Pinch Valve Stepper Motor Leadscrew Precision Flow Control
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Solution Overview
Problem
Existing pinch valve systems lack precise control over fluid or gas flow, particularly in applications requiring high precision and reliability, such as medical and industrial processes, where contamination and power reliability are concerns.
Innovation Solution
A pinch valve assembly utilizing a stepper motor-controlled leadscrew and piston system that allows for incremental linear movement of 0.0005 inches, enabling fine metering control and maintaining flow settings even during power failures, with a controller programmed for various modes like step and direction, flow monitoring, flow and fill, and unclog.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible hose is pinched to control flow, then contamination is reduced due to smooth unobstructed passages, but precise control over fluid or gas flow is insufficient
Solution Approach 1:
The patent replaces traditional mechanical pinch valve mechanisms with a peristaltic pumping system that uses sequential compression of flexible tubing by rollers. This substitution enables precise flow metering through controlled roller movement while maintaining the contamination benefits of flexible hose pinching, as the tubing provides smooth unobstructed passages when not being compressed.
2Measurement precision
If high precision flow control is implemented, then flow metering precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the continuous flexible tubing into segments that are sequentially compressed by multiple rollers. Each roller can be independently controlled to create discrete compression zones, enabling precise flow metering through incremental linear steps. This segmentation approach achieves high precision control while keeping individual roller mechanisms relatively simple and modular.
3Measurement precision
If incremental linear steps of 0.0005 inches are implemented, then flow metering precision is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces a leadscrew and piston mechanism as an intermediary between the motor drive and the roller compression system. The leadscrew converts rotational motion into precise linear displacement of the piston, which then actuates the rollers. This intermediary mechanism enables the achievement of 0.0005 inch incremental steps through standard precision components rather than requiring ultra-precise direct drive mechanisms.
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 system provides precise control over fluid or gas flow, ensuring consistent operation even in remote or critical applications with limited power, reducing contamination risks and enhancing reliability in industries like medical, water desalination, and food and beverage.
Implementation Method 1
an actuator assembly including a stepper motor, where the stepper motor is coupled to the controller such that the stepper motor is controlled by the controller
Implementation Method 2
a leadscrew, the leadscrew being actuated by the stepper motor such that the leadscrew travels in a plurality of incremental linear steps
Implementation Method 3
the projection of the piston and the pin are configured to pinch tubing therebetween such that flow within the tubing can be metered
Data Source
AI summary
Embodiments of a pinch valve assembly include a controller, where the controller is preprogrammed with a plurality of selectable modes including a step and direction mode, a flow monitoring mode, a flow and fill mode, and an unclog mode, and an actuator assembly, the actuator assembly being controlled by the controller, an actuator, the actuator being actuated by the actuator assembly, a piston, the piston being coupled with the actuator, a valve body, the valve body being coupled with the actuator assembly, and an aperture, the aperture being formed in the valve body, wherein the aperture is configured to retain at least a portion of tubing such that fluid or gas flow within the tubing can be metered.