Rotating Aperture Plate Valve for Low-Wear Flow Control
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Solution Overview
Problem
Industrial flow valves experience high wear and require significant energy to operate due to cycling and loads, especially in high-pressure and mass flow rate applications.
Innovation Solution
A variable flow characteristic valve design featuring a first plate with a first aperture pattern and a second plate with a second aperture pattern, where the second plate is rotated relative to the first plate to adjust the alignment between the aperture patterns, allowing for controlled fluid flow without the need for high energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug is moved by a valve stem relative to a valve seat to control flow, then flow control is achieved, but the plug is subject to high wear and significant energy consumption
Solution Approach 1:
The valve divides the flow control function into two separate plates (first plate with first aperture pattern and second plate with second aperture pattern) instead of using a single plug. Each plate can be independently controlled, distributing the mechanical stress and wear across multiple components rather than concentrating it on one plug, thereby improving reliability and reducing wear on individual parts.
Solution Approach 2:
Instead of moving a plug linearly to open/close flow paths, the invention rotates plates to align or misalign aperture patterns. This rotational motion around a fixed axis reduces the mechanical burden compared to linear plug movement, especially in high-pressure applications, thereby reducing energy consumption while maintaining flow control capability.
2Ease of operation
If a plug is moved along with the valve stem to control flow, then flow regulation is achieved, but a significant amount of energy is required especially in high pressure and mass flow rate applications
Solution Approach 1:
The valve employs rotators that can rotate the first and/or second plates dynamically to adjust the alignment between aperture patterns. This dynamic rotational adjustment allows for precise flow regulation by controlling the degree of alignment, providing ease of operation while requiring less power than moving heavy plugs against high pressure differentials.
Solution Approach 2:
The invention transitions from one-dimensional linear plug movement to two-dimensional rotational plate adjustment. By rotating plates to align or misalign aperture patterns in different angular positions, the system achieves fine flow control through angular displacement rather than linear travel, reducing the power requirement especially in high-pressure applications.
3Adaptability or versatility
If the second plate is rotated relative to the first plate to vary alignment between aperture patterns, then flow characteristic control is improved, but device complexity increases
Solution Approach 1:
The first plate and second plate with their respective aperture patterns serve multiple functions: each plate can independently control flow characteristics, and their combined alignment provides additional flow control dimension. This multi-functionality allows a single valve structure to achieve various flow characteristics without requiring multiple separate valves, balancing adaptability with structural efficiency.
Solution Approach 2:
The valve structure nests the first plate and second plate within the same housing, with one rotator system managing the rotation of plates. This nested arrangement allows the complex flow control functionality to be achieved within a compact structure, minimizing the increase in device complexity while maximizing adaptability for flow characteristic adjustment.
Data Source
AI summary
Variable flow characteristic valves are disclosed. A disclosed example valve for controlling a flow characteristic therethrough includes a first plate having a first aperture pattern, a second plate proximate the first plate, the second plate having a second aperture pattern, and a rotator to rotate the second plate relative to the first plate to vary a degree of alignment between the first and second aperture patterns.