Stepper-Driven Refrigerant Valve for Precise Multi-Circuit Flow Control
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Solution Overview
Problem
Current refrigerant control systems lack precise control over refrigerant flow and pressure regulation in refrigeration systems, particularly in high-pressure applications, and often require multiple expansion valves and distributors, which increase complexity and cost.
Innovation Solution
A novel refrigerant control valve with a needle assembly and stepper motor-driven longitudinal needle motion controller, allowing for precise control of refrigerant flow through a single valve body, which can be used in various orientations and pressures up to 1200 psi, integrating expansion and distribution functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple expansion valves and distributors are used for precise refrigerant control, then flow control precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple expansion valves and distributors into a single integrated refrigerant control valve. The valve body contains multiple tubes with lateral openings, channels, and a needle assembly that can simultaneously control refrigerant flow to multiple evaporator circuits. This merging of previously separate components into one unified device reduces system complexity while maintaining precise flow control capabilities through the needle assembly's ability to selectively open, partially open, or close individual tube channels.
Solution Approach 2:
The single refrigerant control valve performs multiple functions that previously required separate components. The needle assembly can independently control refrigerant flow to multiple tubes, providing both expansion valve functionality and distributor functionality within one device. The valve body design with multiple lateral openings, channels, and tubes enables this multi-functional operation, allowing one valve to replace what would traditionally require multiple separate components.
2Device complexity
If a single integrated valve is used to replace multiple components, then device complexity is reduced, but control precision may deteriorate
Solution Approach 1:
The valve body is segmented into multiple independent flow paths, each associated with specific tubes and lateral openings. The needle assembly can selectively control each segment (tube channel) independently, allowing precise control of refrigerant flow to different evaporator circuits. This segmentation within the unified valve structure maintains the precision needed for controlling flow to multiple circuits while keeping the overall device simple.
Solution Approach 2:
The needle assembly provides dynamic control capability within the single valve, allowing it to adjust refrigerant flow to each tube independently by moving to different positions. The needle can be positioned to fully open, partially open, or fully close each lateral opening, enabling dynamic flow regulation that maintains precision control despite the integrated design. This dynamic adjustability ensures that control precision is not compromised by the integration of multiple functions.
3Stress or pressure
If conventional expansion valves are used for high-pressure applications, then pressure handling is insufficient, but system reliability deteriorates
Solution Approach 1:
The valve body design incorporates a robust structure capable of withstanding high pressures up to 1200 psi. The needle assembly and lateral openings are designed to maintain sealing and control functionality under high-pressure conditions. By changing the pressure handling parameters of the valve design, the system achieves reliable operation in high-pressure refrigeration applications where conventional valves would fail or perform unreliably.
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 provides precise control over refrigerant flow and pressure regulation in refrigeration systems, reducing complexity and cost by integrating multiple functions into a single valve, ensuring efficient operation across a wide range of pressures and orientations.
Implementation Method 1
The second end of the needle shaft is connected to a threaded shaft, and the threaded shaft is connected to a complementary threaded sleeve. The needle motion controller is connected to the complementary threaded sleeve to turn the sleeve in a first direction to advance the needle shaft in the needle chamber.
Implementation Method 2
A spring interposed between the first end of the cover and a first end of the sleeve urges the sleeve into its second position closing the bypass hole.
Implementation Method 3
One needle motion controller further includes a stepper motor and a speed reducer. An output on the speed reducer is connected to the threaded sleeve to rotate the sleeve selectively in smooth small increments in the first and second directions.
Data Source
AI summary
A refrigerant valve has a body with a through bore. Multiple tubes have openings aligned in a ring around a middle of the bore. The tubes lead to larger channels in the body. A needle assembly inserted through an end of the bore reciprocates a needle with a stepper motor and speed reducer to precisely control sizes of the openings. Further advancing the needle shaft after closing the openings to the tubes, engages and slides a bypass sleeve against a return spring force to open a bypass in a side of the valve body. A connector connects the bypass in a first end of the bore to outward opening holes of the channels.