Design Of Control Valve Research Articles

Flow rate adjustable ratio analysis of a novel control valve with double sleeve

Control valves are indispensable fluid control units in various industrial systems, and adjustable ratio is a crucial performance indicator of these valves. It represents the ratio between the maximum and the minimum controllable flow of the valve. And adjustable ratio stands as a significant measure of control valve regulation capability. This paper presents a novel sleeve-type control valve with a combined valve core structure composed of an inner sleeve, an outer sleeve, and a valve plug. Throttle windows and orifices are machined onto both sleeves. A dual-layer sleeve movement mechanism is realized through a gear transmission structure, allowing rotation of the inner sleeve and vertical movement of the valve plug. This design can achieve higher adjustable ratios and regulation precision. The sleeve structure design include structural parameters of the inner sleeves, outer sleeves and the shape of the throttle windows. In this study, we get the flow rates at various openings by numerical simulations. And the adjustable ratio of the valve with orifice sleeves reaches up to 695:1. Furthermore, we validate the flow regulation accuracy and maximum adjustable ratio of the combined valve core control valve by experimental methods. This work has a relevance for the design and investigation of control valves under high-pressure differential and high-flow conditions.

Numerical analysis for the thermal performance and flow separation in the vortex tube with different design of flow control valve

Numerical analysis for the thermal performance and flow separation in the vortex tube with different design of flow control valve

Detekcija udara i poboljšanje dizajna za pneumatski kontrolni ventil

The existence of shockwaves in pneumatic valves can greatly affect their efficiency and cause damage to important parts. This study focuses on the examination of a cost-effective pneumatic directional control valve with the aim of augmenting its output mass flow rate. Emphasis is placed on scrutinizing and modifying the critical flow area to facilitate increased flow rates under specific upstream pressures while eliminating the formation of shockwaves. To achieve these objectives, numerical simulations are harnessed to accurately capture the onset of shockwave formation and elucidate the associated conditions, allowing optimizing valve's capacity without introducing the risk of shockwave occurrence. The modified valve design demonstrated the capability to eliminate shockwave formation within the valve while concurrently increasing the mass flow rate by up to 70% within the same range of inlet pressures. This novel approach holds substantial promise for enhancing system response and represents a significant contribution to the field of pneumatic control valve design.

Retracted: Design of Noise-Reducing Two-Stage Cage Control Valve and Its Fluid Characteristics and Cavitation Study

Retracted: Design of Noise-Reducing Two-Stage Cage Control Valve and Its Fluid Characteristics and Cavitation Study

Study on the design of single-seat control valve with stable flow regulation and its fluid flow characteristics and thermal stress

Aiming at technical problems such as unstable flow at small openings and uneven force on the valve core, the single-seat control valve with stable flow regulation is researched and designed. The tapered surface of the outer edge of the valve core can cooperate with the valve seat when the valve core is running stably, resulting in higher flow regulation accuracy and more stable regulation. The mechanical characteristics and flow characteristics are analyzed. The fluid flow simulation analyzes the pressure, velocity, density, mass flow rate and volume flow rate of the fluid under small and large openings of the single-seat control valve. The relationship between the maximum pressure, maximum velocity, maximum density, mass flow rate and volume flow rate of the inlet and outlet with the opening are analyzed from small opening to large opening and smaller opening. The spool motion simulation analyzes the relationship between actuator driving force, unbalanced force, linear displacement, velocity and acceleration with time. The thermal stress simulation analyzes the thermal temperature, resultant heat flow, thermal stress, thermal strain and safety factor, and the material strength meets the requirements. The valve body pressure test, valve seat sealing test, full stroke and switching time test, drift and jitter test, starting deviation test, basic error and return difference test and dead zone test are carried out on the single-seat control valve. The test results all meet the requirements. The simulation results are compared and analyzed with the test results, and the simulation results are consistent with the test result.

Effect of spool posture on control valve performance considering outlet shape and large fit clearance

The control valve serves as a crucial component of the downhole integrated water distributor in water injection oilfields, enabling waterflooding into oil reservoirs. However, the control valve opening cannot be adjusted in the practical environment, resulting in ineffective injection, which means that the spool is stuck. Furthermore, it is difficult to observe the details of the spool sticking and reproduce this phenomenon during testing. To reveal the mechanism of sticking, this paper establishes a CFD model, which considers the spool posture, large fit clearance and outlet shape, to study the spool performance. Additionally, the proposed model is demonstrated experimentally and theoretically. It is found that larger fit clearances result in significant distortion of the flow characteristic curve, with a flow regulation rate of only 90.87% observed when the fit clearance is 0.25 mm. Furthermore, the lateral outlet causes a reduction of 77.27% and 69.15% in radial forces for eccentricity or inclination angles changed from 0° to 180°, respectively. Sticking is strongly correlated with radial forces, the axial force is contingent upon the spool end face area. These findings provide crucial theoretical guidance for the design of control valves.

Study on the design of control valve for U-shaped noise reduction cage and its fluid flow features and noise

In response to technical issues such as the ineffective noise reduction impact of balanced cage and single-seat control valves, the U-shaped noise reduction cage control valve is investigated and developed. In addition, its equal percentage flow properties and noise reduction impact are good, allowing it to effectively minimize the noise created by the change of fluid parameters of medium such as vapor, gas, and gas-liquid two-phase flow. The flow coefficient and flow properties were analyzed. The noise features of the medium air flow at small and large openings of 30% and 85% are simulated and analyzed, respectively. The pressure, velocity, and temperature of the inlet and outlet air, as well as the sound intensity maximum and sound power level maximum, are also analyzed with the opening curves. A small opening of 30% was selected, and the noise characteristics of cavitation generated by the medium water flow were simulated and analyzed. Together with the pressure and temperature change curves of the incoming water, the volume maxima and density minima of water are studied. The maximum sound intensity and sound power level of water are analyzed using the pressure and temperature curves of inlet water, as well as the cavitation coefficient and the degree of opening. The results of the trial for the pressure resistance of the valve body and the trial for the valve seat seal indicate that both the valve body strength and the valve seat seal meet the specifications. Comparing the noise trial results and simulation results reveals that the sound intensity and sound power level assessed by the trial and simulation are comparable, and the noise reduction impact of the control valve is positive.

Effects of throttling windows on cavitation flow of sleeve control valve

The control valve is the key equipment in nuclear power plants, which is mainly used to control the fluid flow, and essential for the safe operation of nuclear power plants. Cavitation is one of the most common phenomenon inside control valves, which will not only generate noise and vibration, but also reduce the service life of control valves. In this paper, the effects of throttling windows numbers and flow directions on the cavitation characteristics of a typical sleeve control valve are analyzed by numerical simulation. Results show that the vapor volume of 2, 4, 6, 8 throttling windows when fluid flows in the forward direction are 33.83, 39.25, 71.56, 59.34 times of the vapor volume in the backward direction respectively, which means increasing the throttling windows number can greatly reduce the vapor volume. Meanwhile, the vapor distribution is significantly different under different flow directions. The energy loss is more serious when the fluid flows in backward direction. Therefore, the erosion and abrasion of the valve body caused by the fluid impact can be reduced by changing the flow direction of the fluid from forward to backward and increasing the throttling windows number. This paper analyzes the cavitation characteristics of the control valve based on the switching conditions and discusses the mechanism of the working conditions and structural parameters on the cavitation characteristics, which is of significance for the anti-cavitation design of control valves.

Influence of the flow area around the ball valve on the flow characteristics of the injector control valve

The increase in common rail pressure can lead to increased cavitation inside the injector, resulting in degradation of injector performance and reduced life. The paper investigates the effect of the pressure block structure parameters (initial flow area around the ball valve) on the velocity field, pressure field, fuel gas phase volume fraction and drain rate of the control valve. The relationship between the initial flow area around the ball valve on the cavitation strength and unloading rate inside the valve was revealed. The results show that both the reduction of the flow area around the ball valve and the increase of the cavitation intensity inhibit the rate of oil discharge from the control valve. The reduction of the fuel flow area inhibits the expansion of the low-pressure region (0–1 MPa) within the flow layer, thus limiting the development of cavitation. The reduction of the cavitation area increases the fuel flow rate, however, the increase in flow rate increases the cavitation phenomenon, and these changes form a cycle (Reviewer 5. comment 2). The increase in cavitation inhibits the control valve pressure relief rate more significantly than the decrease in the initial flow area around the ball valve. Based on this, a stepped-pressure block model is proposed. The stepped pressure block model can effectively reduce the cavitation strength near the seal and enhance the oil discharge rate of the control valve. The study can provide a reference for the engineering optimization design of high-pressure common rail injector control valves.

Experimental and Modelling Analysis of a Downstream Compensation System: Energy Optimization of the Directional Control Valves

Through a study on the Fluid Power innovations in the last years emerged that still few solutions have been successfully implemented for the optimization of the hydraulic circuits. The recent machine electrification offers a potential for investment in energy-saving hydraulic systems to ensure greater performance and higher battery autonomy. From different studies emerged that in the specific field of ICE Off-road Vehicles, only about 10–15% of the available power at fuel level is actually transformed into useful energy for the actuators. Particularly the losses in the Directional Control Valves represent about 35–40% of the hydraulic energy available at the pump level. The traditional Directional Control Valves design solutions, in fact, neglects important opportunities for reducing losses and improving internal regeneration. Especially, energy recovery is rarely applied and in any case by means of important superstructures which considerably increase the costs of the system. This paper presents a new hydraulic architecture: an original Directional Control Valve layout based on a Downstream Compensation approach. In particular, a Flow Sharing system is implemented in this new architecture with the goal to minimize the wasted energy. In fact, this system realizes an important energy recovery from both the inertial loads and the simultaneous use of multiple actuators at different pressure level. The circuit enables recovered energy to be stored in a high-pressure accumulator. The paper presents the simulation results and the energy saving estimation realized through a lumped parameter environment “Amesim Simcenter”. Additionally, the results of experimental activities show the innovative system performance, benefits and physical applicability. This idea is based on concrete objectives and pays particular attention to cost sustainability, industrial manufacturability and system scalability.

Effects of perforated plate on hydrogen flow in L-shaped high pressure reducing valve

Pressure reducing devices are the most vital component of the on-board hydrogen supply system. A good pressure reducing system design helps to achieve long-distance and efficient driving of the hydrogen fuel cell electric vehicle. In this study, a newly L-shaped high pressure reducing valve is proposed for hydrogen decompression. Perforated plate is the most vital throttling component. However, the effects of the perforated plate on hydrogen flow in L-HPRV is not clear now. Therefore, the effects of typical perforated plate parameters as shape, row (n), orifice diameter (d), chamfer radius (r) and pressure ratio (Pi/P1) on the L-HPRV fluid dynamics are investigated. Furthermore, based on the parametric sensitivity analysis, the optimized design of the L-HPRV is achieved. Results show that the L-HPRV is well-designed for hydrogen decompression. The circle, rhombus shaped perforated plate, and the larger diameter help achieve better fluid dynamics during the hydrogen decompression process. The perforated plate numbers have a reduction effect on both the pressure and velocity gradients, while the perforated plate pressure ratio has a proportional effect. This study reveals the perforated plate effects on hydrogen flow for the first time, and provides technological support for experts to achieve throttling design of related control valves in hydrogen industry.

Design of Noise-Reducing Two-Stage Cage Control Valve and Its Fluid Characteristics and Cavitation Study

For all kinds of media noise, noise reduction valve cage cannot meet the equal percentage flow characteristics, and for manufacturing and processing and other technical problems, research and design of new noise reduction two-stage cage control valve are necessary. The valve adopts noise reduction valve cage and curve valve cage with noise reduction, forming a two-stage noise reduction, with uniform flow, diffusion, and noise reduction effect, to meet the regulating valve equal percentage flow characteristics. The spool is evenly stressed and not easy to loosen and fall off, and the small opening is not easy to vibrate and shake. The flow characteristics of the noise-reducing two-stage cage control valve are studied, and the fluid flow coefficients, flow characteristic curves, the relationship of flow coefficients with nominal diameter at the same stroke, and the relationship of flow coefficients with different nominal diameters at different strokes are analyzed. The relationship between nominal diameter constant opening and cavitation coefficient with inlet velocity, the relationship between inlet velocity and cavitation coefficient with nominal diameter at half opening, and the relationship between inlet velocity and cavitation coefficient with nominal diameter at full opening were studied, and the cavitation generation and its effect on noise were analyzed. The noise and cavitation test showed that noise is very small and cavitation is difficult to produce, all meeting the noise reduction requirements.

Solid-body disc valve with a shape memory alloy seat

The relevance of the study is due to the need to increase the technical resource and structural reliability of the disc valve by modernizing its design. Disc valve is the most promising type of shut-off and control valves for oil and gas and chemical industries. Its main problem is a small technical resource and a significant unrealized reliability potential. An increase in the technical resource and the realization of potential reliability will minimize the operating costs due to scheduled repairs, as well as the risks of downtime of production lines due to emergency shutdowns, meet the requirements of industrial safety and environmental legislation, and accelerate the introduction of shut-off and control valves of this class in production. The purpose of this study is to improve the technical life and reliability of a disc valve by modernizing the design with the use of shape memory alloys. To achieve this goal, an analysis of the strength characteristics and resulting deformations of the seat of the developed and existing designs of disc shut-off valves was carried out, the results of studies on the abrasion and cavitation resistance of the Ni – Ti alloy with shape memory effect were described, a seat model made of alloys capable of thermoelastic phase transitions, as well as the deformation behavior of the seat, which ensures installation, was demonstrated. The result of the research was the proposed design of shut-off and control valves, which, in terms of manufacturing complexity, is comparable with existing designs in labor intensity, but at the same time has a large technical resource due to the absence of an additional parting line in it, which is formed in existing designs due to the coupling of the branch pipe and case. Mounting the seat in the case groove is ensured by the peculiarity of materials with a shape memory effect, and increased performance is due to the peculiarity of the properties of alloys with the shape memory effect, in particular, pseudoelasticity, which is manifested during operation in the temperature range Af < T < Md.

Design and Simulation of Electro-hydraulic Control Valve Based on AMESim

In this paper, the electro-hydraulic control valve commonly used in ships is taken as the research object, the working principle of the valve is introduced, the model of the valve is established by AMESim software, the model parameters are set and the simulation analysis is carried out. By changing the relevant parameters of the valve, the response speed of the valve can be improved. The simulation results show that the pressure area of load sensitive cavity and the diameter of damping hole have obvious influence on the response speed of valve.

Design of control valve with low energy consumption based on Isight platform

The pressure drop of a control valve is directly associated with the energy consumption of the control system. The conventional design method of a control valve results in high energy consumption, while the control ability deviates from the design goal. Additionally, repeated corrections via flow experiments are inefficient. To efficiently design a low-energy-consumption control valve that satisfies control requirements, a novel design method is proposed herein. It is parametrically defined in Sculptor software based on the conventional valve spool. Various software packages are integrated using script files in the Isight platform. An approximate model is constructed using sample points generated based on the design of experiments; subsequently, it is solved using an optimization algorithm. Simulation results indicate that the output pressure of the pump and the average pressure drop of the control valve decrease by 4.38% and 5.51%, respectively, under the same flow rate. The working flow characteristics curve exhibits high linearity, implying that energy conservation is realized while the control ability is improved. Moreover, the force on the valve spool decrease by 1.36% on average, while the pressure and velocity in the flow field are reduced.

Cooling system based on double-ball motor control valve

To realize eco-models based on (where 3R represents reducing, reusing, and recycling), both researchers and automobile development departments use controllable components to reduce vehicle fuel consumption and emissions. In this context, this paper presents the design of a double-ball motor control valve (DB-MCV). When compared with use of a traditional thermostat, use of the proposed valve in a Worldwide Harmonized Light Vehicles Test Cycle (WLTC) allows the coolant temperature to be controlled accurately as per the vehicle operating conditions, with control accuracy of ±1°C. Using this approach, the engine pre-heating time is reduced by 61 s, the total hydrocarbon (THC)) emission is reduced by 6.79%, the CO emission is reduced by 7.18%, and NOX emission is reduced by 4.84%. Under the same vehicle and working conditions, the engine fuel consumption is reduced by 2.31% on average. Under the cabin heating condition, the cabin temperature can be increased by 4.3°C, which improves the thermal comfort of the driver. When the vehicle is stopped after running at high speed and the engine is idling, the coolant temperature in the engine decreases rapidly, which reduces the risk of a hot dip occurring in the engine.

Study of Hydrodynamic Torque of Double Offset Butterfly Valve Disc through Experiment and CFD Analysis

A butterfly valve is commonly used as control device in applications where the inlet velocity is high and the pressure drop required is relatively low. Hydrodynamic torque is a significant design parameter for engineers dealing with control valve design. Predicting the hydrodynamic torque for all opening and closing conditions in rotary valves is of utmost importance. This study sought to compare experimental and simulated computational fluid dynamics (CFD) performance factor and hydrodynamic torque of 150mm double offset butterfly disc for various opening and closing angles in the increments of 100. In general, as the flow rate increases through the valve, greater force is exerted upon the disc by the fluid. These increased dynamic forces require more torque to rotate the disc. The amount of torque required to rotate the disc during operation varies depending on type of fluid flowing through the valve, velocity, shape and position of the disc. Finally a correlation has been established between the experiment and CFD values and valve industry can make use of this data for optimum selection of gear box and actuator.

Visualization Experiment and Numerical Analysis of Cavitation Flow Characteristics in Diesel Fuel Injector Control Valve with Different Structure Design

Increasing the injection pressure has been proven an effective method to enhance performance and reduce pollutant of diesel engine. With the increase of the injection pressure, the cavitation damage problem inside common rail fuel injector is more significant, which has direct influences on reliability of diesel engine. While the most studies so far have focused on cavitation occurred in injector nozzle and its atomization characteristics, few researchers studied the cavitation phenomenon in fuel injector control valve. But due to the complexity of flow field and difficulty of experiment, the cavitation in control valve could not be fully described by existing theories. In this paper, the two-dimensional visualization experiment and numerical simulation of control valve was implemented to acquire the image of cavitation intuitively and validate the simulation method and model. Then a new structure design of control valve named convergent model was presented for comparison. The origin model and convergent model with different valve lifts were simulated in three dimensions. The results showed that the sheet cavitation occurred at the surface of seal cone and steel ball then turned to cloud cavitation in downstream area. The intensity of cavitation increased with the increase of valve lift. Convergent model could efficiently reduce the cavitation intensity near the seal area. This research could provide references for engineering optimization design of control valve.

Investigation of the Processes of Formation of Cavitation Bubbles in a New Axial Control Valve Design Featuring a Rotary Locking Device

The article presents a mathematical description of the formation process of cavitation bubbles in a new design of axial control valve fitted with a rotary locking device. The differential distribution function of the number of cavitation bubbles by size is obtained for use in calculating the main valve parameters.

Integration of TRIZ and CFD to New Product Development Process

This paper facilitates the integration of TRIZ and CFD techniques to resolve design challenges and drive innovation in flow handling equipment new product development processes. A new methodology is proposed based on an integrated product lifecycle suited for flow handling equipment product development processes. The methodology accomplishes novel design solutions by designing geometrical flow paths using recommendations from TRIZ and testing same using CFD until the desired design outcome is achieved. The efficacy of this new methodology is tested through a pilot study. Flow problem areas in a valve were visualised and tested using CFD, while TRIZ was used in detecting useful recommended solutions to the identified problems. The result of the pilot process was a novel hybrid control valve design. The new method presented in this paper can be used to manage the entire NPD process, thereby proffering innovative solutions to flow handling equipment new product development.