Pilot Valve Mechanical Actuator Pressure Control
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Solution Overview
Problem
Conventional control valves require external components, differential pressure mechanisms, and electrical power, leading to inefficiencies, higher operational costs, and potential backflow issues in low-pressure fluid systems.
Innovation Solution
A fully mechanical valve system that operates using a pressure set point, eliminating the need for external components and electrical power, with a normally open or closed configuration that prevents backflow by utilizing a spring-actuated piston and diaphragm mechanism to control fluid flow based on system pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional control valves use external components (solenoid valves, electrical connections), then the valve can be actuated, but the manufacturing cost increases and the device complexity increases
Solution Approach 1:
The patent merges the actuation mechanism and sealing mechanism into a single integrated piston assembly. The piston includes both the actuation seal and the valve seal, eliminating the need for separate external components. This integration reduces device complexity while maintaining reliable valve actuation through a unified mechanical structure that responds to pressure differential.
Solution Approach 2:
The patent extracts and eliminates external components (solenoid valves, electrical connections) from the conventional valve system. By removing these external actuation devices and replacing them with an internal pressure-responsive piston mechanism, the invention reduces manufacturing cost and device complexity while achieving reliable valve control through purely mechanical means.
2Reliability
If conventional control valves use differential pressure actuation, then the valve can operate, but the valve size increases and manufacturing cost increases
Solution Approach 1:
The patent changes the actuation parameter from requiring large differential pressure to responding to smaller pressure differential. The piston mechanism is designed with appropriate surface areas and spring pre-compression to be sensitive to smaller pressure changes, enabling compact valve sizing while maintaining reliable operation across a range of operating conditions.
3Reliability
If conventional control valves require electrical power for actuation, then the valve can be controlled, but operational cost increases and the valve cannot function without power
Solution Approach 1:
The patent implements self-service actuation where the valve automatically responds to pressure differential without requiring external electrical power. The piston mechanism uses the system's own pressure differential to drive actuation, and the spring provides restoring force, creating a passive control system that functions autonomously based on process conditions.
4Device complexity
If conventional control valves allow backflow when closed, then the valve structure is simpler, but system components (membranes) can be damaged
Solution Approach 1:
The patent extracts the backflow prevention function from the basic valve structure and implements it through the integrated piston-seal assembly. The valve seal on the piston provides positive shut-off that prevents backflow, eliminating the need for additional backflow prevention components while protecting downstream system elements from damage.
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 allows for consistent operation across varying pressures without external components, reduces manufacturing and operational costs, and prevents backflow when closed, enhancing reliability and efficiency in systems with limited or no power access.
Implementation Method 1
a spring configured to move axially between the lower diaphragm and the upper diaphragm
Implementation Method 2
a pressure differential across the diaphragm responsive to a pressure set point determined by the spring
Data Source
AI summary
Embodiments of the invention provide a normally open valve, a normally closed valve, and a combination valve. The valves include a valve body with an inlet coupled to a fluid supply line, an outlet providing a service flow of fluid, a vent venting to atmosphere, a lower piston, a lower diaphragm, and a mechanical valve actuator. The mechanical valve actuator includes an upper piston, an upper diaphragm, a pilot piston with a bore and a plunger, and a spring. The spring is positioned either inside the pilot piston for the normally open valve or inside the upper piston for the normally closed valve. The valves are actuated based on a control fluid entering a system pressure port and exceeding a pressure set point in order to either open or close the valve.