Piston Pilot Valve Actuator for Wider Setpoints and Lower Leakage
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Solution Overview
Problem
Existing pilot valve actuators face issues with precision and remote control due to diaphragm cracking, limited range of setpoints, and significant leakage through flexible hoses, leading to inefficiencies and reliability concerns.
Innovation Solution
An actuator design featuring a piston within a housing defines an actuator chamber, where fluid pressure controls the compression of a loading spring, enabling a wider range of setpoints and improved reliability by eliminating diaphragm cracking and reducing leakage through integrated solenoid valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an actuator diaphragm is used to transmit control pressure to the loading spring, then the setpoint can be controlled, but the diaphragm is prone to cracking which reduces reliability and causes leakage
Solution Approach 1:
The patent removes the actuator diaphragm from the system entirely, replacing it with a piston that directly transmits control pressure to the loading spring. This extraction eliminates the cracking and leakage problems associated with diaphragms while maintaining the setpoint control function.
Solution Approach 2:
The patent replaces the flexible diaphragm mechanism with a rigid piston mechanism. The piston provides a more reliable mechanical connection that eliminates the harmful cracking and leakage effects while maintaining the ability to transmit control pressure for setpoint adjustment.
2Ease of operation
If a flexible hose is used to connect the control fluid source to the diaphragm, then remote control is enabled, but significant leakage and pressure loss occur
Solution Approach 1:
The patent removes the flexible hose from the control fluid path by integrating the solenoid valves directly into the housing. This extraction eliminates the leakage and pressure loss associated with flexible hoses while maintaining remote control capability through the integrated valve system.
Solution Approach 2:
The patent merges the solenoid valves with the housing structure, eliminating the need for separate flexible hose connections. This integration reduces leakage paths and pressure losses while preserving the ability to control the pilot valve remotely.
3Adaptability or versatility
If an actuator diaphragm with pin arrangement is used, then the loading spring can be compressed, but the limited travel restricts the range of setpoints
Solution Approach 1:
The patent replaces the limited-travel diaphragm-pin mechanism with a piston that has greater travel capability. The piston can move further to compress the loading spring over a wider range, enabling adjustment of a broader range of setpoints while providing more precise control.
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 piston-based actuator provides a more sensitive and reliable control of pilot valve setpoints, achieving a wider range of pressures and reducing power consumption and operational lifetime of valves, while minimizing leaks and maintaining control pressure.
Implementation Method 1
The chamber is fluidly connected to a control fluid feed that allows the fluid pressure within the chamber to be selectively controlled. The fluid pressure acts on the piston against the bias of the loading spring.
Implementation Method 2
The setpoint of the pilot valve is controlled by controlling the compression of a loading spring, which extends between a piston and an actuation member, to exert a biasing force on the actuation member.
Data Source
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AI summary
An actuator (1) for a pilot valve (26), including a housing (2), a piston (4) movably mounted in the housing (2) and an actuator chamber (20) defined between the piston (4) and the housing (2). The actuator (1) includes a control fluid feed (16) for introducing a fluid into the actuator chamber (20) to control fluid pressure, with the fluid pressure acting on the piston (4). The actuator (1) also includes an actuation member for acting on the pilot valve (26) and a loading spring (6) between the piston (4) and the actuation member. The loading spring (6) is arranged to bias the piston (4) against the fluid pressure in the actuator chamber (20). The control fluid feed (16) controls the fluid pressure so the fluid pressure acts on the piston (4) against the bias of the loading spring (6) to control the biasing force.