Control Valve Flow Channels With Staged Expansion for Noise Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Control valves experience unwanted aerodynamic noise due to rapid pressure changes and turbulence in fluid flow, particularly in high-velocity compressible fluids, which existing noise reduction devices fail to address effectively due to limitations in design and fabrication processes.
Innovation Solution
The introduction of an aerodynamic noise reducing element within the valve body featuring a plurality of flow channels with staged expansion chambers, optimized geometry, and additive manufacturing techniques to minimize material usage and enhance noise reduction, allowing for precise control of fluid flow and pressure drop staging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional aerodynamic noise control devices use machined holes in domes or flow channels in ball elements, then noise reduction is achieved, but the design is limited in size and shape and fabrication is time-consuming and expensive
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional machining processes to additive manufacturing, fundamentally changing the fabrication methodology. This enables complex geometries and customized flow channel configurations that were previously impossible or prohibitively expensive to manufacture, directly resolving the contradiction between ease of manufacture and design flexibility
Solution Approach 2:
The patent utilizes composite structures by integrating the aerodynamic noise control device with the valve body or ball element through additive manufacturing. This allows for monolithic construction with internal flow channels that are optimized for noise reduction while simplifying the overall manufacturing process and reducing assembly complexity
2Productivity
If fluid flows through the valve with rapid pressure changes, then flow control is achieved, but turbulence is generated that results in unwanted noise and vibration
Solution Approach 1:
The patent applies segmentation by dividing the single flow path into multiple separate flow channels within the aerodynamic noise control device. This segmentation distributes the fluid flow across multiple pathways, reducing turbulence and preventing the generation of shock waves that cause aerodynamic noise, while still maintaining effective flow control from inlet to outlet
Solution Approach 2:
The aerodynamic noise control device acts as an intermediary element between the inlet and outlet of the valve. It mediates the fluid flow by introducing controlled expansion chambers and flow path variations that reduce pressure changes and minimize turbulence, thereby eliminating noise while preserving flow control functionality
3Object-affected harmful factors
If pressure drops are staged through multiple holes or channels, then noise is reduced, but the number and size of holes are limited
Solution Approach 1:
The patent applies parameter changes by utilizing additive manufacturing to create flow channels with varying cross-sectional areas, lengths, and configurations that are not constrained by traditional machining limitations. This enables optimization of pressure drop staging across multiple channels with greater flexibility in size, shape, and number, directly resolving the contradiction between noise reduction effectiveness and design adaptability
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 effectively reduces aerodynamic noise and turbulence by spreading energy loss over multiple flow paths, resulting in reduced material costs, weight, and increased flow capacity while maintaining efficient pressure drops, thus addressing the limitations of existing noise reduction methods.
Implementation Method 1
The plurality of flow channels includes a first flow channel and a second flow channel. The first flow channel extends along a first flow axis from an open first end to an open second end. The first flow channel includes a first fluid expansion chamber. The second flow channel extends along a second flow axis from an open first end to an open second end. The second flow channel has a second expansion chamber.
Data Source
AI summary
A control valve includes a valve body defining an inlet and an outlet. A valve closure member is also coupled to the valve body, the valve closure member being displaceable relative to the valve body between a first closed position and a second fully-open position. An aerodynamic noise reducing element is disposed within the valve body, the aerodynamic noise reducing element including a plurality of flow channels. The plurality of flow channels includes a first flow channel and a second flow channel. The first flow channel extends along a first flow axis from an open first end to an open second end. The first flow channel includes a first fluid expansion chamber. The second flow channel extends along a second flow axis from an open first end to an open second end. The second flow channel has a second expansion chamber.