using a combination of inexpensive materials, including low carbon or low alloy steel for the retaining pin, guide, and retainer cap, with selective hardening of high carbon content steel for the valve, allowing for cost-effective manufacturing and assembly through techniques like inertia or friction welding, eliminating the need for extensive heat treatment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional single-piece or welded valve assemblies are used, then manufacturing complexity is reduced, but production costs increase due to expensive materials and extensive heat treatment

Engineering Contradiction:

Improvemanufacturing costVSAvoidvalve assembly structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The valve assembly is divided into multiple separate components (body, stem, seat, insert) that can be manufactured independently using different materials and processes. This segmentation allows each part to be optimized for its specific function, reducing overall manufacturing cost while maintaining performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite construction where different materials are combined in the valve assembly. Specifically, a soft seating material (urethane insert) is combined with metal components, allowing the seating surface to provide sealing while the metal provides structural strength. This eliminates the need for expensive alloy steels and extensive heat treatment.

Inventive Principle:

Principle #40Composite materials

2Strength

If high carbon alloy steel is used for the entire valve assembly, then hardness and wear resistance are improved, but manufacturing cost and heat treatment requirements increase

Engineering Contradiction:

ImprovehardnessVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Instead of making the entire valve assembly from high carbon alloy steel, the invention applies hardness and wear resistance only where needed. The urethane insert provides the necessary sealing surface properties, while the metal body and stem can be made from lower-cost, easier-to-manufacture materials. This local quality approach eliminates extensive heat treatment requirements.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The soft seating material (urethane insert) is used as a replaceable component that can be manufactured cheaply and replaced when worn, rather than requiring the entire valve assembly to be made from expensive, hard-to-manufacture high carbon alloy steel. This significantly reduces manufacturing cost while maintaining performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If multiple components are assembled in the valve, then material selection and manufacturing flexibility improve, but assembly complexity and potential failure points increase

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The valve components are designed with nested relationships where the insert is positioned within the body, and the stem connects these elements. This nesting approach organizes the multiple components in a logical, space-efficient manner that reduces assembly complexity while maintaining the benefits of material selection flexibility.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 solution reduces production costs by using easily machined materials and minimizing heat treatment, while maintaining the necessary hardness in only critical areas, thus enhancing the efficiency and cost-effectiveness of valve assembly production.

Implementation Method 1

The retainer cap is welded to an end of the retaining pin to hold the collective assembly together

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

A guide is positioned on the retaining pin. The guide centers the valve assembly inside a pump cylinder

Methodology Applied

Scientific EffectMechanical guidance:

Implementation Method 3

The valve is held closed by springs and open and close by differential pressure

Methodology Applied

Scientific EffectSpring force: Spring

Data Source

PatentUS9470226B2Multi-part valve assembly

Publication Date: 2016.10.18 VALVEWORKS L L C

AI summary

The present invention discloses a multi-component valve system for use in pumps such as fracking pumps for use in subterranean resource production. The assembly includes a retaining pin, a guide on the retaining pin, a valve on the retaining pin, an insert on the retaining pin, a retainer above the insert on the retaining pin, and a retainer cap inertia welded to the end of the retaining pin. In a particular embodiment, the guide component is stamped and folded to create the desired shape.