Multi-Rotor Flow Control Valve for High-Capacity Engine Streams
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Solution Overview
Problem
Flow control valves in engine-related gaseous streams face challenges in balancing flow capacity and controllability, with butterfly and poppet valves offering high flow capacity but non-linear response and high actuator torque, while rotary valves have limited flow area and increased pressure drop due to a 90° turn, leading to reduced capacity.
Innovation Solution
A high-capacity, highly responsive rotary valve design featuring a first and second rotor that rotate simultaneously in opposite directions, with a stator having a maximum flow-through area of over 50% of the total flow area, utilizing a single actuator and high-temperature materials, and incorporating a ceramic spacer to reduce heat transfer and engagement gear for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If butterfly or poppet valves are used, then flow capacity is high, but flow response becomes highly non-linear and actuator torque requirements increase
Solution Approach 1:
The valve is segmented into multiple rotors (first rotor and second rotor) that can rotate independently or in coordination. Each rotor has flow-through areas that can be independently controlled, allowing the total flow capacity to be divided and controlled in a more linear manner while maintaining high overall flow capacity.
Solution Approach 2:
The valve employs dynamic rotation of rotors to control flow, where the rotors can rotate to different positions to adjust flow capacity. This dynamic control mechanism provides a more linear flow response compared to the static or limited-motion butterfly and poppet valves, improving controllability while maintaining high flow capacity.
2Ease of operation
If rotary valves with 90° turn are used, then controllability improves with more linear flow response, but pressure drop increases and flow capacity is reduced
Solution Approach 1:
Instead of using a 90° turn configuration, the invention uses rotors that rotate within a plane to control flow. The rotors can be positioned at various angles to control flow capacity without requiring a 90° turn, thereby maintaining lower pressure drop and higher flow capacity while still providing linear controllability.
Solution Approach 2:
The invention merges multiple flow paths through the rotors and stator configuration. By having both a first rotor with a first flow-through area and a second rotor with a second flow-through area that can operate simultaneously, the valve combines multiple flow channels to maintain high overall flow capacity while each rotor provides linear control of its respective portion of the flow.
3Ease of operation
If rotary valves with 90° turn are used, then controllability improves, but available flow area is limited and flow capacity is reduced
Solution Approach 1:
The valve is segmented into multiple rotors (first rotor and second rotor), each with its own flow-through area. This segmentation allows the total available flow area to be distributed across multiple rotors, increasing the overall available flow area compared to a single-rotor design, while each rotor still provides linear control capability.
Solution Approach 2:
The rotors are designed to rotate dynamically to control flow, with the ability to position themselves at various angles to optimize flow area. This dynamic positioning allows the rotors to maintain larger available flow areas throughout their range of motion compared to fixed or 90° turn configurations, thereby increasing overall flow capacity while preserving controllability.
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 a significant increase in flow capacity while maintaining controllability, with the rotary valve's maximum flow-through area exceeding 50% of the total flow area, reducing pressure drop and actuator torque requirements, and effectively handling high-temperature and corrosive streams.
Implementation Method 1
incorporating a ceramic spacer to reduce heat transfer
Data Source
AI summary
An article of manufacture includes a first rotor having a first flow-through area that is more than 50% of a total first rotor flow area and a first ridged arc member, and a second rotor having a second flow-through area that is more than 50% of a total second rotor flow area and a second ridged arc member. The article further includes an upstream stator and a downstream stator, each stator having a co-extensive stator flow-through area and a co-extensive structural area. The article includes an actuator having an engagement gear between the ridged arc members, where a turn of the engagement gear moves the ridged arc members in opposing directions. The first rotor and second rotor are phased to be at a maximum closed at a first position of the engagement gear and a maximum open at a second position of the engagement gear.