Integrated Zone Valve Filtration for Stable Irrigation Pressure
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Solution Overview
Problem
Irrigation zone control assemblies in valve boxes are limited by space constraints, leading to inefficiencies, increased likelihood of leaks, and high installation costs due to separate components and multiple connection points, which can result in suboptimal flow and pressure loss.
Innovation Solution
A compact, integrated zone control device that combines a valve, filter, and pressure regulator in a single unit, with the pressure regulator positioned downstream of the filter to avoid interference from debris buildup and ensure consistent pressure regulation, facilitating easy maintenance and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If separate components (valve, filter, pressure regulator) are installed in a valve box, then each component can be independently maintained, but the valve box requires large space and has multiple connection points increasing leak likelihood
Solution Approach 1:
The patent combines the valve, filter, and pressure regulator into a single integrated zone control assembly with a common body. This merging reduces the space required in the valve box while maintaining all necessary functions. The components share a common housing and fluid passage system, eliminating the need for separate valve boxes for each component.
Solution Approach 2:
The integrated zone control assembly serves multiple functions within a single device: flow control through the valve, debris removal through the filter, and pressure regulation through the pressure regulator. This multi-functionality allows one compact unit to replace what would traditionally require multiple separate components and valve boxes.
2Ease of repair
If separate components are installed with multiple connection points, then each component can be independently maintained, but installation cost increases and likelihood of leaks increases
Solution Approach 1:
By merging the valve, filter, and pressure regulator into a single integrated assembly with a common body and shared fluid passages, the number of external connection points is reduced. This consolidation minimizes potential leak locations while maintaining the ability to independently maintain each component through dedicated access points on the integrated housing.
3Productivity
If separate components are installed in series, then each component performs its function, but flow efficiency decreases and pressure loss increases
Solution Approach 1:
The integrated design features a common body with optimized internal fluid passages that connect the valve, filter, and pressure regulator in a streamlined manner. This reduces the number of external fittings and connection points where pressure loss typically occurs, improving overall flow efficiency while maintaining all necessary zone control functions.
4Stress or pressure
If pressure regulator is installed upstream of filter, then pressure regulation occurs first, but debris buildup interferes with pressure sensing and regulation
Solution Approach 1:
Instead of placing the pressure regulator upstream of the filter as in traditional designs, this patent inverts the sequence by positioning the pressure regulator downstream of the filter. This ensures that the pressure regulator senses clean, filtered water for accurate pressure regulation while the filter protects the regulator from debris buildup that would interfere with its operation.
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 integrated device enhances space efficiency, reduces leaks and installation costs, and maintains optimal fluid flow and pressure regulation, even with clogged filters, by venting fluid downstream of the filter to ensure accurate pressure sensing and regulation.
Implementation Method 1
a pressure regulator positioned downstream of the filter to avoid interference from debris buildup and ensure consistent pressure regulation
Implementation Method 2
A filter removes the sediment and debris from the water to protect the irrigation system
Implementation Method 3
Fluid flow to the zone is controlled by the opening or closing of the valve 4
Data Source
AI summary
Zone control devices that integrate a valve, filter, and pressure regulator within a single device are provided. Specifically, the zone control devices include a main body having a base portion with an inlet passage and an outlet passage attachable to a conduit and a body portion extending from the base portion having an interior for receiving a filter. The zone control devices further include a valve bonnet including a solenoid bowl for attaching a solenoid. In some embodiments, an adapter removably couples the valve bonnet to the main body of the zone control device and forms an interface between the valve bonnet and the main body to operate the valve. The zone control devices also may include a pressure regulator in the vent flow path positioned in a vent flow path of the valve bonnet downstream of the solenoid for regulating pressure at the valve. In embodiments, the vent flow path is positioned to vent fluid into the main body downstream of the filter.