Multi-Stage Pressure Reduction for Low-Noise Fluid Flow Control
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Solution Overview
Problem
Conventional fluid control devices in process control and distribution systems often produce significant aerodynamic noise and cavitation due to pressure drops, exceeding acceptable levels, and require large actuators for high-pressure conditions.
Innovation Solution
The implementation of a multi-stage pressure-reduction system with spaced-apart plates and actuators that incrementally reduce pressure, using a lever mechanism to align or misalign openings in the plates to control fluid flow, thereby reducing noise and cavitation while minimizing actuator size and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional fluid control devices are used to control flow rates and pressures, then fluid flow control is achieved, but aerodynamic noise exceeds acceptable levels (greater than 85 dBA)
Solution Approach 1:
The fluid flow control function is divided into multiple stages with several plates positioned at different locations in the passageway. Each plate creates a separate pressure reduction stage, allowing the total pressure drop to be distributed across multiple smaller drops rather than one large drop, thereby reducing aerodynamic noise while maintaining flow control capability
Solution Approach 2:
Multiple intermediate plates are introduced between the inlet and outlet to mediate the pressure reduction process. These plates act as intermediaries that progressively reduce pressure in stages, preventing the direct high-to-low pressure transition that generates excessive noise, while still achieving the required flow control
2Stress or pressure
If conventional pressure reduction methods are used, then pressure control is achieved, but cavitation occurs
Solution Approach 1:
The pressure reduction is segmented into multiple stages using several plates positioned along the fluid passageway. Each plate creates a controlled pressure drop, distributing the total pressure reduction across multiple smaller steps. This prevents the sudden pressure drop that causes cavitation while maintaining effective pressure control
Solution Approach 2:
The pressure parameter is changed progressively through multiple stages rather than in a single step. By controlling the pressure gradient across each plate stage, the system maintains pressure control while avoiding the conditions that lead to cavitation
3Stress or pressure
If high-pressure conditions are handled by conventional devices, then pressure control is maintained, but large actuators are required
Solution Approach 1:
The actuation function is segmented across multiple smaller plates rather than requiring one large actuator. Each plate can be actuated by a smaller force, and the cumulative effect of multiple plates achieves the same overall pressure control as a single large actuator would provide, thereby reducing actuator size and weight
Solution Approach 2:
Multiple small actuation forces on individual plates are combined to achieve the equivalent effect of a single large actuator. By merging the control function across several plates, the system handles high-pressure conditions while using smaller, more manageable actuators
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 effectively reduces noise levels by 25 decibels and improves cavitation performance, achieving acceptable noise levels below 85 decibels and reducing the need for large actuators, thus enhancing the operational efficiency and cost-effectiveness of fluid control systems.
Implementation Method 1
The first pressure reducer to cause a first pressure drop of fluid flowing across the first pressure reducer and the second pressure reducer to cause a second pressure drop of the fluid flowing across the second pressure reducer
Implementation Method 2
A second plate is moveable relative to the first plate between a first position to move the pressure-reducing device to a closed position to restrict or prevent fluid flow through the axial fluid passageway and a second position to move the pressure-reducing device to an open position to allow fluid flow through the axial fluid passageway
Data Source
AI summary
Pressure-reduction devices for fluid systems are disclosed. An example device includes a housing defining an axial fluid passageway between an inlet and an outlet. A first plate is fixed to the housing and positioned in the axial fluid passageway. A second plate is positioned adjacent the first plate in the axial fluid passageway. The second plate is moveable relative to the first plate between a first position to move the pressure-reducing device to a closed position to restrict or prevent fluid flow through the axial fluid passageway and a second position to move the pressure-reducing device to an open position to allow fluid flow through the axial fluid passageway.