Piston Pressure Regulator Valve with Manual Shut-Off Plate
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Solution Overview
Problem
Existing pressure control valves in firefighting and other applications face challenges in efficiently regulating pressure and providing a differential pressure for effective foam concentrate production, often relying on spring-loaded poppet valves which may not adequately manage flow control.
Innovation Solution
A pressure control valve with a piston mechanism that moves axially within a pressure chamber, allowing for manual override through a hand wheel, enabling precise control of flow by adjusting the piston's position to regulate pressure and prevent flow entirely when necessary, thereby facilitating increased engine RPM and effective foam concentrate production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring-loaded poppet valve is used for pressure regulation, then the valve can maintain reduced outlet pressure, but the flow control capability and pressure differential production are insufficient
Solution Approach 1:
The valve is segmented into multiple functional components: a piston with multiple faces for pressure regulation, a separate shut-off mechanism with a moveable plate for flow control, and a hand wheel for manual override. This segmentation allows each component to specialize in its function, with the piston handling pressure regulation and the moveable plate handling flow shut-off, resolving the contradiction between reliable pressure regulation and effective flow control.
Solution Approach 2:
The piston serves multiple functions: it acts as both the pressure sensing element and the flow control element through its multiple faces. The rear face regulates pressure while the front face can provide shut-off capability, making the single component universal and eliminating the need for separate poppet valve and regulator components.
2Ease of operation
If the piston is positioned entirely forward to contact the outlet port, then complete flow shut-off is achieved, but the pressure regulation function is lost
Solution Approach 1:
The valve functionality is divided between two independent mechanisms: the piston for pressure regulation and the moveable plate for flow shut-off. This allows the moveable plate to provide complete shut-off by blocking the outlet port entirely, while the piston remains free to regulate pressure independently, resolving the contradiction between shut-off capability and pressure regulation reliability.
Solution Approach 2:
The moveable plate acts as an intermediary shut-off mechanism that works in conjunction with the piston. It provides the complete flow blockage function that the piston cannot achieve when positioned forward, while not interfering with the piston's pressure regulation function. The hand wheel serves as a mediator to control the moveable plate's position.
3Ease of operation
If a moveable plate is brought forward by the hand wheel to reduce piston stroke, then manual override for flow control is achieved, but the device complexity increases
Solution Approach 1:
The hand wheel mechanism is merged with the existing valve body structure, and the moveable plate is integrated into the same chamber as the piston. This combining approach allows manual override functionality to be added without requiring entirely separate systems, reducing the overall complexity increase compared to adding completely independent shut-off and regulation mechanisms.
Solution Approach 2:
The moveable plate serves multiple purposes: it provides manual flow shut-off when brought forward by the hand wheel, and it can also limit the piston stroke to prevent over-opening. This multi-functionality justifies the added complexity by providing multiple control capabilities from a single component.
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 pressure control valve allows for increased engine RPM at consistent discharge pressure, effectively producing the necessary pressure differential for foam concentrate production, enhancing firefighting capabilities and providing a manual override for full or complete flow control.
Implementation Method 1
the piston moves axially within a pressure chamber as the pressure regulating component. The piston is capable of moving freely toward and away from the outlet port allowing the user to control the flow to the discharge port.
Implementation Method 2
By turning the hand wheel, a moveable plate within the pressure chamber is brought forward, and thus the available stroke of the piston is reduced.
Data Source
AI summary
A pressure regulator has a pressure chamber connected to an inlet flow area which receives liquid flow. As liquid flows into a forward chamber of the pressure chamber, pressure is exerted on the forward face of the piston, which in turn causes the piston to slide longitudinally through the pressure chamber. An internal passageway through the piston fluidically connects the forward pressure chamber and rear pressure chamber such that as the piston slides into the rear pressure chamber pressure increases at the rear pressure chamber, which in turn forces the piston to move forwardly, thus regulating flow out of the pressure chamber. A hand wheel is configured to turn a movable plate located inside the pressure chamber, with the movable plate configured to impede the piston from moving rearwardly. Pressure sensors and vents with a pressurized air source may be used to keep the pressure within a desired range.