Additive Manufactured Valve Body with Embedded Sensors
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Solution Overview
Problem
Conventional manufacturing processes cannot produce complex geometric shapes or integrate sensors within valve body elements effectively, leading to inaccurate valve position assessments and potential interference from distant sensors.
Innovation Solution
The use of additive manufacturing processes, such as selective laser melting, to create valve body elements with embedded sensors, allowing for precise geometric control and integration of sensors within the valve body walls, enhancing position measurement accuracy and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional manufacturing processes are used, then production is simpler and more established, but complex geometric shapes cannot be produced and sensors cannot be integrated within valve body elements
Solution Approach 1:
The patent merges the valve body element manufacturing with sensor integration into a single additive manufacturing process. The sensor is embedded within the valve body element during the additive manufacturing process itself, combining what were previously separate manufacturing steps into one unified process, enabling both complex geometry and sensor integration simultaneously
2Measurement precision
If remote sensors are attached to valve ports, then valve position information can be obtained, but measurements are subject to interference and accuracy decreases
Solution Approach 1:
The patent extracts the sensor from its traditional remote position at valve ports and relocates it directly within the valve body element wall. This extraction from the harmful external environment and placement within the structural component eliminates interference from external sources while maintaining direct measurement capability of valve position
3Manufacturing precision
If additive manufacturing is used to create complex valve geometries, then geometric precision and sensor integration are improved, but the manufacturing process becomes more complex and less established
Solution Approach 1:
The patent combines multiple functions (complex geometry creation, sensor housing, sensor integration, and cable routing) into a single additive manufacturing process step. By merging these previously separate manufacturing operations into one process, the overall manufacturing complexity is managed more efficiently despite the advanced technology used
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 approach enables the production of valves with complex geometries and embedded sensors, providing accurate and reliable valve position information, reducing interference and improving measurement precision.
Implementation Method 1
The valve body element can be generated, at least partially, using an additive manufacturing process, in particular by selective laser melting
Data Source
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Figure 5a~5b
AI summary
A combination (9) comprising a valve body element (10) and a sensor (40), wherein the valve body element (10) is at least partially built up layer by layer and in one piece by an additive manufacturing process and the sensor (40) is embedded in the valve body element (10). Furthermore, a method for manufacturing them; a valve (1) comprising such combinations (9); and a set comprising two or more valve bodies (2).