Solenoid Valve Orifice Insert for Flow Calibration
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Solution Overview
Problem
Solenoid valves require precise dimensions and tight tolerances for the orifice and seating area to ensure accurate flow rates, which increases manufacturing costs and complexity, especially in multi-cavity designs where a single error can render an entire block unusable.
Innovation Solution
Incorporating an orifice insert within the solenoid valve package, allowing for calibration of flow characteristics and use of long-life materials like stainless steel for critical components, while using cheaper materials for other components and reducing the number of threaded connections, enabling modular manufacturing and cost savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the orifice and seating area are machined with precise dimensions and tight tolerances in the receiving member, then the flow rate accuracy is improved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent divides the orifice system into separate components: an orifice plate with precisely machined orifice and seating area, and the receiving member with standard tolerances. The orifice plate is inserted into the receiving member to form the complete flow control system. This segmentation allows the critical precision work to be concentrated in a small, replaceable component rather than the entire receiving member block.
Solution Approach 2:
The critical orifice and seating area features are extracted from the receiving member and placed on a separate orifice plate. This extraction removes the requirement for precise machining of the receiving member passages, allowing the receiving member to be manufactured with standard tolerances while the orifice plate receives the specialized precision machining.
2Measurement precision
If the orifice and seating area are machined with precise dimensions and tight tolerances, then the flow rate accuracy is improved, but the device complexity increases
Solution Approach 1:
The system is segmented into modular components where the complex precision features are isolated to the orifice plate. This segmentation simplifies the manufacturing process by allowing different components to be manufactured using different processes and tolerances, then assembled together.
Solution Approach 2:
The complex orifice and seating area features are extracted from the receiving member and placed on a separate orifice plate. This extraction reduces the complexity of the receiving member manufacturing while concentrating the precision requirements in a smaller, more manageable component.
3Duration of action of stationary object
If the receiving member is made from expensive long-life materials, then the valve durability is improved, but the manufacturing cost increases
Solution Approach 1:
The patent applies local quality by using expensive, durable materials only for the orifice plate where precision and durability are critical, while the receiving member can be made from less expensive materials. This localized application of high-quality materials optimizes cost while maintaining performance where it matters most.
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 solution simplifies manufacturing by eliminating the need for precise machining of receiving member passages, reduces tooling costs, and allows for easy adjustment of flow parameters, while maintaining the longevity of the valve.
Implementation Method 1
A solenoid valve commonly comprises a solenoid assembly and a flow-controlling vessel which controls flow in response to energization of the solenoid assembly.
Data Source
AI summary
A valve flow-directing vessel (42) comprising a sleeve (44) having a threaded installation portion (84) for connection to a receiving member, a plunger (46) movable within the sleeve (44) between a closed position and an opened position, and an orifice insert (48/50) fixedly attached to the sleeve (44). The orifice insert (48/50) defines an orifice (132) that is sealed when the plunger (46) is in the closed position and unsealed when the plunger (46) is in the opened position. The orifice (132) is the entrance to a passageway (130) having an exit (134) communicating with a delivery passage of the receiving member, and this exit (134) is positioned beyond the threaded installation portion (84) of the sleeve (44).