Seal Washer Assembly for Digital Valve Controllers
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Solution Overview
Problem
In combustible and explosive gas process control applications, existing digital valve controllers face challenges in safely transmitting pressure information through compartments containing combustible gases, as conventional seal washer assemblies may not adequately prevent gas leakage or ensure explosion-proof ratings.
Innovation Solution
A digital valve controller with a seal washer assembly that includes a body and flange with specific grooves and seals, along with an electrical coupling, is designed to provide a hermetically sealed and explosion-proof conduit between the main housing and terminal box, using materials like aluminum and polyphenylene sulfide, and featuring anti-blowout features and press-fit connections to ensure reliable gas sealing and electrical communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional seal washer assemblies are used in combustible gas environments, then device simplicity is maintained, but gas leakage prevention and explosion-proof ratings are insufficient
Solution Approach 1:
The seal washer assembly is divided into multiple functional segments: a seal washer body with internal sealing, a flange with external sealing, and integrated electrical coupling. This segmentation allows each component to specialize in specific sealing functions, achieving reliable gas leakage prevention while maintaining reasonable structural complexity through modular design.
Solution Approach 2:
The electrical coupling is nested within the seal washer assembly, passing through the flange and body bore. This nesting integrates multiple functions (sealing and electrical conduction) into a single compact structure, improving reliability without proportionally increasing device complexity.
2Reliability
If multiple seals and grooves are added to the seal washer assembly, then explosion-proof ratings are improved, but manufacturing complexity increases
Solution Approach 1:
The seal washer assembly utilizes composite sealing approaches combining multiple seal materials (e.g., elastomeric seals, gaskets) with rigid structural components. The flange and body can be formed from composite or multi-material constructions that integrate sealing surfaces, reducing the need for separate sealing components and simplifying manufacturing while maintaining explosion-proof ratings.
Solution Approach 2:
The design employs specific geometric parameters (groove profiles, seal cross-sections, flange dimensions) that are optimized for both sealing performance and manufacturability. Standardized parameter sets allow for consistent quality control and simplified manufacturing processes while achieving the required explosion-proof ratings.
3Reliability
If hermetic sealing is implemented between main housing and terminal box, then gas transmission prevention is improved, but assembly complexity increases
Solution Approach 1:
The seal washer assembly merges the sealing function with the electrical coupling function into a single integrated component. The flange with its sealing surfaces and the electrical coupling passages are combined in one piece, reducing assembly complexity by eliminating separate sealing components while maintaining hermetic sealing between the main housing and terminal box.
Solution Approach 2:
The seal washer assembly serves multiple functions simultaneously: providing hermetic sealing, accommodating electrical conductors, and facilitating the connection between main housing and terminal box. This multi-functionality reduces the overall number of components needed, simplifying assembly while achieving reliable gas transmission prevention.
Data Source
AI summary
Digital valve controllers and seal washer assemblies for use with digital valve controllers include a seal washer assembly. The seal washer assembly includes a body. The body has a bore. The seal washer assembly includes a flange. The flange is coupled to the body and includes a passage, a face-seal groove, and an exterior-seal groove. The seal washer assembly includes a face seal. The face seal is disposed within the face-seal groove. The seal washer assembly includes an exterior seal. The exterior seal is disposed within the exterior-seal groove.