Pressure regulator with remotely controlled shut-off valve

A pressure regulator includes a housing assembly defining a main fluid flow path from an inlet end to an outlet end. A tubular plunger body is supported within the housing assembly for linear movement toward and away from a valve seat in response to fluid pressure at said outlet end. An actuator sleeve is supported within the housing assembly and engaged with the tubular plunger body, and a pressure chamber defined in part by a shut-off diaphragm extends between the housing assembly and the actuator sleeve. A fluid port is arranged to supply pressurized fluid to the pressure chamber to thereby produce linear movement of the actuator sleeve and the tubular plunger body independent of the pressure at said outlet end, moving the tubular plunger body into engagement with the valve seat to shut off the flow path.

BACKGROUND OF THE INVENTION

This invention relates to valves and pressure regulators generally, and specifically to a fluid pressure regulator particularly suited for (but not limited to) use in agricultural irrigation systems.

It is well known to use pressure regulators in irrigation systems in order to provide substantially constant, regulated outlet pressure over a wide range of regulator inlet pressures, to thereby insure the supply of water is maintained at a substantially uniform pressure to a sprinkler or other irrigation device. The need for such regulators is particularly acute in low pressure systems because even slight variations in pressure along a system operating at low pressure causes much greater variations and discharges than the same system operating at high pressure.

The assignee of this invention currently manufactures and sells fluid pressure regulators of the flow-through type, having an inlet at one end of a tubular housing and an outlet at the other end of the tubular housing. A valve or regulator seat is fixed within the housing and is adapted to be engaged by a tubular plunger which is spring biased away from the seat (in the direction of fluid flow) so that under normal conditions, maximum flow through the regulator is permitted. In the event of a pressure surge, the plunger is moved by back pressure within a diaphragm chamber, against the action of an opposed coil spring (and against atmospheric pressure), toward the regulator seat to thereby decrease flow through the regulator until the pressure is reduced, at which point the plunger will stop or, if pressure decreases sufficiently, move upwardly away from the seat to thereby increase the flow. In this way, the plunger constantly seeks an equilibrium position within the regulator to maintain a substantially uniform outlet pressure.

It would be advantageous to incorporate a remotely controlled shut-off feature in pressure regulators as described above in order to, for example, facilitate repair/replacement of downstream sprinklers or other components, and/or to turn some sprinklers on and off at various times in an automatic multi-sprinkler system to implement desired sprinkling patterns.

BRIEF SUMMARY OF THE INVENTION

In one exemplary but nonlimiting embodiment, the invention provides a pressure regulator comprising a housing assembly defining a fluid flow path from an inlet end to an outlet end; a tubular plunger body supported within the housing assembly for linear movement toward and away from a valve seat in response to fluid pressure at the outlet end; an actuator sleeve supported within the housing assembly and engaged with the tubular plunger body; a pressure chamber defined in part by a shut-off diaphragm extending between the housing assembly and the actuator sleeve; a fluid port arranged to supply pressurized fluid to the pressure chamber to thereby produce linear movement of the actuator sleeve and the tubular plunger body independent of the pressure at the outlet end, moving the tubular plunger body into engagement with the valve seat to shut off the flow path.

In another exemplary but nonlimiting aspect, the invention provides a pressure regulator comprising a housing assembly defining a fluid flow path from an inlet end to an outlet end, the housing assembly including a housing body and a cap secured to the lower housing body; a tubular plunger body supported within the lower housing body and the cap for linear movement toward and away from a valve seat supported in the housing body in response to fluid pressure at the outlet end; an actuator sleeve supported within the housing body and adapted to engage the tubular plunger body; and fluid means for driving the tubular plunger body linearly to close off all flow through the housing assembly independent of the fluid pressure at the outlet end.

In still another exemplary but nonlimiting aspect, the invention provides a pressure regulator comprising a housing assembly defining a fluid flow path from an inlet end to an outlet end; a tubular plunger body supported within the housing assembly for linear movement toward and away from a valve seat in response to fluid pressure at the outlet end; a control diaphragm supported radially between the tubular plunger body and the housing assembly, wherein the control diaphragm is exposed on one side to the fluid pressure at the outlet end to thereby exert a force on the tubular plunger body in a direction toward the valve seat; a shut-off extending between the housing assembly and the actuator sleeve partially defining a pressure chamber; and a fluid port arranged to supply pressurized fluid to the pressure chamber to thereby produce linear movement of the actuator sleeve and the tubular plunger body independent of the pressure at the outlet end, moving the tubular plunger body into engagement with the valve seat to a closed position, shutting off the flow path.

An exemplary but nonlimiting embodiment will now be described in detail in connection with the drawings identified below.

DETAILED DESCRIPTION OF THE DRAWINGS

The pressure regulator10shown inFIGS. 1 and 2includes a housing assembly formed by the attachment of a two-piece housing body12and a cap14. The housing body12is a hollow, annular component formed with upper and lower, open, cylindrical ends (or downstream and upstream ends, respectively)16,18on either side of a larger-diameter middle section20where the upper and lower ends16,18are joined in telescoping fashion at22and secured by screws24or other suitable fasteners. For ease of understanding, use of descriptors “upper” and “lower” herein are made consistently with the exemplary but nonlimiting orientation of the pressure regulator as shown inFIGS. 1 and 2. Use of descriptors “upstream” and downstream” is made relative to the direction of flow through the pressure regulators as indicated by flow arrow “F”.

The downstream end16as housing body12is also telescoped into a depending skirt portion26of the cap14with a snap fit between a radially-outwardly directed annular flange28(continuous or segmented) on the outside of the downstream end16and an annular groove30located internally of the skirt portion26of the cap14. It will be appreciated, however, the attachment features on the downstream end16and skirt portion26may include any conventional attachment mechanism including a press-and-turn bayonet-type fitting, screw fasteners or other suitable arrangements. Moreover, the exact manner of fastening the cap14to the downstream end16of the housing body12, and the downstream end16of the housing body12to the upstream end18are not significant to this invention so long as they are designed to withstand the high fluid pressure within the regulator unit. The upstream or lower end18of the housing body12is formed with a threaded inlet that receives, for example, an adapter32permitting attachment of the pressure regulator to a water-supply conduit, sprinkler riser or the like. Similarly, the cap14tapers from the relatively larger diameter peripheral skirt portion26to an internally-threaded and relatively smaller-diameter outlet end or outlet34, adapted for connection to a water supply conduit, drop hose or the like. It will be understood that the regulator flow path extends along a longitudinal axis or center line CL passing through the inlet (or adapter)32, a tubular plunger body40described further below, and the outlet34.

A valve seat36is supported in the upstream end18of the housing body12below an annular flange38, and centered relative to the longitudinal axis. The seat36is preferably supported by a single radially-oriented strut (not shown) connected to the cylindrical valve housing37, and is engageable by a tubular plunger body40that passes through a center opening42defined by the annular flange38in the lower end18of the lower housing body12and a counterbore39(FIG. 2) in the cap14.

The elongated tubular plunger body40is formed with an upper end44and a lower end46. The lower end46is formed with a tapered knife edge48that serves as a valve, adapted to engage the seat36as explained further below. An O-ring seal47is seated about the inner periphery of the opening in the annular flange38and is held in place by a retainer ring49. The seal47prevents ingress of water into the interior of the housing body.

An annular radial flange50is formed at a location below the upper end44of the plunger body40. The flange50is formed with a plurality of depending, resilient spring fingers52arranged about the tubular plunger body40, each having a radially outwardly extending support tab54at its lowermost end.

The radial flange50also supports an upstanding annular wall56located concentrically and radially outwardly relative to the plunger body40. The wall56is formed with a radially outwardly extending rim58. The wall56and rim58may be discontinuous, i.e., formed as plural, circumferentially-spaced resilient segments.

A control or pressure-regulating diaphragm60is arranged radially between the tubular plunger body40and the cap14. Specifically, an enlarged radially inner end62of the diaphragm60is sandwiched between an annular retention ring64and the flange50. The retention ring64is held in place by the rim58of the upstanding annular wall56and by a shoulder65of the cap14. The radially outer end66of the diaphragm is sandwiched between a radial flange portion68of the cap14and a second annular retention ring70held in place by the upper edge72of the downstream end16of the housing body12. The second annular retention ring70is provided with an annular groove74in which the enlarged radially outer end66of the diaphragm is received.

During operation, the pressure of the water flowing in the direction of flow arrow F through the tubular plunger body40and exiting the outlet end34will be applied to the upper or downstream side of the control diaphragm60by way of a radial space between the upper end44of the tubular plunger body40and the adjacent counterbore39formed in the cap14. The water is able to follow a path about the annular wall56and one or more radial grooves or vents (not shown) in the ring64(and/or in the shoulder76) into the control diaphragm chamber78. Water pressure in the control diaphragm chamber78will tend to push the tubular plunger body40in a downward direction, causing the knife edge48to approach the valve seat36, thus reducing flow. The force exerted on the tubular plunger body40via the control diaphragm60is opposed by a force exerted by a coil spring80seated on the upper surface82of flange38, and pushing upwardly against the underside of the plunger body radial flange50. Thus, as is well understood in the art, as outlet water pressure varies, the tubular plunger body40will be caused to move toward or away from the seat36to thereby decrease or increase flow through the regulator, with the plunger body40always seeking a state of equilibrium where the outlet pressure is substantially constant.

This invention relates to the addition of a remote shut-off feature to the pressure regulator10that allows a user to stop flow through the pressure regulator independently of the pressure regulation function from a remote location.

Specifically, the larger-diameter middle section20permits the inclusion of a second or shut-off diaphragm84and associated shut-off diaphragm chamber86(sometimes referred to herein as a “pressure chamber”) that enable a remote device, such as a solenoid (under the control of a microprocessor or other control device) to shut off the pressure regulator independently of its primary pressure control function. To this end, an interior, substantially cylindrical actuator sleeve88is supported from the support tabs54of the spring fingers52. The upper end of the sleeve88is formed with an inward directed rim90that is seated on the tabs54. Radially adjacent the rim90, an O-ring92is seated in an annular, outwardly-facing groove94, creating a seal between the sleeve88and the inside surface96of the downstream end16of the housing body12. Adjacent the lower end of the sleeve88there is an outwardly-directed flange98, supporting a larger-diameter, depending skirt102. The lower end of the skirt102is formed with an outwardly-oriented shoulder104. A second retention ring106is supported on the shoulder104and serves to clamp a radially-inner end108of the shut-off diaphragm84between the retention ring106and the outer edge100of flange98. The radially-outer end110of the shut-off diaphragm84is held in place by the compressive force exerted by the edge112of an inner sleeve portion114of the upstream end18of the housing body12and an opposed shoulder116of the downstream end16of the lower housing body12. Note the chamfer on edge112that provides the space necessary to accommodate the wedge-shaped inner end of the shut-off diaphragm84.

The space above the shut-off diaphragm84provides the shut-off diaphragm chamber86, sealed at one end by the shut-off diaphragm84and at an opposite end by the O-ring92. A fluid (water or air) inlet port118leading to the shut-off diaphragm chamber86, extends through the downstream end16in the middle section20, and supplies pressurized fluid to the chamber86via conduit120(FIG. 1). The flow of pressurized fluid is controlled by a three-way solenoid122which, in turn, is controlled by a processor or other controller124. The three-way solenoid122has three ports. One is connected to the chamber86; one is vented to atmosphere; and the third is connected to a pressurized fluid source.

When it is desired to shut off flow through the pressure regulator10, the user initiates the supply of pressurized fluid to the pressure chamber86. The fluid pressure acting on the flange98drives the actuator sleeve88and tubular plunger body40downwardly until the knife edge48engages the seat36, thereby shutting off all flow through the regulator as shown inFIG. 2. Note that the connection between the rim90of the actuator sleeve88and the tabs54on the spring fingers52form a one-way driving connection between the actuator sleeve88and the tubular plunger body40.

To resume flow, the solenoid122is vented to atmosphere, allowing fluid to escape the pressure chamber86as the coil spring80pushes the tubular plunger body40in an opposite or upward direction, also pulling the actuator sleeve88upwardly to the position shown inFIG. 1. Absent pressure in the chamber86, the driving connection between the actuator sleeve88and the tubular plunger body40is broken. This is because there is no fixed connection between the actuator sleeve88and the plunger body40, and because the actuator sleeve88will remain in its upper or open position as the tubular plunger body40moves down and up in response to the fluid pressure in the control diaphragm chamber78.

It will be appreciated that the downward axial movement of the tubular plunger body40in a valve shut-off procedure is limited by the downward stroke of the actuator sleeve88. This downward stroke is matched to the closing distance between the knife edge48of the plunger body40and the valve seat36.

It will also be appreciated that as the tubular plunger body40moves up and down during normal use, and with the actuator sleeve88held in its open or uppermost position, there is no interference with the pressure regulation function.