Pressure Regulator Actuator Assembly for Easier In-Place Maintenance
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Solution Overview
Problem
Conventional pressure regulators in industrial processing require disassembly of multiple parts for maintenance, which is cumbersome and inefficient due to the need for multiple mounting flanges and bolts, complicating access to internal components for repair or replacement.
Innovation Solution
A regulator design featuring a single-cast valve body with an actuator assembly that includes a sleeve, pistons, and a stem, allowing for axial alignment and insertion through the valve body, enabling easy assembly and maintenance by removing the inlet fitting, thus simplifying the process of accessing internal components without the need for extensive disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional valve body with multiple mounting flanges and bolts is used, then the structural integrity and pressure containment are improved, but the ease of assembly and maintenance deteriorates due to complex disassembly requirements
Solution Approach 1:
The valve body is divided into a first body portion and a second body portion that can be separately assembled. The actuator assembly is inserted into the first body portion through the inlet, and the second body portion is then coupled to seal the flow path. This segmentation allows for easier assembly and maintenance while maintaining structural integrity through the sealing interface between the two body portions.
2Reliability
If multiple mounting flanges and bolts are used to secure the valve body, then the reliability of pressure containment is improved, but the device complexity increases
Solution Approach 1:
The mounting flange and bolt functions are integrated into a single coupling mechanism between the first and second body portions. The second body portion is coupled to the first body portion to seal the flow path, eliminating the need for separate mounting flanges and bolts while maintaining pressure containment reliability through the integrated sealing interface.
3Ease of repair
If the valve body is divided into several parts, then the ease of repair is improved by allowing component access, but the manufacturing complexity increases
Solution Approach 1:
The valve body is segmented into two main portions that can be assembled around the actuator assembly. This segmentation allows the actuator assembly to be inserted through the inlet and accessed by removing the second body portion, facilitating ease of repair while keeping the manufacturing process manageable through the two-part construction.
4Ease of manufacture
If a single-cast valve body is used, then the manufacturing simplicity is improved, but the ease of maintenance deteriorates due to difficulty in accessing internal components
Solution Approach 1:
The single-cast valve body is segmented into a first body portion and a second body portion. The actuator assembly is inserted into the first body portion through the inlet, and the second body portion is coupled to seal the flow path. This segmentation maintains the simplicity of a single-cast construction while enabling easy maintenance by allowing the second body portion to be removed for component access.
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
This design simplifies the construction, maintenance, and assembly of regulators, reducing manufacturing costs and enabling compact, efficient pressure regulation with accurate pressure sensing, while allowing for easy access and replacement of internal components, even when installed in pipelines.
Implementation Method 1
The first piston, the second piston, the first plate, and the second plate may collectively define a first chamber disposed between the first plate and the first piston, a second chamber disposed between the first piston and the second plate, a third chamber disposed between the second plate and the second piston, and a fourth chamber disposed opposite the second piston from the third chamber.
Implementation Method 2
A stem may be operatively coupled to the control element and axially aligned with the longitudinal axis. An indicator assembly may be at least partially disposed in a bore of the valve body along an indicator axis that is non-parallel with the longitudinal axis. Movement of the stem along the longitudinal axis may cause movement of a rod of the indicator assembly along or about the indicator axis to indicate a position of the control element.
Data Source
AI summary
A fluid regulator includes an actuator assembly disposed in a valve body. A sleeve includes a cylindrical wall, a first plate, and a second plate. Each of the first plate and the second plate is disposed in a cavity of the sleeve. A stem extends through the sleeve and is axially aligned with a longitudinal axis of the body, and includes a passage extending partially through the stem. The actuator assembly includes first and second pistons. First, second, third, and fourth chambers are separately disposed between the sleeve, the first or second plate, or the first or second piston. The first and third chambers are in fluid communication, and the second and fourth chambers are in fluid communication via the passage of the stem. The actuator assembly actuates a control element in response to a fluid pressure receivable in the first, second, third, and/or fourth chambers.