Pre-Flexed Flow Washer Assembly for Stable Pressure Compensation
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Solution Overview
Problem
Conventional flow washer assemblies experience a spike in flow rate as inlet pressure increases, leading to inefficiencies in agricultural sprinkler systems where multiple sprinklers exceed the water pump's capacity, preventing optimal operating pressure and proper function.
Innovation Solution
A flow washer assembly with a pre-flexed elastomeric washer, facilitated by an outside diameter ring or protrusions, that maintains a dynamically changing orifice diameter to regulate flow rate, using a housing with a channel, seat, and retainer to ensure consistent fluid flow across a pressure range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the inlet pressure is increased to improve flow rate, then the flow rate increases, but the elastomeric washer deflects causing orifice diameter reduction and flow rate reduction
Solution Approach 1:
The elastomeric washer is pre-deflected during assembly by positioning it in a grooved recess that constrains its initial position. This preliminary action ensures the washer starts in a controlled state, preventing the sudden deflection and flow spike that occurs when pressure is first applied to conventional washers.
Solution Approach 2:
The invention changes the physical state of the washer from flat to pre-deflected curved shape. This parameter change in the washer's initial configuration allows it to progressively deflect under pressure without causing a sudden flow spike, thereby maintaining more stable flow characteristics across the operating pressure range.
2Reliability
If the washer is made more rigid to maintain orifice diameter, then flow rate stability improves, but the ability to dynamically regulate flow at different pressures is reduced
Solution Approach 1:
The invention uses a flexible elastomeric washer with a specific curvature that allows controlled deflection. The pre-deflected shape provides initial stability while maintaining the flexibility needed to progressively adjust the orifice diameter as pressure changes, achieving both stability and adaptability.
Solution Approach 2:
The washer is designed to dynamically adjust its orifice diameter in response to pressure changes. The pre-deflected configuration enables this dynamic regulation to occur progressively and controllably, preventing sudden spikes while maintaining the ability to adapt flow rates to different operating conditions.
3Productivity
If multiple sprinklers are operated simultaneously to increase system coverage, then the total water flow requirement increases, but the water pump cannot supply enough flow to pressurize the system
Solution Approach 1:
The pre-deflected washer configuration creates preliminary resistance to flow spikes at the onset of pressure application. This preliminary anti-action prevents the sudden surge in flow demand that would otherwise occur when multiple sprinklers are activated, allowing the pump to maintain adequate pressure and flow for the entire system.
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 pre-flexed washer assembly eliminates flow spikes by maintaining a consistent flow rate, ensuring optimal system pressure and sprinkler function by dynamically adjusting the orifice diameter in response to pressure changes.
Implementation Method 1
the inlet pressure is great enough to cause a deflection of the elastomeric washer, which in turn causes a reduction in washer orifice diameter
Implementation Method 2
the flow washer may include an outside diameter ring that is cooperable with the housing to 'pre-flex' the washer
Data Source
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AI summary
A flow washer assembly includes a housing with a channel for fluid flow, a seat positioned in the channel and including an upstream surface, and a washer press fit in the channel and engaging the upstream surface of the seat. The washer may be provided with a central opening that is sized according to predefined flow characteristics. An outside diameter of the washer at least adjacent an upstream end may be greater than an inside diameter of the channel such that the washer assumes a flexed orientation when press fit into the channel. Since the washer is pre-deflected, it will deflect further as inlet fluid pressure increases, effectively keeping the fluid flow rate relatively constant. The "pre-flexing" of the washer eliminates a spike in flow rate that occurs with conventional flow washer assemblies.