Modular Valve Apparatus and System

• US 20160239025A1
• Filed: 12/11/2015
• Published: 08/18/2016
• Est. Priority Date: 07/09/2013
• Status: Active Grant

• Current Assignee: Deka Products Limited Partnership
• Original Assignee: Deka Products Limited Partnership
• Inventors: van der Merwe, Dirk A., Moreau, Timothy D., Lanigan, Richard J., Baker, Michael A., Blumberg, David Jr.
• Granted Patent: US 10,613,553 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: F04B 43/0009 Special features
• CPC Class Codes: F04B 43/06 Pumps having fluid drive
• CPC Class Codes: F04B 49/22 by means of valves F04B49/03 takes precedence
• CPC Class Codes: F16K 11/044 with movable valve members positioned between valve seats
• CPC Class Codes: F16K 27/003 Housing formed from a plurality of the same valve elements
• CPC Class Codes: F16K 27/0263 multiple way valves
• CPC Class Codes: F16K 27/029 Electromagnetically actuated valves
• CPC Class Codes: F16K 31/003 operated without a stable intermediate position, e.g. with snap action F16K31/56 takes precedence
• CPC Class Codes: F16K 31/0606 fluid passing through the solenoid coil
• CPC Class Codes: F16K 31/0627 with movable valve member positioned between seats
• CPC Class Codes: F16K 31/0631 with ball shaped valve members
• CPC Class Codes: F16K 31/0679 with more than one energising coil
• CPC Class Codes: F16K 31/082 using a electromagnet and a permanent magnet
• CPC Class Codes: G05D 7/0635 by action on throttling means G05D7/0688, G05D7/0694 take precedence
• CPC Class Codes: G05D 7/0676 by action on flow sources G05D7/0688, G05D7/0694 take precedence

Abstract

A valved manifold module is disclosed, constructed and arranged to be readily connected in a chain with similar modules to form a manifold assembly. The modular nature of the apparatus allows for convenient expansion or modification of the manifold assembly to suit any application that comprises a group of pneumatically or hydraulically driven pumps, valves or combinations thereof in a liquid flow control apparatus. The valved manifold module in an example can be configured to accept a group of four substantially identical valve assemblies, and can be controlled by a local controller mounted to the manifold module, thus forming an independently programmable valved manifold module. The resulting modular system is readily expandable to allow for coordinated operations of a liquid flow control system, using substantially independent controller functions originating at the manifold assembly level.

Claims

1. A manifold module comprising:

a manifold base reversibly connectable to a pressure line containing pressurized fluid;

a first valve assembly mounted to the manifold base;

a controller mounted to the manifold base and connected to the valve assembly;

the manifold base configured to fluidically connect a pressure line inlet port of the manifold base to an inlet of the valve assembly, to fluidically connect a cavity of the valve assembly to a pressure sensing port of the manifold base, to fluidically connect an outlet of the valve assembly to an outlet of the manifold base, and to fluidically connect the pressure line inlet port to a pressure line outlet port of the manifold base;

the first valve assembly configured to be electrically actuated by the controller to either open or block communication between the inlet of the valve assembly and the cavity of the valve assembly, and the cavity of the valve assembly being in fluid communication with the outlet of the valve assembly;

the controller comprising a pressure sensor mounted on a control board, the pressure sensor configured to form a reversible sealed connection with the pressure sensing port of the manifold base, the control board having one or more electrical output connectors for connection to an electromagnetic coil to actuate the valve assembly, and the control board having a first electronic communications connector for sending and receiving electronic communications to or from a communications bus on a first side of the manifold module, and having a second electronic communications connector for sending and receiving electronic communications to or from the communications bus on a second side of the manifold module;

wherein the manifold module is configured to reversibly connect with a second manifold module via the first or second electronic communications connector and via the pressure line inlet port or the pressure line outlet port of the manifold base.

2. A modular manifold assembly comprising;

a plurality of concatenated manifold blocks, each manifold block having a flowpath connecting a pressure line inlet port on a first side of the manifold block to a pressure line outlet port on a second side of the manifold block via a fluidic bus in the manifold block, the pressure line outlet port of a first manifold block connected to the pressure line inlet port of an adjacent second manifold block;

the first and second manifold blocks each reversibly connected to each other, and each separately reversibly connected to a pressurized fluid line;

each manifold block having a valve assembly receiving station for mounting a pre-determined number of valve assemblies;

each valve assembly comprising an inlet configured to fluidically communicate with a respective fluidic bus port of the manifold block;

each valve assembly configured to be electrically actuated to open or block fluid communication between a cavity of the valve assembly and the inlet of the valve assembly, the cavity of each valve assembly in fluid communication with a respective outlet of the manifold block and in fluid communication with a respective pressure sensing port of the manifold block;

each valve assembly having electrical contacts for actuating the respective valve assemblies, the electrical contacts configured to connect to a programmable controller board mounted on the manifold block;

the controller board comprising pressure sensors configured to reversibly and sealably connect to respective sensing ports on the manifold block;

wherein each of the plurality of manifold blocks is tasked by its programmable controller to control one of a plurality of pumps or valves of a liquid flow control apparatus.

3. A manifold module for controlling a pneumatically actuated diaphragm pump comprising:

a manifold base reversibly connectable via a first pressure line inlet port to a first pressure line containing positively pressurized gas and a second pressure line inlet port to a second pressure line containing negatively pressurized gas;

first, second, third and fourth valve assemblies, each mounted to a valve assembly receiving station on the manifold base;

a controller mounted to the manifold base and connected to the four valve assemblies;

the manifold base configured to fluidically connect the first pressure line inlet port of the manifold base to a first inlet respectively of the first, second and third valve assemblies, to fluidically connect the second pressure line inlet port of the manifold base to a second inlet respectively of the first, second and fourth valve assemblies, to fluidically connect a cavity of each of the third and fourth valve assemblies to a respective pressure sensing port of the manifold base, to fluidically connect an outlet of each of the valve assemblies to a respective outlet of the manifold base, and to fluidically connect the first and second pressure line inlet ports of the manifold base to respective first and second pressure line outlet ports of the manifold base;

each of the first and second valve assemblies configured to be electrically actuated by the controller to establish communication between the cavity of said first or second valve assemblies and the first inlet of said first and second valve assemblies, or establish communication between the cavity of said first or second valve assemblies and the second inlet of said first and second valve assemblies;

the third valve assembly configured to be electrically actuated by the controller to open or close communication between the cavity of said third valve assembly and the first inlet of said third valve assembly;

the fourth valve assembly configured to be electrically actuated by the controller to open or close communication between the cavity of said fourth valve assembly and the second inlet of said fourth valve assembly;

wherein the first valve assembly is configured to fluidically connect to a fluid inlet valve of the diaphragm pump, the second valve assembly is configured to fluidically connect to a fluid outlet valve of the diaphragm pump, and the third and fourth valve assemblies are configured to fluidically connect to a control chamber of the diaphragm pump;

wherein the controller comprises first and second pressure sensors mounted on a control board, the pressure sensors configured to form a reversible sealed connection respectively with the pressure sensing ports of the manifold base connected to the cavities of the third and fourth valve assemblies; and

wherein the controller is configured to coordinate actuation of the four valve assemblies to open the inlet valve, close the outlet valve and generate a fill stroke in the diaphragm pump, or close the inlet valve, open the outlet valve and generate a deliver stroke in the diaphragm pump.

4. A manifold pressure measurement module comprising:

a manifold base having a first pressure line inlet port for connection to a first pressure line containing positively pressurized gas, a second pressure line inlet port for connection to a second pressure line containing negatively pressurized gas, a third inlet port for venting to atmospheric pressure; and

a fourth inlet port for connection to a control chamber of a pneumatically actuated diaphragm pump;

first, second third and fourth valve assemblies, each mounted to a valve assembly receiving station on the manifold base;

a controller mounted to the manifold base and connected to the four valve assemblies;

the manifold base configured to fluidically connect the first pressure line inlet port to a first inlet of the first valve assembly, to fluidically connect the second pressure line inlet port to a first inlet of the second valve assembly, to fluidically connect the third inlet port to a first inlet of the third valve assembly, and to fluidically connect the fourth inlet port to a first inlet of the fourth valve assembly;

the manifold base also configured to connect valve cavities of each valve assembly to respective pressure sensing ports of the manifold base, and to connect each of the valve cavities to a reference reservoir of known volume;

the first, second, third and fourth valve assemblies configured to be selectively electrically actuated by the controller to open or close communication between the cavities of said valve assemblies and the first inlets of said valve assemblies;

the controller comprising first, second, third and fourth pressure sensors mounted on a control board, the pressure sensors configured to form a reversible sealed connection respectively with the pressure sensing ports of the manifold base;

wherein the controller is configured to operate the first, second, third and fourth valve assemblies to charge the reference reservoir with positive or negative pneumatic pressure, or to open the reference reservoir to atmospheric pressure, and to fluidically connect the reference reservoir with the control chamber of the diaphragm pump to equalize pressures between the control chamber and the reference reservoir, and to record pressures in one or more valve chambers before and after pressure equalization.

5. A valve assembly comprising:

a shuttle within a valve cavity configured to move linearly from a first position blocking a first inlet of the valve cavity to a second position allowing the first inlet to fluidly communicate with the valve cavity, movement of the shuttle being actuated electromagnetically, magnetically, or through a biasing force applied by a spring;

a molded insert having an outer wall configured to conform to an inner wall of the valve cavity, and having an inner wall configured to surround the shuttle and permit the shuttle to move from the first position to the second position;

the molded insert having an inlet orifice configured to mate with the first inlet of the valve cavity and to be interposed between the first inlet of the valve cavity and a first face of the shuttle;

the molded insert having an outlet orifice configured to fluidly communicate with a fluid outlet of the valve cavity;

wherein the molded insert is manufactured from an elastomeric or plastic material that reduces acoustical noise generated by movement of the shuttle.

6. A fluid pumping system comprising:

a cassette having a flexible diaphragm;

a system controller; and

a manifold module comprising;

a manifold base reversibly connectable to a pressure line containing pressurized fluid;

a first valve assembly mounted to the manifold base;

a module controller mounted to the manifold base and connected to the valve assembly;

the manifold base configured to fluidically connect a pressure line inlet port of the manifold base to an inlet of the valve assembly, to fluidically connect a cavity of the valve assembly to a pressure sensing port of the manifold base, to fluidically connect an outlet of the valve assembly to an outlet of the manifold base, and to fluidically connect the pressure line inlet port to a pressure line outlet port of the manifold base;

the first valve assembly configured to be electrically actuated by the module controller to either open or block communication between the inlet of the valve assembly and the cavity of the valve assembly, and the cavity of the valve assembly being in fluid communication with the outlet of the valve assembly;

the module controller comprising a pressure sensor mounted on a control board, the pressure sensor configured to form a reversible sealed connection with the pressure sensing port of the manifold base, the control board having one or more electrical output connectors for connection to an electromagnetic coil to actuate the valve assembly, and the control board having a first electronic communications connector for sending and receiving electronic communications to or from a communications bus on a first side of the manifold module, and having a second electronic communications connector for sending and receiving electronic communications to or from the communications bus on a second side of the manifold module, the control board configured to receive a summary command from the system controller, the control board configured to generate, based on the summary command, at least one module command addressed to the first valve assembly, the at least one module command enabling selective application of pressure to the flexible diaphragm,

wherein the manifold module is configured to reversibly connect with a second manifold module via the first or second electronic communications connector and via the pressure line inlet port or the pressure line outlet port of the manifold base.

7. A fluid flow control system for controlling a pump cassette, the fluid flow control system comprising:

a pump cassette including a diaphragm pump having an inlet valve and an outlet valve;

a system controller;

a manifold base reversibly connectable via a first pressure line inlet port to a first pressure line containing positively pressurized gas and a second pressure line inlet port to a second pressure line containing negatively pressurized gas;

first, second, third and fourth valve assemblies, each mounted to a valve assembly receiving station on the manifold base;

an on-board controller mounted to the manifold base and connected to the four valve assemblies;

the manifold base configured to fluidically connect the first pressure line inlet port of the manifold base to a first inlet respectively of the first, second and third valve assemblies, to fluidically connect the second pressure line inlet port of the manifold base to a second inlet respectively of the first, second and fourth valve assemblies, to fluidically connect a cavity of each of the third and fourth valve assemblies to a respective pressure sensing port of the manifold base, to fluidically connect an outlet of each of the valve assemblies to a respective outlet of the manifold base, and to fluidically connect the first and second pressure line inlet ports of the manifold base to respective first and second pressure line outlet ports of the manifold base;

each of the first and second valve assemblies configured to be electrically actuated by the on-board controller to establish communication between the cavity of said first or second valve assemblies and the first inlet of said first and second valve assemblies, or establish communication between the cavity of said first or second valve assemblies and the second inlet of said first and second valve assemblies;

the third valve assembly configured to be electrically actuated by the on-board controller to open or close communication between the cavity of said third valve assembly and the first inlet of said third valve assembly;

the fourth valve assembly configured to be electrically actuated by the on-board controller to open or close communication between the cavity of said fourth valve assembly and the second inlet of said fourth valve assembly;

wherein the first valve assembly is configured to fluidically connect to the inlet valve of the diaphragm pump, the second valve assembly is configured to fluidically connect to the outlet valve of the diaphragm pump, and the third and fourth valve assemblies are configured to fluidically connect to a control chamber of the diaphragm pump;

wherein the on-board controller comprises first and second pressure sensors mounted on a control board, the pressure sensors configured to form a reversible sealed connection respectively with the pressure sensing ports of the manifold base connected to the cavities of the third and fourth valve assemblies; and

wherein the on-board controller is configured to coordinate actuation of the four valve assemblies to open the inlet valve, close the outlet valve and generate a fill stroke in the diaphragm pump, or close the inlet valve, open the outlet valve and generate a deliver stroke in the diaphragm pump, the system controller being configured to provide commands to the on-board controller including a start pumping command, a stop pumping command, or a command to pump a pre-determined quantity of liquid.