Additive-Manufactured Pressure Reduction Cage for Low-Noise Valves
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Solution Overview
Problem
Conventional fluid pressure reduction devices in process control systems often lead to increased noise and vibration, and are costly and inefficient to manufacture.
Innovation Solution
A fluid pressure reduction device manufactured using additive manufacturing techniques, featuring a unitary body with customizable flow paths that include inlet, curved intermediate, and outlet sections, optimized for efficient pressure reduction with minimal noise and vibration, and capable of complex designs for specific applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional flow restriction devices (stacked disks, valve cages, diffusers) are used to reduce fluid pressure, then pressure reduction is achieved, but noise and vibration levels increase
Solution Approach 1:
The flow restriction device is segmented into multiple discrete elements (flow restriction members) arranged in series within the flow path. Each member creates a localized pressure drop through restricted openings, distributing the total pressure reduction across multiple stages rather than a single abrupt restriction, thereby reducing noise and vibration generation
Solution Approach 2:
The flow restriction members extend radially outward from the central flow path into the annular space between the valve body and valve bonnet. This radial dimension provides additional space for multiple restriction members to be stacked in series, creating multi-stage pressure reduction without increasing the axial length of the valve assembly
2Stress or pressure
If conventional manufacturing methods (stacking multiple disks) are used to create flow restriction devices, then pressure reduction functionality is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
Multiple flow restriction members that would traditionally be separate stacked disks are merged into a single integrated valve cage component. The valve cage is formed as a unitary structure with multiple internal passages or recesses that house the flow restriction members, eliminating the need for separate manufacturing and assembly of multiple discrete disks
Solution Approach 2:
The valve cage serves multiple functions simultaneously: it provides the structural housing for the flow restriction members, creates the annular flow path, positions the restriction members in series, and integrates with the valve body and bonnet. This multi-functionality reduces the total number of components needed in the pressure reduction device
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 solution effectively reduces fluid pressure with reduced noise and vibration, while being easier and less costly to produce than conventional methods, enabling customizable and efficient pressure management in process control systems.
Implementation Method 1
Each of the flow paths includes an inlet section, an outlet section, and a curved intermediate section between the inlet and outlet sections
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A method of custom manufacturing a fluid pressure reduction device (300) for use in a process control valve. The method includes creating the fluid pressure reduction device using an additive manufacturing technique, which generally includes forming a body (304) and forming a plurality of flow paths (308) in the body. The body has an inner wall (220) and an outer wall (224) spaced radially outward of the inner wall. The flow paths are formed in the body between the inner wall and the outer wall of the body. Each of the flow paths includes an inlet section (312) formed in one of the inner and outer walls, a curved intermediate section (320), and an outlet section (316) formed in the other of the inner and outer walls.