Self-Aligning Valve Plug for Balanced Pressure Regulators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Balanced pressure regulators face issues with contact seal alignment between the valve disc and valve seat due to manufacturing tolerances and orientation, leading to increased pressure requirements for sealing and inefficient regulator performance.
Innovation Solution
A self-aligning valve plug with a retainer connected to a valve stem via a ball joint, allowing the valve plug to automatically rotate and align with the valve seat, reducing the force needed for sealing and enhancing regulator efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional valve plug is used in a balanced pressure regulator, then the regulator can control fluid flow, but manufacturing tolerances and orientation variations cause misalignment between the valve disc and valve seat, requiring increased sealing pressure and reducing regulator efficiency
Solution Approach 1:
The valve plug is designed with a ball joint connection to the valve stem, allowing it to dynamically rotate and self-align with the valve seat during operation. This dynamic adjustment capability compensates for manufacturing tolerances and orientation variations, ensuring proper alignment without requiring excessive sealing pressure
Solution Approach 2:
The valve plug automatically aligns itself with the valve seat through the ball joint mechanism during the valve opening/closing operation. The self-aligning feature eliminates the need for precise pre-alignment during assembly and compensates for tolerance variations without external intervention, reducing the force required for sealing engagement
2Reliability
If higher sealing pressure is applied to ensure contact seal alignment, then sealing reliability improves, but the force required for lockup increases and valve disc indentation occurs
Solution Approach 1:
The ball joint connection enables the valve plug to dynamically adjust its orientation and automatically align with the valve seat during operation. This dynamic self-alignment ensures reliable sealing contact is achieved through proper geometric alignment rather than excessive force, preventing valve disc indentation while maintaining sealing reliability
3Device complexity
If the valve plug is rigidly connected to the valve stem, then the structure is simpler, but manufacturing tolerances cause misalignment and reduced regulator performance
Solution Approach 1:
The ball joint connection provides a simple yet effective dynamic mechanism that allows the valve plug to self-align with the valve seat. This relatively simple structural modification enables automatic compensation for manufacturing tolerances and orientation variations, significantly improving regulator performance efficiency without adding substantial complexity to the overall device
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 self-aligning mechanism ensures proper alignment and sealing engagement between the valve disc and valve seat, maintaining consistent outlet pressure and improving regulator performance by reducing the force required for lockup and minimizing valve disc indentation.
Implementation Method 1
A retainer is partially disposed within the bore of the self-aligning valve plug and operatively connects the self-aligning valve plug to a valve stem having a ball portion, the retainer having a recess for receiving the ball portion of the stem
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A balanced pressure regulator includes a valve body (119) having a fluid inlet (116) and a fluid outlet (118) connected by a fluid passageway. A valve seat (122) is disposed within the fluid passageway. A self-aligning valve plug (128)is at least partially disposed within the fluid passageway, the self-aligning valve plug (128) interacting with the valve seat (122) to selectively open or close the fluid passageway. A retainer (139) is partially disposed within a bore of the self-aligning valve plug (128) and operatively connects the self-aligning valve plug (128) to a valve stem (127) having a ball portion. More specifically, the retainer (139) includes a recess adapted to receive the ball portion of the valve stem (127), such that the self-aligning valve plug (128) automatically rotates around the ball portion of the valve stem (127) to achieve alignment and sealing engagement between a valve disc of the self-aligning valve plug (128) and the valve seat (122).