Valve Superstructure With Internal Fluid Pathways for Compact Assembly
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Solution Overview
Problem
Conventional flow control devices with multi-part designs face challenges in manufacturing, assembly, cost, and space constraints due to geometric complexities and interference issues, making them cumbersome and costly to install in industrial settings.
Innovation Solution
The integration of advanced manufacturing techniques, such as additive manufacturing, to create a compact superstructure with internal flow passages that eliminate the need for external pipes, allowing for a more robust and compact design that can withstand industrial conditions and fit into smaller spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-part design is used for flow control devices, then accurate and stable flow control is achieved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple separate components (valve body, actuator housing, flow control elements) into a single integrated superstructure. This merging maintains the functional accuracy of flow control while reducing the total number of parts and simplifying assembly operations.
Solution Approach 2:
The superstructure is designed to perform multiple functions simultaneously: it houses the valve mechanism, contains flow passages, provides structural support, and integrates actuator mounting. This multi-functionality reduces the need for separate dedicated components for each function.
2Ease of operation
If external pipes and conduit are used for fluid pathways, then flow control functionality is achieved, but the working envelope and installation space requirements increase
Solution Approach 1:
The flow passages are nested within the superstructure itself, with fluid pathways integrated into the internal geometry of the valve body. This nesting eliminates the need for external piping and reduces the overall installation footprint while maintaining full flow control functionality.
Solution Approach 2:
The patent transitions from a two-dimensional arrangement where external pipes connect to the valve, to a three-dimensional integrated design where flow passages are embedded within the superstructure's volume. This dimensional integration reduces the external envelope required.
3Ease of manufacture
If conventional multi-part assembly is used, then manufacturing and assembly are straightforward, but interference issues and fit problems occur onsite
Solution Approach 1:
The superstructure is manufactured as a pre-assembled integrated unit with all flow passages and mounting features built-in during production. This preliminary integration of multiple functions into a single component eliminates onsite fit and interference problems while maintaining manufacturing efficiency through advanced manufacturing techniques.
Data Source
AI summary
A superstructure is configured for use on a flow control, like a control valve. These configurations may have internal plumbing to carry fluid between parts of the valve. In one implementation, the plumbing connects a controller with an actuator to allow a pneumatic signal from the controller to pressurize the actuator. The internal plumbing forgoes the need for external pipes or tubes. This feature can simplify the assembly, as well as reduce the overall package size of the valve to avoid potential fit or interference issues at its location on a process line.