阅读说明：本技术 用于制造流体控制设备部件以及相关流体控制设备的方法和装置 (Method and apparatus for manufacturing fluid control device components and related fluid control devices ) 是由 T·N·加布里 于 2019-08-06 设计创作，主要内容包括：本公开内容涉及用于制造流体控制设备部件以及相关流体控制设备的方法和装置。一种制造阀部件的示例性方法包括：从用户接口设备访问对制造阀部件的第一请求,第一请求指定阀部件的第一特性；当第一特性不与第一构建文件相关联时,将第一特性与第一参考特性进行比较以确定第一特性是否满足阈值；如果第一特性不满足阈值,则提供能够在用户接口设备处访问的反馈,以将第一特性更改为第二特性,其中,第二特性满足阈值；并且当第一特性与第一构建文件相关联时或者当第一特性或第二特性满足阈值时,使用一个或多个处理器来使得增材制造机器制造阀部件。(The present disclosure relates to methods and apparatus for manufacturing fluid control device components and related fluid control devices. An exemplary method of manufacturing a valve component includes: accessing, from a user interface device, a first request to manufacture a valve component, the first request specifying a first characteristic of the valve component; when the first characteristic is not associated with the first build file, comparing the first characteristic to a first reference characteristic to determine whether the first characteristic satisfies a threshold; providing feedback accessible at the user interface device to change the first characteristic to a second characteristic if the first characteristic does not satisfy the threshold, wherein the second characteristic satisfies the threshold; and causing, using the one or more processors, an additive manufacturing machine to manufacture the valve component when the first characteristic is associated with the first build file or when the first characteristic or the second characteristic satisfies a threshold.)

1. A method of manufacturing a valve component, comprising:

accessing, using one or more processors, a first request from a user interface device to manufacture a valve component, the first request specifying a first characteristic of the valve component;

determining whether the first characteristic is associated with a first build file;

when it is determined that the first characteristic is not associated with the first build file, comparing, using the one or more processors, the first characteristic to a first reference characteristic to determine whether the first characteristic satisfies a threshold;

providing, using the one or more processors, feedback accessible at the user interface device to change the first characteristic to a second characteristic if the first characteristic does not satisfy the threshold; and

causing, using the one or more processors, an additive manufacturing machine to manufacture the valve component when the first characteristic is associated with the first build file or when the first characteristic or the second characteristic satisfies the threshold.

2. The method of claim 1, wherein when the first characteristic is altered to the second characteristic, determining whether the second characteristic is associated with the build file, and wherein when the first characteristic and the second characteristic are determined not to be associated with the first build file, altering the first build file to a second build file based on the first characteristic or the second characteristic and causing the additive manufacturing machine to manufacture the valve component based on the second build file.

3. The method of claim 2, wherein modifying the first build file to the second build file comprises using parameterized three-dimensional modeling software.

4. The method of claim 1, further comprising: causing a post-manufacturing process to be performed on the valve component based on the first build file.

5. The method of claim 4, further comprising: causing a characteristic of the valve component to be measured and comparing the measured characteristic to a second reference characteristic to determine whether the measured characteristic meets a second threshold, and wherein a first identifier is associated with the valve component when the measured characteristic meets the second threshold, and wherein a second identifier is associated with the valve component when the measured characteristic does not meet the second threshold.

6. The method of claim 1, further comprising: accessing a second valve component and causing the valve component to be incorporated into a valve assembly that includes the second valve component.

7. The method of claim 6, further comprising: providing the valve assembly to an individual or entity associated with the first request.

8. The method of claim 1, further comprising: providing the valve component to an individual or entity associated with the first request.

9. An apparatus for manufacturing a valve component, the apparatus comprising:

one or more processors;

a communication unit; and

one or more non-transitory computer-readable media coupled to the one or more processors and the communication unit, the one or more non-transitory computer-readable media storing instructions thereon, which when executed by the one or more processors, cause the one or more processors to perform the steps of:

accessing, from a user interface device, a first request to manufacture a valve component, the first request specifying a first characteristic of the valve component;

determining whether the first characteristic is associated with a first build file;

when it is determined that the first characteristic is not associated with the first build file, comparing the first characteristic to a reference characteristic to determine whether the first characteristic satisfies a threshold;

providing feedback accessible at the user interface to change the first characteristic to a second characteristic if the first characteristic does not satisfy the threshold, wherein the second characteristic satisfies the threshold; and

cause an additive manufacturing machine to manufacture the valve component when the first characteristic is associated with the first build file or when the first characteristic or the second characteristic satisfies the threshold.

10. The apparatus of claim 9, wherein when the first characteristic is altered to the second characteristic, the instructions, when executed by the one or more processors, further cause the one or more processors to determine whether the second characteristic is associated with the build file, and wherein, when it is determined that the first characteristic and the second characteristic are not associated with a first build file, the instructions, when executed by the one or more processors, further cause the one or more processors to alter the first build file to a second build file based on the first characteristic or the second characteristic, and cause the additive manufacturing machine to manufacture the valve component based on the second build file.

11. The apparatus of claim 10, wherein modifying the first build file to the second build file comprises using parameterized three-dimensional modeling software.

12. The apparatus of claim 9, wherein when the first characteristic is not associated with the first build file, the instructions, when executed by the one or more processors, further cause the one or more processors to cause a post-manufacturing process to be performed on the valve component based on the first build file.

13. The apparatus of claim 12, wherein the instructions, when executed by the one or more processors, further cause the one or more processors to perform the steps of:

causing a characteristic of the valve member to be measured;

comparing the measured characteristic to a second reference characteristic to determine whether the measured characteristic satisfies a second threshold;

associating a first identifier with the valve component when the measured characteristic satisfies the threshold; and

associating a second identifier with the valve component when the measured characteristic does not satisfy the threshold.

14. The apparatus of claim 9, wherein the instructions, when executed by the one or more processors, further cause a valve assembly including the valve member to be provided to or to an individual or entity associated with the first request.

15. One or more non-transitory computer-readable media storing instructions thereon, which when executed by one or more processors, cause the one or more processors to perform the steps of:

accessing, from a user interface device, a first request to manufacture a valve component, the first request specifying a first characteristic of the valve component;

determining whether the first characteristic is associated with a first build file;

when it is determined that the first characteristic is not associated with the first build file, comparing the first characteristic to a reference characteristic to determine whether the first characteristic satisfies a threshold;

providing feedback accessible at the user interface to change the first characteristic to a second characteristic if the first characteristic does not satisfy the threshold, wherein the second characteristic satisfies the threshold; and

cause an additive manufacturing machine to manufacture the valve component when the first characteristic is associated with the first build file or when the first characteristic or the second characteristic satisfies the threshold.

16. The one or more non-transitory computer-readable media of claim 15, wherein when the first characteristic is altered to the second characteristic, the instructions, when executed by the one or more processors, further cause the one or more processors to determine whether the second characteristic is associated with the build file, and wherein when the first characteristic and the second characteristic are not associated with the first build file, the instructions, when executed by the one or more processors, further cause the one or more processors to alter the first build file to a second build file based on the first characteristic or the second characteristic, and cause the additive manufacturing machine to manufacture the valve component based on the second build file.

17. The one or more non-transitory computer-readable media of claim 16, wherein modifying the first build file to the second build file comprises using parameterized three-dimensional modeling software.

18. The one or more non-transitory computer-readable media of claim 15, wherein when the first characteristic or the second characteristic is not associated with the first build file, the instructions, when executed by the one or more processors, cause the one or more processors to further cause a post-manufacturing process to be performed on the valve component based on the first build file.

19. The one or more non-transitory computer-readable media of claim 15, wherein the instructions, when executed by the one or more processors, further cause the one or more processors to perform the steps of:

causing a characteristic of the valve member to be measured;

comparing the measured characteristic to a reference characteristic to determine whether the measured characteristic satisfies a threshold;

associating a first identifier with the valve component when the measured characteristic satisfies the threshold; and

associating a second identifier with the valve component when the measured characteristic does not satisfy the threshold.

20. The one or more non-transitory computer-readable media of claim 15, wherein the instructions, when executed by the one or more processors, further cause a valve assembly including the valve component to be provided to or cause the valve component to be provided to an individual or entity associated with the first request.

Technical Field

This patent relates generally to fluid control device components and, more particularly, to methods and apparatus for manufacturing fluid control device components and related fluid control devices.

Background

Fluid control devices may be used to control the flow of process fluid at a process control facility. The fluid control device may be configured differently depending on the type of process in which it is implemented.

Disclosure of Invention

According to a first example, a method of manufacturing a valve component comprises: accessing, using one or more processors, a first request from a user interface device to manufacture a valve component, the first request specifying a first characteristic of the valve component; it is determined whether the first characteristic is associated with a first build file. When it is determined that the first characteristic is not associated with the first build file, comparing, using the one or more processors, the first characteristic to a first reference characteristic to determine whether the first characteristic satisfies a threshold. Providing, using the one or more processors, feedback accessible at the user interface device to change the first characteristic to a second characteristic if the first characteristic does not satisfy the threshold, wherein the second characteristic satisfies the threshold. Causing, using the one or more processors, an additive manufacturing machine to manufacture the valve component when the first characteristic is associated with the first build file or when the first characteristic or the second characteristic satisfies the threshold.

According to a second example, an apparatus for manufacturing a valve component, the apparatus comprising: one or more processors; a communication unit; and one or more non-transitory computer-readable media coupled to the one or more processors and the communication unit, the one or more non-transitory computer-readable media storing instructions thereon, which when executed by the one or more processors, cause the one or more processors to perform the steps of: accessing, from a user interface device, a first request to manufacture a valve component, the first request specifying a first characteristic of the valve component; determining whether the first characteristic is associated with a first build file; when it is determined that the first characteristic is not associated with the first build file, comparing the first characteristic to a reference characteristic to determine whether the first characteristic satisfies a threshold; providing feedback accessible at a user interface to change the first characteristic to a second characteristic if the first characteristic does not satisfy the threshold, wherein the second characteristic satisfies the threshold; and causing an additive manufacturing machine to manufacture the valve component when the first characteristic is associated with the first build file or when the first characteristic or the second characteristic satisfies the threshold.

According to a third example, one or more non-transitory computer-readable media having instructions stored thereon, which when executed by one or more processors, cause the one or more processors to perform the steps of: accessing, from a user interface device, a first request to manufacture a valve component, the first request specifying a first characteristic of the valve component; determining whether the first characteristic is associated with a first build file; when it is determined that the first characteristic is not associated with a first build file, comparing the first characteristic to a reference characteristic to determine whether the first characteristic satisfies a threshold; providing feedback accessible at a user interface to change the first characteristic to a second characteristic if the first characteristic does not satisfy the threshold, wherein the second characteristic satisfies the threshold; and causing an additive manufacturing machine to manufacture the valve component when the first characteristic is associated with the first build file or when the first characteristic or the second characteristic satisfies the threshold.

Further in accordance with the foregoing first, second, and/or third examples, the apparatus and/or method may further comprise any one or more of:

according to one example, when the first characteristic is altered to the second characteristic, determining whether the second characteristic is associated with the build file, and wherein, when it is determined that the first characteristic and the second characteristic are not associated with the first build file, altering the first build file to a second build file based on the first characteristic or the second characteristic and causing the additive manufacturing machine to manufacture the valve component based on the second build file.

According to another example, modifying the first build file to the second build file includes using parameterized three-dimensional modeling software.

According to another example, the method includes causing a post-manufacturing process to be performed on the valve component based on the first build file.

According to another example, the method comprises: causing a characteristic of the valve component to be measured and comparing the measured characteristic to a second reference characteristic to determine whether the measured characteristic meets a second threshold, and wherein a first identifier is associated with the valve component when the measured characteristic meets the second threshold, and wherein a second identifier is associated with the valve component when the measured characteristic does not meet the second threshold.

According to another example, the method includes accessing a second valve component and causing the valve component to be incorporated into a valve assembly that includes the second valve component.

According to another example, the method includes providing the valve assembly to an individual or entity associated with the first request.

According to another example, the method includes providing the valve component to an individual or entity associated with the first request.

According to another example, when the first characteristic is altered to the second characteristic, the instructions, when executed by the one or more processors, further cause the one or more processors to determine whether the second characteristic is associated with the build file, and wherein, when it is determined that the first characteristic and the second characteristic are not associated with the first build file, the instructions, when executed by the one or more processors, further cause the one or more processors to alter the first build file to a second build file based on the first characteristic or the second characteristic, and cause an additive manufacturing machine to manufacture the valve component based on the second build file.

According to another example, modifying the first build file to the second build file includes using parameterized three-dimensional modeling software.

According to another example, when the first characteristic is not associated with the first build file, the instructions, when executed by the one or more processors, further cause the one or more processors to cause a subsequent manufacturing process to be performed on the valve component based on the first build file.

According to another example, the instructions, when executed by the one or more processors, further cause the one or more processors to perform the steps of: causing a characteristic of the valve member to be measured; comparing the measured characteristic to a second reference characteristic to determine whether the measured characteristic satisfies a second threshold; associating a first identifier with the valve component when the measured characteristic satisfies the threshold; and associating a second identifier with the valve component when the measured characteristic does not satisfy the threshold.

According to another example, the instructions, when executed by the one or more processors, further cause a valve assembly including the valve member to be provided to an individual or entity associated with the first request or cause the valve member to be provided to an individual or entity associated with the first request.

According to another example, when the first characteristic is altered to the second characteristic, the instructions, when executed by the one or more processors, further cause the one or more processors to determine whether the second characteristic is associated with the build file, and wherein when the first characteristic and the second characteristic are not associated with the first build file, the instructions, when executed by the one or more processors, further cause the one or more processors to alter the first build file to a second build file based on the first characteristic or the second characteristic, and cause the additive manufacturing machine to manufacture the valve component based on the second build file.

According to another example, modifying the first build file to the second build file includes using parameterized three-dimensional modeling software.

According to another example, when the first characteristic or the second characteristic is not associated with the first build file, the instructions, when executed by the one or more processors, cause the one or more processors to further cause a post-manufacturing process to be performed on the valve component based on the first build file.

According to another example, the instructions, when executed by the one or more processors, further cause the one or more processors to perform the steps of: causing a characteristic of the valve member to be measured; comparing the measured characteristic to a reference characteristic to determine whether the measured characteristic satisfies a threshold; associating a first identifier with the valve component when the measured characteristic satisfies the threshold; and associating a second identifier with the valve component when the measured characteristic does not satisfy the threshold.

According to another example, the instructions, when executed by the one or more processors, further cause a valve assembly including the valve member to be provided to an individual or entity associated with the first request or cause the valve member to be provided to an individual or entity associated with the first request.

Drawings

FIG. 1 illustrates an exemplary system that may be used to manufacture one or more valve components in accordance with the teachings of the present disclosure.

FIG. 2 is a block diagram of an exemplary computer employed in the system of FIG. 1.

FIG. 3 is a flow chart representing an exemplary method for implementing the exemplary system of FIG. 1.

FIG. 4 is another flow chart representing another exemplary method for implementing the exemplary system of FIG. 1.

FIG. 5 is another flow chart representing another exemplary method for implementing the exemplary system of FIG. 1.

FIG. 6 illustrates an example chart for manufacturing an example valve member according to the teachings of the present disclosure.

FIG. 7 illustrates an exemplary user interface that may be displayed at an exemplary user interface device of the system of FIG. 1.

FIG. 8 illustrates another example chart for manufacturing an example valve member according to the teachings of the present disclosure.

FIG. 9 illustrates another exemplary user interface that may be displayed at an exemplary user interface device of the system of FIG. 1.

FIG. 10 illustrates another exemplary user interface that may be displayed at an exemplary user interface device of the system of FIG. 1.

FIG. 11 illustrates another example chart for manufacturing an example valve member according to the teachings of the present disclosure.

Detailed Description

Although the following text discloses a detailed description of example methods, apparatus, and/or articles of manufacture, it should be understood that the legal scope of the title is defined by the words of the claims set forth at the end of this patent. Thus, the following detailed description is to be construed as exemplary only and does not describe every possible example because describing every possible example would be impractical, if not impossible. Many alternative examples may be implemented using either current technology or technology developed after the filing date of this patent. It is anticipated that such alternative examples will still fall within the scope of the claims.

Examples disclosed herein relate to adaptive configuration processes that may be used to manufacture components for fluid control devices, such as valve bodies, valve covers, valve seat ring retainers, valve trim, Coriolis (Coriolis) meters having flow splitting fins, and/or grids used in connection with attenuating combustible media. Examples disclosed herein may be used to reduce the mass of a component while maintaining structural integrity. For example, if a first closing force is applied to the valve plug, the disclosed example may fabricate the valve plug to include a first amount of material, whereas if a second closing force is applied to the valve plug, the disclosed example may fabricate the valve plug to include a second amount of material, the second amount being less than the first amount. In some examples, the valve plug may be manufactured using a first amount of material to a first amount and a second amount of material to a second amount less than the first amount.

In examples of generating trim components for a valve, the trim components may be configured to control flow characteristics, such as, for example, equal percentage characteristics, linear characteristics, quick-opening characteristics, noise attenuation characteristics, and/or anti-cavitation characteristics. Using the examples disclosed herein, customers are able to have valve components manufactured with trim options configured for their particular process application, even when the customer requires non-standard trim options to meet their particular needs. In other words, examples disclosed herein enable customized or customized solutions to be manufactured using, for example, additive manufacturing, parametric three-dimensional (3D) modeling, example workflows, and/or example user interfaces.

To enable manufacturing of valve components according to the teachings of the present disclosure, in some examples, a customer logs into an online web application and provides data, such as characteristics of the application process and/or whether it is desired to standardize the provided trim suite (trimpackage) or a custom trim suite. The characteristics of the application process may include temperature, pressure, media, valve body type, and/or seal component type. The standardized supply of trim kits may include noise attenuating trim, anti-cavitation trim, window cage trim, and the like. When a customized trim kit is desired, in some examples, different flow value percentages may be available. For example, different flow value percentages for the valve plug travel may be applied (e.g., 10% increments). In response to the provided data, feedback may be generated and accessible by the user interface device in the form of real-time visual feedback at the 3D model of the part being designed.

To ensure that the selected trim set satisfies the engineering parameters, in some examples, a characteristic (value) associated with the trim set is compared to a reference characteristic (value) to determine whether the characteristic and the reference characteristic are within or outside of a threshold of each other, or more generally, whether the characteristic and/or the trim set to be manufactured satisfies the engineering parameters. In examples where the characteristic is within a threshold of the reference characteristic, the characteristic associated with the valve trim is approved or otherwise accepted. However, in examples where the characteristic and the reference characteristic are outside of the threshold, feedback may be generated and/or provided to the user interface device to prompt the customer to alter one or more characteristics of the valve member in order to cause a subsequent characteristic associated with the next customized trim kit to satisfy the threshold. In some such examples, the feedback may include an audible and/or visual alert indicating that the component or a portion of the component is outside of the suggested engineering parameters. For example, if the engineering parameters suggest that the part be at an angle between 40 ° and 45 ° and the design currently has an angle of 20 °, the part may be highlighted and/or some other audible and/or visual alert may be provided to prompt the user to change the angle to be within the suggested range.

To design a trim kit or another valve component as requested by a user, the associated parameter values are accessed by a parameter-driven 3D modeling program and used to modify an existing file, such as by automatically filling the values of percent flow versus percent valve travel. To enable the fabrication of customized trim suites by additive manufacturing machines, in some examples, the 3D modeling program ultimately decides the design conditions and/or generates a build file (e.g.,. stl file) that contains any modifications to existing files. The additive manufacturing machine may be a 3D printer associated with powder bed melting and/or direct energy deposition.

In some examples, after the trim set is manufactured (e.g., custom trim set, standard trim set), the machining operation is performed using a Computer Numerical Control (CNC) machine and/or the specification is verified using a Coordinate Measuring Machine (CMM), optical comparator, and/or 3D scanning process. When the specifications of the valve member meet the threshold, the valve member is used in conjunction with additional parts to manufacture a complete valve that can be provided to a customer and/or requester. Alternatively, the valve components themselves may be provided to the customer without integration into the complete valve. While the above examples relate to manufacturing an exemplary trim kit, other components may additionally or alternatively be manufactured.

FIG. 1 illustrates an exemplary system or workflow 100 that may be used to manufacture one or more valve components. In the illustrated example, the example user interface device 102 provides a user (e.g., a customer) with a user interface that enables the user to generate the request 104 to create the valve member 117. The request 104 includes characteristics provided by the user regarding the valve member 117 to be created. In some examples, the characteristic includes a temperature, a pressure, a media, a size, a shape, a type of valve body (e.g., a shut-off valve body, etc.), a type of sealing component (e.g., a valve seat, a valve plug, etc.), or more generally, a characteristic of an environment in which the fluid control device is to be used. The environment in which the control equipment is to be used may include antifouling services (dirty services), clean services, oil and gas industry, pulp and paper industry, etc. Additionally or alternatively, the characteristic may be associated with whether the component 117 is a standard component or a custom component. As described herein, the phrase "customized component" means a component having a specification that is different from the specification of a conventionally manufactured component. When a characteristic is associated with a standard component, the characteristic may be associated with noise attenuation, anti-cavitation, window cages, and the like. When a characteristic is associated with a customized component, the characteristic may include a percentage flow value that is different from the percentage flow value associated with a standard component. Of course, different values and/or different characteristics may be associated with a component depending on what component is being manufactured.

To ensure that the characteristics of the request 104 meet the engineering parameters, the request 104 is accessed by an example valve component characteristic analyzer 106 of an example computer 108. In this example, the analyzer 106 compares the user-selected component characteristics to reference characteristics stored at the example database 110 to determine whether the component characteristics and the reference characteristics satisfy a threshold. When the component characteristics do not meet the threshold, the analyzer 106 generates feedback 111 that is provided to the user by the user interface device 102. For example, the user-selected component characteristic may be an 18.5mm flow area, the reference characteristic may be a 19mm flow area, and the threshold may be 5%, in which case the user-selected component characteristic satisfies the threshold. The feedback 111 may be visual and/or audible feedback. The feedback 111 may indicate that the valve component manufactured according to the initial request 104 is not manufacturable or does not satisfy one or more of the engineering parameters. Additionally or alternatively, the feedback 111 may include suggested modifications to the initial request to enable subsequent user-selected valve member characteristics to meet the threshold.

When the initial or later selected component characteristic satisfies the threshold, in the illustrated example, computer 108 includes an example valve component designer 116, and valve component designer 116 generates build file 112 that is used by example additive manufacturing machine 114 to manufacture desired component 117. In some examples, the valve component designer 116 uses valve component characteristics in association with a parameter driven 3D modeling program to generate build file 112. In examples where valve component characteristics are associated with a customized component, the valve component designer 116 can modify a reference build file associated with a standard component using, for example, a characteristic (value) of percent flow versus percent valve travel. In other examples, valve component designer 116 accesses build file 112 from database 110.

In some examples, build file 112 enters a workflow queue to manufacture a part at additive manufacturing machine 114. In this example, build file 112 is used as a work order. To enable a user of the user interface device 102 to view the component 117 being designed, in some examples, real-time visual feedback of the 3D model generated by the valve component designer 116 is accessible by the user interface device 102. The real-time visual feedback may include a message and/or a visual alert indicating when the characteristic is outside of the suggested characteristics for the particular component. For example, one side of a designed part may become a different color when its associated characteristic does not meet the suggested reference characteristic.

To generate the valve member 117, the additive manufacturing machine 114 accesses a build file 112 that defines the dimensions and/or any other parameters and/or characteristics of the valve member 117 to be manufactured. After the additive manufacturing machine 114 manufactures the valve member 117, the example post-manufacturing machine 118 performs one or more post-manufacturing processes on the valve member 117. In some examples, the post-manufacturing process uses a plating process, a coating process (e.g., epoxy coating), a sanding process, a bead blasting process, a shot peening process, a heat treatment process, and/or a tumbling process to modify the surface of the valve member 117. Additionally or alternatively, the post-manufacturing process may include a process (subtractive machining process) of removing material from the valve component 117 using, for example, a CNC machine, drilling machine, milling machine, lathe, or the like.

In the illustrated example, the example characteristic verification machine 122 verifies specifications of an example finished valve part 120 made from the valve part 117. The property verification machine 122 may be implemented by a CMM and/or a 3D scanner, which accesses reference data from the example data 124. When the characteristic verification machine 112 is unable to verify the specifications of the completed valve component 120, because, for example, the specifications do not meet the threshold value, in this example, the example alarm 126 is configured to generate an alarm to notify an operator that the completed valve component 120 is not meeting the design specifications and/or otherwise reject the part. However, if the characteristic verification machine 122 determines that the completed valve component 120 meets design specifications, in some examples, the example valve assembler 128 accesses additional parts or components 130 (if available and/or required to do so) and assembles the parts including the completed valve component 120 into the complete valve 132. The complete valve 132 may be provided to a requester of the completed valve component 120 and/or to an individual associated with the user interface device 102. In other examples, the completed valve component 120 itself is provided to the requester of the completed valve component 120.

FIG. 2 shows a block diagram of an example of computer 108 of FIG. 1. The computer 108 may be a desktop computer (such as a traditional operator workstation, control room display) or a mobile computing device (such as a laptop, tablet, mobile device smartphone, Personal Digital Assistant (PDA), wearable computing device), or any other suitable client computing device. The computer 108 may include a display 202 and one or more cameras 204 or image sensors. The one or more cameras 204 may include a depth sensor, such as a light detection and ranging (LIDAR) or any other suitable 3D image sensor. Further, computer 108 includes one or more processors or CPUs 206, memory 208, Random Access Memory (RAM)210, input/output (I/O) circuitry 212, and a communication unit 214 for sending and receiving data via a local area network, wide area network, or any other suitable network. Computer 108 may use communication unit 214 to communicate with user interface device 102, additive manufacturing machine 114, post-manufacturing machine 118, property verification machine 122, and/or any other suitable computing device.

In the illustrated example, the memory 208 includes an operating system 216 and a control unit 218 for controlling the display 202 and communicating with the user interface device 102, the additive manufacturing machine 114, the post-manufacturing machine 118, and/or the property verification machine 122 to control the manufacturing and/or assembly processes as disclosed herein. In some examples, the control unit 218 obtains user input from the I/O circuitry 212, such as details of an application process and/or specifications of a part that a user at the user interface device 102 wants to manufacture.

In some examples, the control unit 218 implements the analyzer 106 and determines whether a characteristic (e.g., detail) of the request 104 satisfies one or more engineering parameters. In some examples, based on the analysis of the request 104, the control unit 218 implementing the analyzer 106 generates the feedback 111 based on the analysis. For example, the control unit 218 may generate feedback 111 for display at the user interface device 102 approving the design of the valve component according to the request 104, or the control unit 218 may generate feedback 111 for display at the user interface device 102 not approving the design of the valve component according to the request 104. In some examples, control unit 218 implements valve component designer 116 and generates and/or accesses build file 112 used by additive manufacturing machine 114 to generate valve component designer 116.

Fig. 3, 4, and 5 depict flowcharts representative of example methods 300, 400, 500 that may be used to implement the example system 100 of fig. 1. The methods 300, 400, 500 may be performed by one or more of the user interface device 102, the analyzer 106, the computer 108, the valve component designer 116, the additive manufacturing machine 114, the post-manufacturing machine 118, the property verification machine 122, the valve assembler 128, the control unit 218, and/or by any other computing device. Although the methods 300, 400, 500 are described in a particular order, the order in which the blocks are performed may be altered and/or one or more of the blocks may be altered, divided, eliminated, or combined. Further, although the processes disclosed below are described in connection with an automated process, any and/or all of the processes disclosed may alternatively be implemented manually.

Fig. 3 illustrates a method 300 that may be performed to implement at least a portion of the system 100 of fig. 1. In some examples, one or more aspects of method 300 represent computer readable instructions that may be executed to implement system 100 of fig. 1. The method 300 begins with the analyzer 106 accessing a request 104 from a user interface device 102 to manufacture a valve component having a particular characteristic (block 302). The characteristics may, for example, include the desired size of the valve components. The computer 108 determines whether there is additional data available from the user interface device 102 (block 304). In some examples, the available additional data may include characteristics of the environment in which the valve component is to be used, provided at the user interface device 102. If there is additional data available, the analyzer 106 accesses the data (block 306).

After the analyzer 106 accesses the data and/or request 104 from the user interface device 102, the computer 108 determines whether the valve component is custom configured (block 308). In some examples, the valve components are custom configured when the requested characteristics (e.g., values, dimensions) are different than the characteristics (e.g., values, dimensions) of the valve components that are typically manufactured and/or have existing build files available for use by the additive manufacturing machine 114. If the computer 108 determines that the valve components are custom configured, the analyzer 106 compares the characteristics (e.g., dimensions) to reference characteristics stored at the database 110 (block 310). At block 312, the analyzer 106 determines whether the characteristic associated with the request 104 and the reference characteristic stored at the database 110 are within a threshold of each other.

If the characteristics of the request 104 are not within the threshold, the analyzer 106 generates feedback 111 that is accessible by the user interface device 102 (block 314). In some examples, the user interface device 102 prompts a user of the user interface device 102 to alter the request or the associated characteristic of the valve component so that the subsequent characteristic is within a threshold. Feedback 111 may be in the form of an indicator on a 3D presentation generated by valve unit designer 116 and displayed at user interface device 102. If the characteristics of the request 104 are within the thresholds, the valve component designer 116 designs the valve component according to the characteristics associated with the request 104 (block 316), and the valve component designer 116 generates and/or accesses a build file 112 for manufacturing the valve component 117 (block 318). In some examples, the designed valve member 117 is a standardized valve member, while in other examples, the designed valve member 117 is a customized valve member. In examples where the valve unit 117 is a standard valve unit, the valve unit designer 116 can access build files 112 associated with the standard valve unit from the database 110.

The computer 108 causes the additive manufacturing machine 114 to manufacture the valve member 117 based on the build file 112 (block 320), and the post-manufacturing machine performs one or more post-manufacturing processes on the valve member 117 to manufacture the completed valve member 120 (block 322). In some examples, one or more of the post-manufacturing processes are performed without physically moving the valve member 117 from the first position or machine to the second position or machine. In other words, the additive manufacturing process and the post-manufacturing process may be performed at the same location and/or using the same machine. However, in other examples, one or more of the post-manufacturing processes may be performed at a location different from the location at which the additive manufacturing process is performed.

The finished valve component 120 is measured and/or tested using the characteristic verification machine 122 to analyze characteristics (e.g., specifications) of the finished valve component 120 (block 324). The characteristic verification machine 122 compares the determined characteristic of the completed valve component 120 to the reference characteristic accessed from the database 124 (block 326), and then determines whether the characteristic of the completed valve component 120 and the reference characteristic are within a threshold value (block 328). If the measured characteristic does not satisfy the threshold, the characteristic verification machine 122 and/or the alarm 126 associates the completed valve component 120 with not having a characteristic that satisfies the reference characteristic (block 330) and/or the alarm 126 generates an alarm to notify an operator that the completed valve component 120 does not satisfy the design characteristic. However, if the measured characteristic satisfies the threshold value of the reference characteristic, the characteristic verification machine 122 and/or the alarm 126 associates the completed valve component 120 with having a characteristic that satisfies the reference characteristic (block 332) and/or the alarm 126 generates an alarm to notify an operator that the completed valve component 120 satisfies the design characteristic. In some examples, the completed valve component 120 is associated with meeting and/or not meeting design characteristics by associating an identifier with the part being manufactured and/or the part number.

Fig. 4 illustrates a method 400 that may be performed to implement at least a portion of the system 100 of fig. 1. In some examples, one or more aspects of method 400 represent computer readable instructions that may be executed to implement system 100 of fig. 1. The method 400 begins with the valve assembler 128 accessing the completed valve component 120 (block 402). The valve assembler 128 determines whether there are additional parts 130 to be used to assemble the complete valve 132 (block 404).

If the completed valve component 120 is to be used to assemble a complete valve 132, the valve assembler 128 accesses additional valve components 130 (block 406) and manufactures the complete valve 132 using the components 120, 130 (block 408). In some examples, additional valve components 130 include a valve body, a bonnet, a stem, an actuator, and/or a valve controller. At block 410, the complete valve 132 and/or valve component 120 is provided to an individual and/or entity associated with the user interface device 102 (block 410). In some examples, the completed valve component 120 is a valve trim component, and the additional components 130 include a valve body, a bonnet, a stem, an actuator, and the like.

Fig. 5 illustrates a method 500 that may be performed to implement at least a portion of the system 100 of fig. 1. In some examples, one or more aspects of method 500 represent computer readable instructions that may be executed to implement system 100 of fig. 1. The method 500 begins with the analyzer 106 accessing a first request from the user interface device 102 to manufacture a valve component (block 502). The first request includes, for example, a first characteristic (e.g., size). The analyzer 106 compares the first characteristic to characteristics associated with a reference build file (e.g., a first build file) (block 504) to determine whether the first characteristic and the requested valve component, and more generally, a standard valve component, are associated (block 506). When it is determined that the first characteristic is not associated with the reference build file, and thus the requested valve component is not associated with a standard valve component, the analyzer 106 compares the first characteristic to a first reference characteristic (block 508) to determine whether the first characteristic and the reference characteristic satisfy a threshold (block 510).

If the first characteristic does not satisfy the threshold, the analyzer 106 provides feedback 111 accessible at the user interface device 102 to change the first characteristic to a second characteristic, wherein the second characteristic satisfies the threshold (block 512). When the first characteristic or the second characteristic is not associated with a first one of the reference build files but satisfies the threshold, the valve component designer 116 modifies the first build file to a second build file based on the first characteristic or the second characteristic (block 514). In some examples, modifying the first build file to the second build file includes using parameterized three-dimensional modeling software.

When the first characteristic is associated with the first build file or when the first characteristic or the second characteristic satisfies a threshold, the computer 108 causes the additive manufacturing machine 114 to manufacture the valve member 117 (block 516). The computer 108 causes the post-manufacturing machine 118 to perform a post-manufacturing process on the valve component 117 based on the build file 112 (block 518). The computer 108 causes the characteristic verification machine 122 to measure a characteristic of the valve member 117 (block 520) and compare the measured characteristic to a reference characteristic (block 522) to determine whether the measured characteristic satisfies a threshold (block 524).

When the measured characteristic satisfies the threshold value of the reference characteristic, the characteristic verification machine 122 and/or the alarm 126 associates the completed valve component 120 with a first identifier indicating that the measured valve component 120 is approved (block 526). When the measured characteristic does not satisfy the threshold value for the reference characteristic, the characteristic verification machine 122 and/or the alarm 126 associates the completed valve component 120 with a second identifier indicating that the valve component is not approved (block 528). The computer 108 determines whether to access the second valve component 130 (block 530), e.g., for assembly with the completed valve component 120. If the second valve component 130 is to be accessed, the computer 108 causes the valve assembler 128 to access the second valve component 130 (block 532) and cause the completed valve component 120 to be incorporated into the valve 132 that includes the second valve component 130 (block 534). The valve 132 or completed valve component 120 is provided to the individual or entity associated with the first request 104 (block 536).

Fig. 6 illustrates an example graph 600 including a parabolic flow curve that may be used to implement examples disclosed herein. In particular, the parabolic flow curve represents the flow area at different travel distances of the fluid control device and may be displayed at the user interface device 102 in response to received user input. For example, at a 5.1 centimeter (cm) stroke, the flow area is 18.5 cm. As shown, an x-axis 602 is associated with stroke and/or horizontal linear dimension, and a y-axis 604 is associated with flow and/or linear dimension.

Fig. 7 illustrates an example user interface 700 that may be used to implement examples disclosed herein and that may be displayed at the user interface device 102 of fig. 1. In particular, the user interface 700 of fig. 7 shows a table in which values may be entered that generate the parabolic flow curve of fig. 6. As shown, the user interface 700 includes a first column 702 listing names of global variables and a second column 704 listing values and/or equations associated with the respective global variables. In some examples, the user may enter a value into a field of the second column 704 to alter the parabolic flow curve shown in fig. 6. In this example, the user interface 700 includes a third column 706 and a fourth column 708 associated with comments, the third column 706 listing values associated with global variables and/or values generated by entering values into equations included in fields of the second column 704.

Fig. 8 illustrates another exemplary diagram 800 that may be used to implement examples disclosed herein and that may be displayed at the user interface device 102. In particular, graph 800 represents a parametric sketch of a 3D model controlled by correlation equations included in or associated with the fields of the second column 704 of fig. 7. As shown, an x-axis 802 is associated with travel and a y-axis 804 is associated with flow. In contrast to diagram 600 of fig. 6, diagram 800 of fig. 8 illustrates an association between second column 704 and third column 706, such that a change in value can automatically update the geometry of the associated 3D model.

Fig. 9 illustrates an example user interface 900 that may be used to implement examples disclosed herein and that may be displayed at the user interface device 102 of fig. 1. In particular, similar to the user interface of fig. 7, the user interface 900 of fig. 9 enables a user to enter values at associated fields. As shown, the user interface 900 includes a default tab (tab)902 that is selectable to enable default values to populate fields 904, 906, 908, 910, 912, 914, 916, 918, 920, 922, 924, 926 associated with different flows 927, 928, 930, 932, 934, 936, 938, 940, 942, 944, 946, 948. Alternatively, the user may enter a value into field 904 and 926. In this example, user interface 900 also includes an example last used tab 950 that is selectable to enable field 904 and 948 to be populated with the last used value. To enable values to be cleared, user interface 900 includes a clear tab 952 and to enable generation of request 104, user interface 900 includes an exemplary create tab 954.

Fig. 10 illustrates an exemplary user interface 1000 that can be used to implement examples disclosed herein. As shown, the user interface 1000 includes engineering parameters (rules) associated with, for example, the manufacture of the trim kit. As an example of an engineering rule, when the A-flow value input is 18.5, the B-flow value input is 5.0, and the C-flow value input is 18.5, an error message may be provided because there is more than 5% difference between the A-flow value and the B-flow value and between the B-flow value and the C-flow value. However, user interface 1000 may include the ability to manufacture different parts and/or include the ability to add, remove, and/or alter rules to manufacture the disclosed parts.

Fig. 11 shows an exemplary graph 1100 that includes an x-axis 1102 associated with stem opening% (percent) and a y-axis 1104 associated with flow% (percent). As shown, the flow characteristic is associated with the amount of valve plug travel. For example, the greater the percentage of spool travel, the greater the percentage of flow through the valve. As shown, a first line 1106 is associated with a fast opening flow characteristic, a second line 1108 is associated with a square root flow characteristic, a third line 1110 is associated with a linear flow characteristic, a fourth line 1112 is associated with a modified parabolic flow characteristic, a fifth line 1114 is associated with an equal percentage flow characteristic, and a sixth line 1116 is associated with a hyperbolic flow characteristic.

Examples disclosed herein relate to apparatus and methods for enabling valve components (including customized valve components) to be manufactured on demand and, in some cases, assembled into complete valve assemblies. Although the examples described herein refer to the manufacture of particular valve components, such as valve plugs, seat rings, cages, the teachings of the present disclosure may be used to manufacture other valve components or the fluid control devices themselves. For example, the disclosed examples may be used to manufacture rotating segmented balls or grating drive features for noise attenuation and/or fire retardance.

When implemented in software, any of the applications, services, and engines described herein can be stored in any tangible, non-transitory computer-readable memory, such as on a magnetic disk, a laser disk, a solid state memory device, a molecular memory storage device, or other storage medium, in RAM or ROM of a computer or processor, and so forth. Although the example systems disclosed herein are disclosed as including, among other components, software and/or firmware executed on hardware, it should be noted that such systems are merely illustrative and should not be considered as limiting. For example, it is contemplated that any or all of these hardware, software, and firmware components could be embodied exclusively in hardware, exclusively in software, or in any combination of hardware and software. Thus, while the exemplary systems described herein are described as being implemented in software executing on the processors of one or more computer devices, one of ordinary skill in the art will readily appreciate that the examples provided are not the only way to implement such systems.

The figures are not necessarily to scale and the same reference numerals may be used to describe the same or similar parts. As used herein, the phrases "a," "an," "at least one of," "including," "having," and "have" are open-ended. Thus, the singular forms "a", "an" and "the" do not exclude the plural forms thereof, and at least one of the phrases "a", "an" and "the" are open ended in the same way that the term "comprising" is open ended. As used herein, the phrases "coupled," "rotatably coupled," "fixedly coupled," "connected," "rotatably connected," "fixedly connected," or any other words used to describe a relationship between components are open-ended. Thus, when a first element is "fixedly coupled" to a second element, the first element can be directly coupled to the second element without any intervening elements, or the first element can be indirectly coupled to the second element with one or more intervening elements disposed therebetween.

In addition, although several examples have been disclosed herein, any feature from any example may be combined with or substituted for another feature from another example. Additionally, although several examples have been disclosed herein, modifications may be made to the disclosed examples without departing from the scope of the claims.