Pressure-Balanced Valve Assembly for Compact Fluid Flow Control
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Solution Overview
Problem
Existing fluid flow control devices in industrial settings are complex, costly, and bulky, requiring significant space and maintenance, especially when regulating high mass flow rates and pressures, and often necessitate redesigning pipework for installation.
Innovation Solution
A compact fluid flow control device with a simple design featuring a valve aperture, a cylindrical mounting member, and a movably mounted valve member, utilizing a control pressure to regulate fluid flow through a control volume, which is sealed and actuated by the pressure difference between the upstream and control pressures, allowing for efficient pressure regulation without additional space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a computer controlled pressure regulator is used to regulate fluid pressure, then the desired output pressure can be delivered, but the device becomes very complicated with extensive control circuitry and valve actuation
Solution Approach 1:
The patent replaces complex electronic control circuitry and motorized valve actuation with a purely mechanical pressure balancing mechanism. The valve member responds automatically to pressure differences between upstream pressure and control volume pressure, eliminating the need for sensors, controllers, and power supplies while achieving precise pressure regulation
Solution Approach 2:
The pressure regulator is designed to be self-regulating through the automatic balance between upstream pressure acting on the valve member and control pressure acting on the piston. The system self-adjusts the valve position based on pressure conditions without external control signals, making it autonomous and eliminating complex control systems
2Measurement precision
If a pilot operated pressure regulator is used to regulate fluid pressure, then pressure control is achieved, but the device becomes large and protrudes significantly from the pipework
Solution Approach 1:
The patent nests the control volume mechanism within the valve body structure itself. The piston and control volume are integrated into the valve assembly, with the control volume formed by internal cavities and passages within the existing valve components. This eliminates the need for external protruding elements and reduces the overall device length
Solution Approach 2:
The patent combines the control volume, piston, and valve member into a single integrated assembly. The control volume is formed using existing valve body cavities, and the piston is mounted directly on the valve member. This merging of functions into unified components significantly reduces the device's external dimensions and protrusion from pipework
3Measurement precision
If a pilot operated pressure regulator with multiple moving components is used, then pressure regulation is achieved, but the device requires calibration and maintenance
Solution Approach 1:
The patent extracts and eliminates unnecessary moving components such as separate pilot valves, springs, and adjustment mechanisms. The design retains only the essential valve member and piston, both of which are simple in structure. This reduction in component count directly decreases calibration and maintenance requirements while preserving pressure regulation functionality
Solution Approach 2:
The patent discards complex adjustable mechanisms and spring-based return systems in favor of a simpler direct-acting valve member and pressure-balanced piston. The eliminated components would require calibration and maintenance, while the retained simple components are inherently more reliable and easier to service
4Productivity
If conventional pressure regulators are used for high mass flow rates, then the required flow capacity is achieved, but the device cost increases significantly
Solution Approach 1:
The patent segments the valve member into a simple cylindrical component with a hole, eliminating the need for complex machined valve bodies and multiple assembled parts. This simplified geometry is easier and cheaper to manufacture, especially for large sizes required for high flow rates, while maintaining the necessary flow capacity through the valve aperture
Solution Approach 2:
The patent inverts the conventional approach by making the valve member a simple positive-displacement element rather than a complex throttling mechanism. This inverted design with its simple cylindrical shape and hole is much easier to manufacture at large scales compared to traditional regulated valve bodies, reducing cost for high flow rate applications
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 device provides robust, reliable, and cost-effective pressure regulation with minimal space requirements, capable of handling high mass flow rates and pressures, and can be easily retrofitted into existing systems with reduced installation costs and complexity.
Implementation Method 1
the valve member is acted on by the pressure of the upstream side and the control pressure so as to be moved by the difference between these pressures
Data Source
AI summary
A device is provided for controlling the flow of a fluid through a conduit from an upstream side to a downstream side of the device. The device includes a valve aperture, a cylindrical mounting member on the downstream side of the valve aperture, a valve member on the outside of the cylindrical mounting member that moves reciprocally to open and close the valve aperture, a control volume defined between the cylindrical mounting member and the valve member, an arrangement for introducing a control pressure into the control volume, and a seal between the outer surface of the cylindrical mounting member and the inner surface of the valve member that substantially seals the control volume. The valve member is acted on by the pressure of the upstream side (P1) and the control pressure (P4) so as to be moved by the difference between these pressures.