Balance-Piston Pressure Regulator for Low-Force Accurate Control
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Solution Overview
Problem
Conventional pressure regulators face challenges in balancing labor-saving features with pressure regulating accuracy, often requiring significant force to operate effectively, which compromises accuracy or vice versa.
Innovation Solution
The high-pressure labor-saving pressure regulator incorporates a main body with a pressure reducing space divided into two subspace, a valve core assembly, a main piston assembly, and a balance piston. The design allows fluid to flow between the bottom surface of the main piston and the top surface of the balance piston, reducing the force required to operate the pressure regulator while maintaining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the cross-section of the piston assembly is reduced to reduce operating force, then the force required to twist or press downward on the pressure regulating handle is reduced, but the pressure regulating accuracy deteriorates
Solution Approach 1:
The piston assembly is segmented into two separate pistons: a main piston (32) and a balance piston (5). The main piston maintains a relatively large cross-sectional area for accurate pressure regulation, while the balance piston has a smaller effective area that utilizes fluid pressure to reduce the operating force on the handle (4). This segmentation allows each piston to optimize for its specific function without compromising the other.
Solution Approach 2:
Fluid pressure acts as an intermediary force through the balance piston (5). The fluid pressure applied to the balance piston's effective area generates an assisting force that reduces the manual operating force required on the handle (4). This intermediary mechanism transfers part of the force requirement to the fluid pressure system, thereby reducing the direct mechanical force needed from the operator while maintaining the main piston's accuracy.
2Adaptability or versatility
If a larger pressure range is applied to the pressure regulator, then the versatility and adaptability improve, but the force required to operate the pressure regulating handle increases significantly
Solution Approach 1:
The invention utilizes pneumatic principles by introducing fluid pressure to act on the balance piston (5). The fluid pressure, generated by the high-pressure fluid flowing through the pressure reducing space (13), creates an assisting force on the balance piston's effective area (A5). This pneumatic assistance reduces the manual operating force required on the handle (4), enabling the regulator to handle larger pressure ranges without proportionally increasing the operating force. The relationship is expressed as: Fhand + F51 = F321, where F51 (fluid force on balance piston) offsets part of the required hand force.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves a labor-saving effect by reducing the required operating force by more than 80% while maintaining pressure regulating accuracy, allowing for easy operation without sacrificing precision.
Implementation Method 1
a space between a bottom surface of the main piston and the main body is communicated with a space between a top surface of the balance piston and the main body, so as to allow a fluid to flow into the top surface of the balance piston
Implementation Method 2
A pressure regulating spring is disposed between the main piston and the balance piston
Implementation Method 3
Two ends of the poppet spring are respectively abutted against the valve core member and the main body
Data Source
AI summary
A high-pressure labor-saving pressure regulator includes a main body, valve core assembly, main piston assembly, balance piston, and pressure regulating handle. The inside of the main body has a pressure reducing space, an input channel, and an output channel. The pressure reducing space includes a first subspace and a second subspace communicated by a seat port. The valve core member is used to regulate an opening of the seat port, and two ends of a poppet spring are respectively abutted against the valve core member and the main body. The main piston assembly includes a piston rod, a main piston, and a pressure regulating spring. A space between a bottom surface of the main piston and the main body, and a space between a top surface of the balance piston and the main body, allows fluid to flow into the top surface of the balance piston.