Talking about the Technical Innovation and Improvement of Multifunctional Valve and Hydraulic Control Valve
------------ Talk about multi-function valve and hydraulic control valve technology innovation and improvement experience Abstract: This article briefly describes the main products of Hunan Zhuzhou South Valve Co., Ltd. - multi-function pump control valve and Hydraulic control valve in the key components: the rubber diaphragm in the structural design of the improvement process, through structural innovation to produce the highest pressure level 6.4MPa diaphragm multi-function pump control valve to fill the gaps in the domestic and through The structural improvement of the old model products, for the enterprise tremendous economic and social benefits. Reflects the technological innovation is the rapid development and expansion of the scientific truth. And on the basis of the existing one, the author once again improved the rubber diaphragm and developed a multi-function water pump control valve with a higher pressure level of 10 MPa. Keywords: rubber diaphragm structure innovative assembly effort pressure level 6.4Mpa multi-function pump control valve higher pressure level 10MPa multi-function pump control valve control valve finite element analysis FLUENT software simulation simulation calculation resistance loss huge economic and social benefits Hunan Zhuzhou South Valve Co., Ltd. is the provincial science and technology hall that high-tech enterprises, but also the domestic production of hydraulic control valve leading enterprises. Multifunctional pump control valves and hydraulic control valves are the company's leading products are widely used in municipal, petrochemical, steel, mining, irrigation and other fields, the company chief editor of a number of industry standards, is the valve industry in the production of hydraulic control valve series nominal The largest diameter (DN1200), the highest nominal pressure (PN64) of the well-known enterprises. Passed the ISO9001 and ISO14001 certification, multi-function pump control valve won the "Hunan Famous Brand" title and "Hunan famous brand." Zhuzhou Southern valve hydraulic control valve overall structure of advanced, safe and reliable operation, high degree of automation, eliminating the effect of water hammer, since the market access to the user's recognition and praise, the products are sold throughout the country and exported to Europe, the Americas and Africa. As the company's production scale continues to expand and the market demand, product specifications and pressure levels are also increasing, to 2003, the production of multi-function and hydraulic control valve pressure rating reached 4.0MPa, the maximum size also reached DN1200. At this moment, the problems are constantly exposed, mainly due to the leakage of PN2.5-PN4.0Mpa on the seal of the rubber diaphragm, which is mainly reflected in the key parts of the equipment. It has been criticized by customers so that we After-sales service into a passive situation, does not break the rubber seal on the technical difficulties, to develop a higher pressure level of the hydraulic control valve is no longer possible, for which the company haunted, looking for a breakthrough in this technical bottleneck Method. Improve the situation before: 1, the rubber diaphragm structure for the disk, used in the PN1.0-PN4.0Mpa hydraulic control valve. 2, for PN25 and PN40 pressure rating, the assembly of labor-intensive, tighten the diaphragm on the bolt when you need to increase the force at the wrench sleeve. 3, the factory PN2.5MPa PN4.0MPa hydraulic control valve, the user after a period of time, the diaphragm often leaks at the location, fastening bolts still can not solve the problem, the user a headache, we are helpless. 4, after-sales service costs are high, service staff are tired of traveling around the country. In mid-2003, I accepted the development of new DN200 PN6.4Mpa multi-function pump control valve work, used for supporting the use of Shandong Gold Group Sanshima gold mine valves. At that time, no such products were available in China. According to my company's technical status at the time, do not break the technical barriers on the membrane seal, is unable to achieve the smooth delivery of the product. To overcome this technical stumbling block, I drafted several structural improvement programs, selected a simple and economical, but also safe and reliable the best program applied to the development and design of new products. After the completion of the design, we promptly invested in the production and processing of the parts. At the final assembly site, the operator reflected that the assembly was convenient and labor-saving. The utility model did not need to use the additional sleeve to fasten the connecting bolts at the diaphragm, thus greatly reducing the labor intensity . The final product factory pressure test, we strictly in accordance with the requirements of national standards, whether it is 1.5 times the intensity test or 1.1 times the seal test, under the watchful eyes, the diaphragm seal reached the ideal state drip leaks. Subsequently, we decompose the valve, carefully check each part of the diaphragm, without any abnormalities, then, we again according to the standard re-made the factory pressure test, the results of the diaphragm seal is still drip ... ... At this moment, That breaks through the technical difficulties and feel pleased that arises spontaneously, we cheered the memorable moment of the highest record on the domestic diaphragm hydraulic control valve. Improved situation: 1, the diaphragm structure on the basis of an increase of a ring seal. 2, the diaphragm seal at any pressure to achieve the size of the ideal situation is still drip. 3, greatly reducing the PN25 hydraulic control valve assembly in the labor intensity. 4, Breaking through the technical difficulties of the diaphragm leakage of the high-pressure hydraulic control valve troubling us for a long time, laying a solid foundation for the development of the hydraulic control valve of the higher pressure level. Subsequently, the company made technical improvements to the membrane structure of all the hydraulic control valves produced. Soon after, we have developed a DN650 DN150 DN250 DN300 DN350 PN6.4Mpa multi-function pump control valve, used in many large domestic enterprises, access to the user's wide acclaim. After the breakthrough in the diaphragm technology was over, we conducted technical improvements and structural optimization work on the valve body structure of our multi-purpose and hydraulic control valves in early 2006. Prior to this, some users of domestic water companies reflect our DN800 PN1.0Mpa and other specifications of the hydraulic control valve resistance loss, energy consumption to enterprises to enhance the economic benefits have an impact. In response to the user's opinion, we carefully studied the characteristics of the product, looking for the crux of the resistance loss and the best way to overcome. I use the powerful modeling function of PRO / E software to draw the 3D solid model of complex old DN400-DN1200 valve body, and use the advanced Fluent CAE software to carry on the finite element analysis and simulation simulation of the flow field. Through the observation and analysis In the flow field, the distribution of pressure distribution, velocity vector and simulation results show that the major problem of resistance loss is the crux of the problem. The valve body structure has been improved and the new DN400-DN1200 multi-purpose valve has been newly designed. Through the finite element analysis and simulation calculation of the new and old product models, it is found that under the same conditions, the resistance loss of the new product is obviously lower than that of the old one, and the velocity vector condition and pressure distribution in the flow field are obviously improved. Simulation The use of new simulation techniques has brought immediate results in optimizing our product designs. Then, the improved DN800-II multi-function valve manufactured has been applied to the existing specifications of our company with the old - a water company in Huaihua City, Hunan Province, the use of customers after the practice proved that the new resistance after the improvement of the loss in the 2m / s flow rate, from the original 1.8 m water column dropped to the current less than 1.0 m water column, greatly reducing energy consumption, when turned on the noise from the original noise to the new product, has been highly praised by users, resulting in Good social benefits, the user's economic benefits have also been significantly improved. Since then, we continue to receive a large user demand for improved new products. From May 2006 to the first half of this year, we provided 117 high-quality multi-purpose valves throughout the country only for the improved product sales of DN800 Other hydraulic control valve products, a record industrial output value of more than 10 million yuan, bringing huge economic benefits for the enterprise. At present, on the basis of DN200 PN6.4Mpa multi-function valve, I have made new innovations and improvements on the structure of rubber diaphragm and designed a multi-function water pump control valve with DN200 PN10MPa higher pressure grade. Now it has passed the technical review , Soon after production will be applied to a large coal mines in China, it will in turn create a new glory in the history of China's hydraulic control valve to further consolidate our company in the domestic hydraulic control valve technology leadership. From mid-2003 to present, in the past few years, our company used the above-mentioned diaphragm and valve body to improve the technical production of multi-function and hydraulic control valves, creating an industrial output value of 2 billion, which is widely used in various industries and large enterprises across the country. National economic development plays an important role. Technical progress has brought fruitful results for our company and also played a positive role in promoting the development of hydraulic control valve technology in our country. I deeply feel that technological innovation, the use of new technologies, the transformation of old products in many domestic enterprises Valuable, the continuous improvement of product technology to reduce energy consumption, improve product efficiency and enhance the overall grade of our valve products Has a bright future.
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