3D-Printed Pressure-Regulating Valve for Faster Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pressure regulating valves require time-consuming assembly, testing, and maintenance due to factors like defects in Belleville springs and machining tolerances, necessitating multiple assembly and testing cycles to achieve desired regulated pressure.
Innovation Solution
A pressure regulating valve with a unitary valve element comprising a regulator head, adjustment head, and integrally formed helical springs, manufactured using additive manufacturing, which simplifies assembly and calibration by allowing pre-fabrication and testing of the valve element before assembly, reducing the need for lubricant and minimizing the complexity of spring arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Belleville springs are used in the pressure regulating valve, then the valve can achieve pressure regulation function, but the assembly and testing process becomes time-consuming due to defects in springs and machining tolerances
Solution Approach 1:
The patent combines the regulator head, adjustment head, and spring into a single integrally formed valve element. This merging eliminates the need for separate assembly of these components, thereby reducing assembly time and eliminating defects that could arise from separate manufacturing and assembly processes. The integral structure ensures consistent performance without requiring multiple assembly and testing cycles.
2Manufacturing precision
If multiple Belleville spring washers are used, then the desired outlet pressure can be achieved, but the valve requires disassembly and modification multiple times before appropriate regulating performance is achieved
Solution Approach 1:
The spring is pre-compressed during the additive manufacturing process itself, rather than requiring post-assembly compression and testing. The initial compression is built into the integral structure during fabrication, allowing the valve element to be produced with the correct pre-compression already in place. This eliminates the need for iterative disassembly, modification, and re-testing during maintenance and assembly.
3Ease of operation
If traditional separate components are used for regulator head, spring, and adjustment head, then assembly and maintenance is straightforward, but lubricant is required between components which impacts valve operation
Solution Approach 1:
By integrating the regulator head, adjustment head, and spring into a single valve element, the patent eliminates the interfaces between these components. This removal of interfaces eliminates the need for lubricant, thereby eliminating the harmful effects of lubricant on valve operation such as contamination, degradation, and interference with the precise mechanical action of the spring.
4Ease of repair
If separate Belleville springs are used, then the spring can be replaced during maintenance, but the entire Belleville spring set must be replaced to achieve desired regulated pressure
Solution Approach 1:
The integration of the spring with the regulator and adjustment heads creates a single valve element that maintains consistent performance throughout its service life. While the spring becomes part of the permanent structure and cannot be separately replaced, this eliminates the need to replace the entire spring set during maintenance to achieve desired pressure regulation. The single integrated element ensures consistent performance without requiring maintenance intervention for spring replacement.
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 facilitates easier and faster assembly, reduces the impact of lubricant on valve operation, and lowers production costs by enabling accurate spring force determination and consistent performance, while allowing for various spring configurations to achieve different outlet pressures.
Implementation Method 1
The at least one spring is integrally formed with and extends between the regulator head and the adjustment head
Implementation Method 2
The adjustment head, the regulator head and the at least one spring may be integrally formed by additive manufacturing
Data Source
AI summary
A pressure regulating valve comprises a valve housing comprising a pressure-regulating chamber having an inlet for high pressure fluid and an outlet for pressure-regulated fluid, and a valve element received in the pressure-regulating chamber and movable axially therein for regulating the pressure of the fluid passing from the inlet to the outlet. The valve element comprises a regulating element having a regulator head slidably and sealingly received in the valve housing, the regulating element extending into the regulating chamber, at least one spring, and an adjustment head for adjusting an initial compression of the at least one spring within the regulating chamber. The at least one spring is integrally formed with and extends between the regulator head and the adjustment head.