Thermostatic Valve Overload Unit Ramp Adjustment
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Solution Overview
Problem
Existing thermostatic valves require complex and space-consuming mechanisms for releasing the expansion element during cleaning or thermal disinfection, leading to increased maintenance costs and the need for recalibration of the mixing temperature.
Innovation Solution
An overload unit with a sleeve featuring a ramp on its peripheral surface, allowing for compact design and simplified adjustment, enables the thermostatic valve to be rotated and adjusted parallel to its longitudinal axis, facilitating the release and re-engagement of the expansion element for cleaning and maintaining a constant temperature without additional alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate adjustment mechanism connected in series is used to release the overload unit, then the overload unit can be released for cleaning, but the device complexity and installation space increase
Solution Approach 1:
The adjustment mechanism for releasing the overload unit is merged with the existing temperature adjustment mechanism. Both functions share the same rotational adjustment element, eliminating the need for a separate adjustment mechanism and reducing device complexity while maintaining ease of operation for both temperature calibration and cleaning release operations
2Ease of operation
If the overload unit is released by removing it completely, then the expansion element is released for cleaning, but the mixing temperature must be readjusted after cleaning
Solution Approach 1:
The adjustment mechanism is pre-configured with a memory function that automatically recalls the original temperature setting after the overload unit has been released and reinstalled. This preliminary setup eliminates the need for manual readjustment after cleaning, reducing maintenance time while maintaining ease of operation
3Manufacturing precision
If the ramp angle is shallow (5°), then the adjustment is gentle and precise, but the adjustment range is limited
Solution Approach 1:
The adjustment mechanism incorporates a dynamic ramp system where the effective ramp angle changes during the adjustment process. The mechanism transitions from a shallow ramp angle for precise initial adjustments to a steeper effective angle for covering the full adjustment range, combining precision with versatility through dynamic geometric transformation
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
The solution allows for efficient cleaning and disinfection of thermostatic valves with reduced maintenance costs and simplified temperature adjustment, ensuring operational reliability and compact design.
Implementation Method 1
a contact piece pre-tensioned in the chamber by a spring
Implementation Method 2
The thermal expansion element is surrounded by the mixed water and changes its length proportionally to the water's temperature
Data Source
Figure 1~2
Figure 3~4
AI summary
The over load unit (1) has a sleeve (3) with a chamber (4) and an attachment piece pre-stressed in the chamber by a spring (5). The sleeve has a ramp (9) with a slope angle of 5 degrees to 80 degrees at a circumferential surface. The ramp increases in the direction of a longitudinal axis (11). The ramp extends in a radial direction (12) of the sleeve orthogonal to the longitudinal axis. The ramp has an extension (13) of 1 millimeter to 5 millimeter starting from the peripheral surface (7) in the radial direction of the sleeve. An independent claim is included for a thermostat valve with an expansion element.