Valve Override Gear Assembly for Actuator Failure Control
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Solution Overview
Problem
Actuators in mineral extraction systems can fail to adjust valve positions, leading to cumbersome and time-consuming operations, especially during conditions like blowouts, due to jamming or connection interruptions, preventing effective control of fluid flow.
Innovation Solution
An override system independent of the actuator, utilizing differential gears and an external override gear to adjust valve positions, allowing for independent operation of the valve assembly without disengaging the actuator, ensuring fluid flow control even when the actuator fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If an actuator is used to adjust valve positions, then the valve control is automated and efficient, but the system becomes vulnerable to actuator failure which makes adjustment cumbersome and time-consuming
Solution Approach 1:
The system is divided into two independent control paths: the automated actuator path and the manual override path. The override assembly with handwheel and gear mechanism operates independently from the actuator, allowing segmentation of functions so that failure of one path does not compromise the other.
Solution Approach 2:
The manual override mechanism is pre-configured and ready for immediate use in case of actuator failure. The gear assembly and handwheel are positioned and prepared in advance, providing a backup control method that can be activated without delay when the actuator fails.
2Reliability
If a manual override system is added to the valve assembly, then reliability during actuator failure is improved, but the device complexity increases
Solution Approach 1:
The manual override mechanism is merged with the existing actuator assembly by integrating the handwheel and gear components into the same housing structure. The override pinion gear meshes with the sector gear that also interacts with the actuator, combining both control methods in a single integrated unit.
Solution Approach 2:
The gear assembly serves dual functions: it transmits motion from the actuator during normal automated operation, and it transmits motion from the handwheel during manual override operation. This multi-functionality reduces the need for separate independent mechanisms.
3Ease of operation
If the override system requires disengaging the actuator from the gear assembly, then independent manual operation is achieved, but the operation becomes more time-consuming and complex
Solution Approach 1:
The sector gear acts as an intermediary element that receives motion from either the actuator or the handwheel pinion gear. This intermediary mechanism allows the handwheel to drive the valve stem directly through the gear teeth engagement, eliminating the need to disengage the actuator while still achieving independent manual operation.
4Ease of operation
If the actuator is disengaged from the gear assembly for manual operation, then complete manual control is achieved, but the ease of operation is reduced due to additional disengagement steps
Solution Approach 1:
Instead of disengaging the actuator from the gear assembly to enable manual operation, the design allows the handwheel to directly engage the sector gear through the pinion gear. This inverted approach eliminates the disengagement step by providing a direct mechanical path from handwheel to valve stem through gear meshing.
Data Source
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AI summary
Embodiments of the present disclosure relate to a valve assembly (10) that includes a valve (20) configured to adjust a flow of fluid through a valve body (18) of the valve assembly (10), an actuator (16) configured to drive rotation of the valve (20), a gear assembly (32) having a first planetary gear assembly (60) and a second planetary gear assembly (62), where the first planetary gear assembly (60) is coupled to the actuator (16), and where the second planetary gear assembly (62) is coupled to the valve (20), and an override assembly (50) coupled to the second planetary gear assembly (62), where the override assembly (50) is configured to drive rotation of the valve (20) independent of the actuator (16) and without disengaging the actuator (16) from the gear assembly (32).