Splined Dump Valve Assembly for Accurate Liquid Level Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional trunnion assemblies and dump valves with D-shaped shafts and hubs suffer from accuracy and durability issues due to rotational slack, and the process of adjusting float weights is cumbersome and prone to leaks, requiring additional piping for manual bleeding which increases complexity and cost.
Innovation Solution
The use of splined connections in trunnion and dump valve assemblies for precise torque transmission, and a float weight assembly with removable ring-shaped weights that eliminate the need for drilling and reattaching the float arm, along with manual bleed-off ports integrated into the dump valve to reduce piping requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If D-shaped shafts and hubs are used in trunnion assemblies and dump valves, then the structure is simple and easy to manufacture, but rotational slack occurs leading to accuracy and durability issues
Solution Approach 1:
The connection between shaft and hub is segmented into multiple engagement points through splines. Instead of a single D-shaped interface, multiple radial splines create discrete contact zones that distribute torque and eliminate rotational play while maintaining structural integrity and manufacturability.
Solution Approach 2:
The spline profile employs asymmetric geometry with specific tooth shapes and engagement angles optimized for torque transmission. The asymmetric spline teeth engage in a way that prevents backlash while accommodating manufacturing tolerances, improving accuracy without requiring overly complex symmetric designs.
2Device complexity
If D-shaped shafts and hubs are used in dump valves, then the structure is simple, but durability issues occur due to rotational slack
Solution Approach 1:
The connection interface is divided into multiple spline segments that engage radially around the shaft. This segmentation eliminates rotational slack by creating multiple contact points that prevent play, significantly improving durability and reliability while adding only moderate complexity to the overall device structure.
3Adaptability or versatility
If float weights are adjusted by drilling and reattaching float arm, then weight adjustment is possible, but the process is cumbersome and prone to leaks
Solution Approach 1:
The float weight system is segmented into removable ring-shaped weights that can be independently added or removed from the float arm. This eliminates the need for drilling and reattaching operations, making weight adjustment simple and leak-free while maintaining full adaptability for different weight configurations.
Solution Approach 2:
The ring-shaped weights are designed to be easily removed and stored when not needed. Operators can quickly discard unnecessary weights or store them for later use, enabling rapid adjustment of float weight without permanent modifications to the float arm structure.
4Reliability
If additional piping is added for manual bleeding, then fluid leaks can be managed, but system complexity and cost increase
Solution Approach 1:
The manual bleeding function is merged directly into the dump valve body by integrating bleed-off ports into the valve structure. This eliminates the need for separate piping systems for bleeding operations, reducing system complexity and cost while maintaining reliable fluid leak management through the integrated valve design.
Data Source
AI summary
An improved mechanical dump valve for a liquid level control system. The dump valve comprises a splined shaft that communicates with the valve actuator by a toothed member, such as a splined bore in a dump valve hub. The dump valve also may include pressure ports. Still further, the present invention includes a liquid level control system comprising a trunnion assembly and a mechanical dump valve in which the trim motion of the float valve is transmitted by means of splined shafts in both the trunnion assembly and the dump valve assembly. The inventive system may comprise float weights for weighting the float accurately without having to drill the float and load it with sand or other weighting material. Also included is a kit for retrofitting existing liquid level control systems that use D-shaped connections with splined components.