Characterized Orifice Insert for Precise Ball Valve Throttling
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Solution Overview
Problem
V-port ball valves, while cheaper than globe valves, are more expensive to produce and lack the performance characteristics required for precise control applications, necessitating a cost-effective alternative with similar control capabilities.
Innovation Solution
A ball valve assembly incorporating a characterization orifice insert with a V-shaped geometry, which mimics the operation of a V-port valve, is designed to provide precise control and throttling capabilities, using a semi-spherical body portion and a locating feature to minimize rotation, and is manufactured through processes like stamping and mold pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a V-port ball valve is used to achieve precise control and throttling capabilities, then control performance is improved, but manufacturing cost increases
Solution Approach 1:
The valve assembly is divided into separate functional components: a standard ball valve body and a separate characterization orifice insert. The insert contains the V-shaped orifice geometry that provides control capabilities, while the ball valve body provides the basic valve function. This segmentation allows the expensive V-port geometry to be achieved through a simple insert rather than a complex machined ball, reducing manufacturing cost while maintaining control performance.
Solution Approach 2:
A characterization orifice insert is introduced as an intermediary component between the ball and the valve body. This insert contains the V-shaped orifice that characterizes the flow control behavior. The insert acts as a mediator that provides the precise control capabilities of a V-port valve without requiring the entire valve assembly to be complex and expensive to manufacture.
2Ease of manufacture
If a standard ball valve with cylindrical bore is used, then manufacturing cost is reduced, but control and throttling capabilities are lost
Solution Approach 1:
Instead of making the entire ball or valve body complex to achieve control capabilities, the V-shaped orifice geometry is localized to a specific insert component. The majority of the valve assembly remains simple and easy to manufacture, while only the small insert requires precision features. This local quality approach provides control capability where needed without increasing overall manufacturing complexity.
3Manufacturing precision
If a V-port ball valve is used to achieve control performance, then throttling capability is improved, but device complexity increases
Solution Approach 1:
The complex V-shaped orifice geometry is extracted from the main valve body or ball and placed into a separate, removable insert. This extraction simplifies the main valve structure to a standard ball valve design while isolating the complexity to a small insert component that can be easily manufactured and replaced. The overall device complexity is reduced while maintaining throttling capability.
Data Source
AI summary
The present disclosure provides a ball valve assembly and a method of manufacturing a ball valve assembly. In one example embodiment, the method comprises providing a pair of end caps, providing a rotary ball including a bore formed therethrough, providing a handle operatively connected to the rotary ball and configured to rotate the rotary ball, providing a characterization orifice insert including a characterization shape, positioning the rotary ball between the pair of end caps, and positioning the characterization orifice insert proximate the rotary ball. Before the characterization orifice insert is positioned proximate the rotary ball, the characterization orifice insert may be converted and/or formed from an initial state into a final state, wherein the characterization shape of the characterization orifice insert in the initial state differs from the characterization shape of the characterization orifice insert in the final state.