Patent Description:
Aircraft include systems that require valves to control the flow of fluid, e.g., a gas or a liquid, therethrough. Butterfly valves are one type of valve used to control the flow of fluid through aircraft systems. Butterfly valves must be able to operate in harsh conditions. For example, butterfly valves must be able to withstand high temperature and high vibrational environments. As a result of the conditions, butterfly valves can fail and require manual manipulation. Butterfly valves are disclosed in <CIT>, <CIT> and <CIT>.

In one example, a valve assembly includes a cylindrical valve housing and a shaft extending through the cylindrical valve housing. The shaft includes a first end and a second end. The first end is mechanically coupled to an actuation mechanism. A disc is attached to the shaft. The shaft and the disc rotate within the cylindrical valve housing to position the disc in an open position or a closed position. The valve assembly also includes a manual positioning assembly attached to the cylindrical valve housing opposite of the actuation mechanism. The manual positioning assembly includes a housing removably coupled to the cylindrical valve housing and a double universal joint. The double universal joint includes a first end and a second end. The first end of the double universal j oint is mechanically coupled to the second end of the shaft. The second end of the double universal joint includes a socket that is configured to receive a tool to manually turn the double universal joint, the shaft, and the disc to manually orient the disc in the open position or the closed position.

In another example, a manual positioning assembly for connection to a shaft of a valve and is configured to manually manipulate a disc of the valve between an open and a closed position. The manual valve positioning assembly includes a housing having a first end and a second end. The first end includes a flange configured for fastening the housing to the valve. The second end includes a conical feature. The manual positioning assembly also includes an alignment bushing within the second end of the housing and a double universal joint. The double universal joint includes a first end and a second end. The first end of the double universal joint is configured to be mechanically fastened to the shaft of the valve. The second end of the double universal joint is positioned within the alignment bushing and includes a socket that is configured to receive a tool that manually turns the double universal j oint, the shaft, and the disc to position the disc in the open or the closed position.

While the above-identified drawing figures set forth one or more embodiments of the invention, other embodiments are also contemplated. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope of the invention as defined by the claims. The figures may not be drawn to scale, and applications and embodiments of the present invention may include features and components not specifically shown in the drawings. Like reference numerals identify similar structural elements.

This disclosure relates to a valve that includes a manual positioning assembly. The valve includes a valve housing, a shaft, a disc, and an actuation mechanism. The manual positioning assembly is attached to the valve housing opposite the actuation mechanism. The manual positioning assembly includes a housing, a double universal joint, and an alignment bushing. The housing includes a flange on a first end and a conical feature on a second end. The flange of the housing is used to attach the manual positioning assembly to the valve housing. In addition, the housing includes a bend between the first end and the second end. Thus, the first end of the housing and the second end of the housing are angularly misaligned.

The double universal joint includes a first shaft, a center yoke, and a second shaft. The first shaft of the double universal joint extends from a first end of the double universal joint towards the center yoke. The first shaft of the double universal joint includes a first hinge that attaches the first shaft to the center yoke. A first end of the first shaft of the double universal joint is hollow to receive the shaft of the valve. In one example, a pin is used to secure the shaft of the valve and the first shaft of the double universal joint. The second shaft of the double universal joint extends from the second end of the double universal j oint toward the center yoke. The second shaft includes a second hinge that attaches the second shaft of the double universal joint to the center yoke opposite of the first shaft of the double universal joint. At the second end of the double universal joint, the second shaft includes a socket that is sized and shaped to receive a maintenance tool.

When the valve becomes stuck or the actuation mechanism is unable to manipulate the valve into the open or closed positions, the manual positioning assembly actuates the valve by inserting a maintenance tool into the socket of the second end of the double universal joint and applying a torque to the socket of the second end of the double universal joint. The second shaft transmits the torque from the socket to the center yoke. The center yoke transmits the torque from the second shaft of the double universal joint to the first shaft of the double universal joint. The pin that secures the shaft of the valve and the first shaft of the double universal joint transmits the torque from the first shaft of the double universal joint to the shaft of the valve. In response to the torque on the shaft of the valve, the shaft of the valve and the disc rotate within the valve housing to manually open or close the valve. The valve with the manual positioning assembly will be discussed below with reference to the figures.

<FIG> is a partial cross-sectional view of valve <NUM> with manual positioning assembly <NUM>. Valve <NUM> includes valve housing <NUM>, shaft <NUM>, disc <NUM>, and actuation mechanism <NUM>. Manual positioning assembly <NUM> includes housing <NUM>, double universal joint <NUM>, pin <NUM> (shown in <FIG>), and alignment bushing or bushing <NUM> (shown in <FIG>). Housing <NUM> includes first end <NUM>, second end <NUM>, and bend <NUM>. First end <NUM> includes flange <NUM>. Second end <NUM> includes conical surface or conical feature <NUM>. Double universal j oint <NUM> includes first end <NUM>, second end <NUM>, center yoke <NUM>, first shaft <NUM>, and second shaft <NUM>. Second shaft <NUM> includes socket <NUM> at second end <NUM> of double universal joint <NUM>. Center yoke <NUM> includes first end <NUM> and second end <NUM>. First shaft <NUM> includes first hinge <NUM>. Second shaft <NUM> includes second hinge <NUM>. Bushing <NUM> includes internal surface <NUM> (shown in <FIG>).

In the non-limiting example of <FIG>, valve housing <NUM> is cylindrical. In another non-limiting example, valve housing <NUM> can be cubic, spherical, or any other shape containing a valve to control flow through a system. Valve shaft <NUM> extends from first end <NUM> to second end <NUM>. Valve shaft <NUM> extends through valve housing <NUM>. First end <NUM> and second end <NUM> of shaft <NUM> extend outside valve housing <NUM>. Disc <NUM> is attached to shaft <NUM>, such that shaft <NUM> and disc <NUM> rotate within valve housing <NUM> to position disc <NUM> in an open position or a closed position. In one non-limiting example, disc <NUM> can be removably coupled, e.g., bolted or fastened in any other manner, to shaft <NUM>. In another non-limiting example, disc <NUM> can be permanently attached, e.g., welded, to shaft <NUM>. In another non-limiting example, disc <NUM> and shaft <NUM> can be one unitary piece that extends through valve housing <NUM>, with disc <NUM> contained within valve housing <NUM>.

Actuation mechanism <NUM> is mounted on valve housing <NUM> and is attached to first end <NUM> of shaft <NUM>. In one non-limiting example, actuating mechanism <NUM> can be a servo-valve-controlled actuator. In another non-limiting example, actuating mechanism <NUM> can be any other device that can translate one form of energy into a rotational force. Actuating mechanism <NUM> rotates first end <NUM> of shaft <NUM> to orient shaft <NUM> and disc <NUM> in the open or closed positions in standard operating conditions. If actuating mechanism <NUM> fails, or if valve <NUM> fails in a manner that prevents the rotation of shaft <NUM> and disc <NUM>, manual positioning assembly <NUM> is used to manipulate shaft <NUM> and disc <NUM>.

Manual positioning assembly <NUM> is attached to valve housing <NUM> opposite of actuation mechanism <NUM>. Housing <NUM> is connected to valve housing <NUM> and double universal joint <NUM> is inside housing <NUM>. Housing <NUM> extends from first end <NUM> to second end <NUM>. Bend <NUM> is between first end <NUM> and second end <NUM>, such that first end <NUM> and second end <NUM> are angularly misaligned. Flange <NUM> at the first end <NUM> of housing <NUM> is mechanically fastened to valve housing <NUM>. Conical feature <NUM> of housing <NUM> tapers radially inward between second end <NUM> and bend <NUM>. Conical feature <NUM> is configured to direct a tool, e.g., wrench, bit, pneumatic or battery-powered drill, or ratchet, toward socket <NUM> in second shaft <NUM> on the second end <NUM> of double universal joint <NUM>. Manual positioning assembly <NUM> will be discussed below with reference to <FIG>.

<FIG> is a perspective view of manual positioning assembly <NUM> with housing <NUM> in phantom view. First shaft <NUM> of double universal joint <NUM> extends from first end <NUM> of double universal joint <NUM> toward center yoke <NUM>. First hinge <NUM> attaches first shaft <NUM> to center yoke <NUM> such that first shaft <NUM> can rotate in unison with center yoke <NUM> while out of alignment with center yoke <NUM>. Second shaft <NUM> of double universal joint <NUM> extends from second end <NUM> of double universal joint <NUM> toward center yoke <NUM>. Second hinge <NUM> attaches second shaft <NUM> to center yoke <NUM> such that second shaft <NUM> can rotate in unison with center yoke <NUM> while out of alignment with center yoke <NUM>.

First shaft <NUM> is hollow at first end <NUM> of double universal joint <NUM> to receive second end <NUM> of shaft <NUM>. As shown in <FIG>, first shaft <NUM> of double universal joint <NUM> and shaft <NUM> are concentrically aligned. The concentric alignment between shaft <NUM> and first shaft <NUM> of double universal joint <NUM> helps transfer torque from first shaft <NUM> of double universal joint <NUM> to shaft <NUM> without adding additional bending or torsional stresses to shaft <NUM>.

In the non-limiting example shown in <FIG>, pin <NUM> couples first shaft <NUM> of double universal joint <NUM> and second end <NUM> of shaft <NUM>. Pin <NUM> prevents second end <NUM> of shaft <NUM> from having axial play within first shaft <NUM>. Additionally, pin <NUM> transmits torque from first shaft <NUM> to second end <NUM> of shaft <NUM>. Pin <NUM> is sized to withstand a maximum torque applied by tool to socket <NUM> at second end <NUM> of double universal joint <NUM>. In another non-limiting example, first shaft <NUM> of double universal joint <NUM> and second end <NUM> of shaft <NUM> can be coupled with any other means of transferring torque while maintaining axial positioning. For example, first shaft <NUM> of double universal joint <NUM> and second end <NUM> of shaft <NUM> can be coupled with an internal lug system or any other type of shaft coupler that can transmit torque in harsh environments, e.g., high temperature and high vibrational conditions.

Bushing <NUM> is contained within second end <NUM> of housing <NUM> and circumferentially surrounds second shaft <NUM> at second end <NUM> of double universal joint <NUM>. Bushing <NUM> ensures that second shaft <NUM> of double universal joint <NUM> is aligned correctly within housing <NUM> by eliminating slop or play between second shaft <NUM> of double universal joint <NUM> and housing <NUM>. Internal surface <NUM> of bushing <NUM> can include a coating that provides low surface energy, e.g., less than <NUM> dynes/cm. In one non-limiting example, internal surface <NUM> can be coated in Teflon™. In another non-limiting example, internal surface <NUM> can be coated with any other coating that results in surface energy of less than <NUM> dynes/cm. The coating on internal surface <NUM> of bushing <NUM> decreases the friction between internal surface <NUM> of bushing <NUM> and second shaft <NUM> of double universal joint <NUM>. The decreased friction between internal surface <NUM> of bushing <NUM> and second shaft <NUM> of double universal joint <NUM> decreases the resistance to rotation of shaft <NUM> and disc <NUM> within valve housing <NUM>. The decreased resistance to rotation of shaft <NUM> and disc <NUM> within valve housing <NUM> decreases the load on all components of valve <NUM>, which increases the anticipated life of valve <NUM>.

Housing <NUM> can be adjusted in size to accommodate various scenarios. Bend <NUM> can be altered to change the positioning of second end <NUM> of housing <NUM> relative to first end <NUM> of housing <NUM>. For example, if valve <NUM> is installed in a location that has limited space, bend <NUM> can be altered to change an angle of approach that maintenance personal can engage with socket <NUM> in second shaft <NUM> on second end <NUM> of double universal j oint <NUM>. Additionally, the length of housing <NUM> can be altered to improve access to socket <NUM> of double universal joint <NUM>. For example, the distance between first end <NUM> of housing <NUM> and bend <NUM> can be increased to increase the clearance below valve <NUM>. In another non-limiting example, if valve <NUM> requires more axial clearance from a centerline of shaft <NUM>, the distance between second end <NUM> and bend <NUM> of housing <NUM> can be increased. Conversely, if valve <NUM> requires less clearance axially from the centerline of shaft <NUM>, the distance between second end <NUM> and bend <NUM> of housing <NUM> can be decreased.

The dimensions of double universal joint <NUM> can be altered to accommodate changes in size to housing <NUM>. For example, center yoke <NUM> can be altered to accommodate changes to bend <NUM>. If bend <NUM> is altered to decrease the angle between the center point of first end <NUM> of housing <NUM> and the center point of second end <NUM> of housing <NUM>, the length of center yoke <NUM> can be decreased accordingly. Alternatively, if the length of bend <NUM> is increased, the length of center yoke <NUM> can be increased. In another non-limiting example, if the distance between first end <NUM> and bend <NUM> of housing <NUM> is increased, the length of first shaft <NUM> of double universal j oint <NUM> can be increased accordingly. Conversely, if the distance between first end <NUM> and bend <NUM> of housing <NUM> is decreased, the length of first shaft <NUM> of double universal joint <NUM> can be decreased accordingly. If the distance between second end <NUM> and bend <NUM> is increased, the length of second shaft <NUM> can be increased accordingly. If the distance between second end <NUM> and bend <NUM> of housing <NUM> is decreased, the length of second shaft <NUM> can be decreased accordingly.

<FIG> and <FIG> will be discussed concurrently. <FIG> is a partial cross-sectional view of valve <NUM> after manually rotating manual positioning assembly <NUM> to orient disc <NUM> in the open position. <FIG> is a partial cross-sectional view of valve <NUM> after manually rotating manual positioning assembly <NUM> to orient disc <NUM> in the closed position. As discussed above with reference to <FIG>, conical feature <NUM> is configured to direct a tool, e.g., wrench, bit, pneumatic or battery-powered drill, or ratchet, toward socket <NUM> in second shaft <NUM> on the second end <NUM> of double universal joint <NUM>. Socket <NUM> in second shaft <NUM> on the second end <NUM> of double universal joint <NUM> is configured to receive a tool to turn double universal joint <NUM>, shaft <NUM>, and disc <NUM> to orient disc <NUM> in the open position or the closed position. In the non-limiting examples shown in <FIG>, socket <NUM> is a square socket configured to receive a square bit. In another non-limiting example, socket <NUM> can be configured to receive Phillips bits, Allen or hex bits, Torx or star bits, slot or flathead bits, or any other bit that can be used to transfer torque from a tool to a socket.

A tool (not shown) is inserted into socket <NUM>, and torque is applied. The torque applied to socket <NUM> is directly transferred to center yoke <NUM> through second hinge <NUM> of second shaft <NUM>. The torque transferred to center yoke <NUM> is transferred to first shaft <NUM> through first hinge <NUM>. Pin <NUM> (shown in <FIG>) transfers the torque of first shaft <NUM> to second end <NUM> of shaft <NUM>. The torque transmitted to second end <NUM> of shaft <NUM> is transmitted through shaft <NUM> to first end <NUM> of shaft <NUM>. The torque transferred to first end <NUM> of shaft <NUM> is transmitted through shaft <NUM> to actuation mechanism <NUM>. Thus, if actuation mechanism <NUM> is bound, applying torque to socket <NUM> can release the bind to manipulate shaft <NUM>, and disc <NUM> into an open or closed position. Similarly, because the torque applied to socket <NUM> is transmitted throughout the components of valve <NUM>, applying torque to socket <NUM> can release a bind anywhere within valve <NUM>. Additionally, if actuation mechanism <NUM> is disengaged or disconnected from valve <NUM>, manual positioning assembly <NUM> can manipulate shaft <NUM> and disc <NUM> to orient disc <NUM> in an open or closed position.

In the non-limiting example shown in <FIG>, torque is applied to socket <NUM> to manually orient shaft <NUM> and disc <NUM> in the open position. In the non-limiting example shown in <FIG>, torque is applied to socket <NUM> to manually orient shaft <NUM> and disc <NUM> in a closed position. In another non-limiting example, torque can be applied to socket <NUM> to manually orient shaft <NUM> and disc <NUM> in any position between the open and closed position.

In operation valve <NUM> can be incorporated within a bleed-air line of a jet turbine engine of an aircraft. When a pilot is ready to start the jet turbine engine, the pilot attempts to open valve <NUM> by engaging actuation mechanism <NUM> to supply a bleed air into a turbine section of the jet turbine engine. If valve <NUM> fails to open, the pilot can mitigate a flight cancellation by having a maintenance person or machine manipulate valve <NUM> with manual positioning assembly <NUM>. As discussed above, a tool is guided into socket <NUM> by conical feature <NUM>, and a torque is applied to socket <NUM> in second shaft <NUM> on second end <NUM> of double universal joint <NUM>. The torque applied to socket <NUM> is transferred from socket <NUM>, through second shaft <NUM>, second hinge <NUM>, center yoke <NUM>, first hinge <NUM>, first shaft <NUM>, pin <NUM> (shown in <FIG>), and shaft <NUM> to manually orient shaft <NUM> and disc <NUM> in the open position. As valve <NUM> is opened, bleed air is supplied to the turbine section of the jet turbine engine, which enables the pilot to start the jet turbine engine.

After the jet turbine engine is started, the pilot can attempt to close valve <NUM> with actuation mechanism <NUM> to stop bleed air from flowing into the turbine section of the jet turbine engine. If the pilot cannot close valve <NUM>, the pilot can mitigate a flight cancellation by having a maintenance person or system manipulate valve <NUM> with manual positioning assembly <NUM>. As discussed above, a tool is guided into socket <NUM> by conical feature <NUM>, and torque is applied to socket <NUM> in second shaft <NUM> on second end <NUM> of double universal joint <NUM>. The torque applied to socket <NUM> is transferred from socket <NUM> through second shaft <NUM>, second hinge <NUM>, center yoke <NUM>, first hinge <NUM>, first shaft <NUM>, pin <NUM> (shown in <FIG>), and shaft <NUM> to manually orient shaft <NUM> and disc <NUM> in the closed position. As valve <NUM> is closed, valve <NUM> cuts off the supply of bleed air to the turbine section of the jet turbine engine, which helps prepare the jet turbine engine for flight.

<FIG> is a perspective view of an alternative attachment solution between shaft <NUM> of valve <NUM> and first shaft <NUM> of double universal joint <NUM>. As shown in <FIG>, first shaft <NUM> can include a star-patterned socket on first end <NUM> of double universal j oint <NUM>. Further, second end <NUM> of shaft <NUM> can include a star-shaped plug such that the star-shaped plug on second end <NUM> of shaft <NUM> fits within the star-patterned socket of first shaft <NUM> on first end <NUM> of double universal joint <NUM>. The star-patterned socket and star-shaped plug act in concert to transmit torque from first shaft <NUM> of double universal joint <NUM> to shaft <NUM>. In another non-limiting example, any mating shape, e.g., a twist, square, slot-post, or any other mating union that can transmit torque from one body to another, can be used to transmit the torque from first shaft <NUM> of double universal joint <NUM> to shaft <NUM>.

In one example, a valve assembly includes a cylindrical valve housing and a shaft extending through the cylindrical valve housing. The shaft includes a first end and a second end. The first end is mechanically coupled to an actuation mechanism. A disc is attached to the shaft. The shaft and the disc rotate within the cylindrical valve housing to position the disc in an open position or a closed position. The valve assembly also includes a manual positioning assembly attached to the cylindrical valve housing opposite of the actuation mechanism. The manual positioning assembly includes a housing removably coupled to the cylindrical valve housing and a double universal joint. The double universal joint includes a first end and a second end. The first end of the double universal joint is mechanically coupled to the second end of the shaft. The second end of the double universal joint includes a socket that is configured to receive a tool to manually turn the double universal joint, the shaft, and the disc to manually orient the disc in the open position or the closed position.

The valve assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:.

The manual positioning assembly of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:.

Claim 1:
A valve assembly comprising:
a cylindrical valve housing (<NUM>);
a shaft (<NUM>) extending through the cylindrical valve housing comprising a first end (<NUM>) and a second end (<NUM>), wherein the first end is mechanically coupled to an actuation mechanism (<NUM>);
a disc (<NUM>) attached to the shaft, wherein the shaft and the disc rotate within the cylindrical valve housing to position the disc in an open position or a closed position; and
a manual positioning assembly (<NUM>) attached to the cylindrical valve housing opposite of the actuation mechanism, characterized in that the manual positioning assembly comprises:
a housing (<NUM>) removably coupled to the cylindrical valve housing; and
a double universal joint (<NUM>) comprising a first end (<NUM>) and a second end (<NUM>), wherein the first end of the double universal joint is mechanically coupled to the second end of the shaft, and wherein the second end of the double universal joint comprises a socket (<NUM>) that is configured to receive a tool to manually turn the double universal joint, the shaft, and the disc to manually orient the disc in the open position or the closed position.