Valve Actuator Rod Coupling for Low-Wear Maintenance
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Solution Overview
Problem
Existing valve actuators experience high wear during assembly and disassembly, leading to reduced switching cycles and increased downtime due to asymmetrical force transmission and complex design, which complicates maintenance and replacement.
Innovation Solution
A valve actuator design featuring a removable and connectable second coupling contour on the actuator rod, allowing for low-wear assembly and disassembly, precise force transmission, and easy replacement, with a non-self-locking gearbox facilitating manual connection and a modular prestressing assembly for quick maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the coupling contours are designed for permanent connection, then force transmission is strong, but wear during assembly and disassembly increases
Solution Approach 1:
The actuator rod is divided into two separate sections (first section in housing, second section in drive unit) that can be independently assembled and disassembled. The coupling contours on these sections enable connection during assembly and separation during disassembly, reducing wear while maintaining force transmission strength during operation.
Solution Approach 2:
The coupling contour design allows the connection state to change dynamically between locked (during operation) and separable (during maintenance). The second coupling contour is specifically designed to be removable from the first coupling contour, enabling the system to transition between connected and separated states without damage.
2Ease of repair
If the coupling contours are designed for easy separation, then maintenance is simplified, but force transmission precision decreases
Solution Approach 1:
The coupling contours feature asymmetric geometry where the second coupling contour has specific features that allow it to engage precisely with the first coupling contour. This asymmetric design ensures accurate alignment and precise force transmission during operation, while still allowing for tool-assisted separation during maintenance.
Solution Approach 2:
The coupling contours act as an intermediary mechanism between the drive unit and actuator rod sections. They provide a standardized interface that ensures precise alignment and force transmission during operation, while also enabling controlled separation during maintenance through the removable design.
3Stability of the object's composition
If the actuator rod sections are permanently connected, then alignment is maintained, but replacement time increases
Solution Approach 1:
The actuator rod is segmented into two replaceable sections with standardized coupling contours. This segmentation allows individual sections to be replaced independently without replacing the entire actuator assembly, significantly reducing replacement time while the coupling contours maintain alignment stability during operation.
Solution Approach 2:
The coupling contours are designed as universal interfaces that can accommodate different actuator rod sections while maintaining consistent alignment. This universal design allows for quick interchange of components while preserving the alignment stability required for proper operation.
4Stability of the object's composition
If the gearbox is self-locking, then position stability is improved, but manual assembly becomes difficult
Solution Approach 1:
The non-self-locking gearbox is designed to be manually positionable during the assembly process. The operator can preliminarily position the actuator rod section and gearbox together before final securing, making manual assembly possible while the gearbox maintains adequate position stability during operation.
Data Source
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AI summary
The invention relates to a valve actuator (2) for a valve which limits a flow of a process fluid, wherein the valve actuator (2) comprises: a first portion (24) of a drive rod (6) having a first coupling contour (28), which first portion is arranged in a housing (20) and so as to be movable along an advancing axis (26), and an electric-motor drive unit (30) having an axially movable second portion (34) of the drive rod (6), wherein the second portion (34) of the drive rod (6) has a second coupling contour (38).