Needle Throttle Valve Stem Assembly for Vibration-Resistant Joining
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Solution Overview
Problem
Existing valve stems for needle throttle valves in drilling installations face issues with wear resistance, corrosion resistance, and reliability due to high-frequency vibration, as well as challenges in the fabrication process such as coating detachment and low welding reliability.
Innovation Solution
A valve stem design featuring a metal washer with solder sheets between the head and body parts, joined by medium frequency heating to ensure strong and reliable connections, with a washer providing stress relief and shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sprayed coating of hard alloy is applied on the head part, then wear resistance and corrosion resistance are improved, but the coating is easy to drop off due to high frequency vibration
Solution Approach 1:
The patent applies a composite structure consisting of a base material (head part) and a sprayed hard alloy coating layer. The coating provides wear and corrosion resistance while the base material provides structural integrity. This composite approach allows each layer to perform its optimized function, resolving the contradiction between improving surface properties and maintaining overall stability.
2Strength
If head part and body part are connected by manual welding, then joint strength can be achieved, but welding reliability is low due to large joint face making full welding difficult
Solution Approach 1:
The patent introduces a washer as an intermediate component that segments the jointing process. Instead of directly welding the head part to the body part (which requires welding a large joint face), the washer is first joined to each component separately, then assembled together. This segmentation reduces the welding area for each operation and improves overall welding reliability.
Solution Approach 2:
The washer acts as an intermediary component between the head part and body part. It facilitates the connection by providing separate, smaller welding surfaces that are easier to weld completely and reliably, then assembling these pre-welded components together. This mediator approach resolves the contradiction between achieving joint strength and maintaining welding reliability.
3Ease of manufacture
If connected parts are joined by hot charging process or connectors, then assembly can be achieved, but the connected parts are not solid and body part is easy to fall off
Solution Approach 1:
The patent replaces mechanical connection methods (hot charging process or connectors) with a welding-based joining method. By using welding to join the washer to both the head part and body part, the connection achieves solid, permanent bonding that prevents the body part from falling off, while still maintaining ease of manufacture through the segmented assembly approach.
4Reliability
If washer is added between head part and body part, then stress relief and shock absorption are improved, but device complexity increases
Solution Approach 1:
The washer serves multiple functions simultaneously: it provides stress relief, shock absorption, a bonding surface for the solder sheets, and acts as a mechanical spacer. By making this single component multi-functional, the patent improves reliability without significantly increasing device complexity, as one component performs several critical roles.
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 enhances the reliability and lifespan of the valve stem by providing strong connections, improved wear and corrosion resistance, and efficient fabrication, effectively addressing the issues of vibration and manufacturing challenges.
Implementation Method 1
heating the valve stem by a medium frequency heater to melt the first solder sheet and the second solder sheet to joint the head part, the washer and the body part together
Implementation Method 2
the head part, the washer and the body part are jointed together by the melted first solder sheet and the melted second solder sheet
Data Source
AI summary
This disclosure provides a valve stem of a needle throttle valve and the method of fabricating the same. The valve stem includes ahead part, a body part, a washer, a first solder sheet and a second solder sheet. The washer is made of metal. The first solder sheet is placed between the head part and the washer, and the second solder sheet is placed between the body part and the washer. The head part, the washer and the body part are jointed together by the melted first solder sheet and the melted second solder sheet.