Additive Valve Flow Element With Vortex Control for Cavitation
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Solution Overview
Problem
Conventional fluid control valves experience erosion, cavitation, and noise due to high-pressure and high-velocity fluid flow, leading to unpredictable flow characteristics and excessive weight, which complicates energy management and safety.
Innovation Solution
A fluid control valve with a housing, flow control element, and valve seat featuring vortex generators and a lightweight honeycomb structure, formed via additive manufacturing, to induce vortices and reduce flow separation, noise, and weight, while maintaining strength and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional control devices are used to achieve energy loss through abrupt turns in annular stacks, then pressure drop is achieved, but flow separation occurs leading to cavitation, vibration, and noise
Solution Approach 1:
The flow control element is segmented into multiple zones with radial passageways that subdivide the fluid flow into multiple smaller streams. This segmentation prevents flow separation by distributing the flow across numerous paths rather than forcing abrupt turns in a single annular passage, thereby reducing cavitation and vibration while maintaining energy loss.
Solution Approach 2:
The radial passageways are configured with curved geometries that guide fluid flow smoothly from the inlet to the outlet. The curved paths eliminate sharp corners and abrupt direction changes, preventing flow separation and the associated harmful effects while still achieving the required pressure drop through the extended flow path.
2Loss of energy
If conventional control devices with annular stacks are used, then energy loss is achieved, but the components become heavy requiring large energy demands
Solution Approach 1:
The flow control element incorporates a porous or honeycomb-like structure with multiple radial passageways distributed throughout its body. This porous configuration achieves the required flow resistance and energy loss through the cumulative effect of numerous small passages, while using significantly less material than solid annular stacks, thereby reducing weight and operational energy demands.
3Loss of energy
If high pressure and high velocity flow are used to achieve energy loss, then pressure drop is increased, but erosion due to cavitation increases
Solution Approach 1:
The invention changes the flow parameters by subdividing high-velocity flow into multiple lower-velocity streams through radial passageways. This parameter transformation reduces the kinetic energy of individual flow streams, minimizing cavitation and erosion while maintaining the overall pressure drop required for energy loss through the cumulative resistance of multiple passages.
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 valve effectively minimizes cavitation, noise, and vibration, achieving desired energy loss and pressure drop with a lightweight, efficient design that reduces material usage and operational energy demands.
Implementation Method 1
A valve seat is positioned within the housing and includes a plurality of vortex generators which induce vortices in the fluid as the fluid flows through the valve seat
Data Source
AI summary
A valve for regulating the flow of a fluid includes a housing defining a fluid inlet and a fluid outlet. A flow control element is disposed within the housing and is configured to dissipate energy in a fluid flowing therethrough from the fluid inlet to the fluid outlet. A valve seat is positioned within the housing and includes a plurality of vortex generators which induce vortices in the fluid as the fluid flows through the valve seat. A plug is disposed within the housing and is moveable relative thereto between closed and open positions. The plug moves away from the valve seat as the plug moves from the closed position toward the open position such that fluid flow through the flow control element and the valve seat increases as the plug is moved from the closed position toward the open position.