Balanced Axial Gas Regulator for Stable Pressure and In-Line Service
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Solution Overview
Problem
Existing gas pressure regulators with indirect acting mechanisms face challenges in maintaining a constant output pressure independently of inlet pressure changes, require removal from the line for servicing, and lack balanced nozzles, leading to reduced flow characteristics and increased maintenance complexity.
Innovation Solution
The axial regulator features a balanced nozzle axially mounted in sliding gaskets, with a spring-pressed inlet nozzle and a membrane housing assembly that includes a sliding piston and lever mechanism, allowing for independent output pressure regulation and in-line servicing of the membrane and lever mechanism, including damage detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the nozzle is directly coupled with the membrane assembly in existing regulators, then the structure is simpler, but the movement ratio is fixed at 1:1 which reduces regulation precision and flow characteristics
Solution Approach 1:
A lever mechanism is introduced as an intermediary between the membrane assembly and the nozzle. The lever mechanism includes a first lever coupled to the membrane assembly and a second lever coupled to the nozzle, with the levers connected through a pivot point. This intermediary mechanism transforms the 1:1 direct coupling into a variable ratio coupling, allowing the membrane to move a greater distance than the nozzle to achieve the same pressure regulation, thereby improving regulation precision while maintaining structural simplicity.
2Volume of moving object
If the membrane assembly is directly coupled with the nozzle, then the structure is more compact, but servicing the membrane requires removal from the line
Solution Approach 1:
The regulator is divided into separable modules: the membrane assembly housed in its own carrier, the lever mechanism as a distinct component, and the nozzle assembly. The membrane carrier can be independently removed from the regulator body through a service port, allowing the membrane and lever mechanism to be serviced, inspected, or replaced without removing the entire regulator from the gas line. This segmentation maintains compact overall dimensions while dramatically improving serviceability.
3Device complexity
If an unbalanced nozzle is used in existing regulators, then the structure is simpler, but additional inlet pressure force is required which reduces flow characteristics
Solution Approach 1:
The nozzle is designed as a balanced nozzle where the inlet pressure force acting on the nozzle surface is counterbalanced by an equal and opposite force from the outlet pressure acting on the balanced portion of the nozzle. This is achieved through specific geometric design of the nozzle where the pressure forces create equal and opposite moments about the nozzle pivot point. This balancing eliminates the need for additional inlet pressure force to close the regulator, maximizing the gas flow coefficient while maintaining structural simplicity.
4Ease of repair
If the regulator is removed from the line for servicing, then complete maintenance can be performed, but operational time is lost and productivity is reduced
Solution Approach 1:
The regulator is equipped with a service port and removable membrane carrier that enable self-service maintenance. The membrane assembly can be independently accessed, removed, inspected, and replaced through the service port without removing the regulator from the gas line. This allows operators to perform maintenance during normal operation, eliminating downtime and maintaining productivity while ensuring complete maintenance capability. The lever mechanism is also designed to be accessible through the same service port for inspection and adjustment.
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 constant output pressure across varying inlet pressures, enhances gas flow coefficient, facilitates in-line maintenance, and ensures the regulator remains closed in case of membrane damage, offering improved regulation and maintenance accessibility.
Implementation Method 1
On the inlet side of the housing, the nozzle is pressed by a spring and an extension of the inlet flange
Implementation Method 2
A membrane is squeezed between lower and upper parts... In the center of the support, a piston is mounted in whose axis a choking chanal is performed which is connected to the space above the membrane and with the space beneath the membrane
Implementation Method 3
The last lever in the lever mechanism is slidingly movably connected with a balanced nozzle... by its upper end, through a guide and gaskets, and placed in the upper part of the membrane housing
Data Source
Figure 1
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Figure 3
AI summary
Axial gas pressure regulator in which in a housing (01) is axialy positioned a balanced nozzle (02), slidingly movably placed in sliding gaskets (23). Nozzle (02) is pressed by spring (10) and extension (03), while a seat (05) with a gasket (07) is mounted opposite to it, which is squeezed between the housing (01) and an outlet flange (04) and in which are performed openings (29). On the upper side of the housing (01) is mounted a carrier (30) of a second housing (21), consisting of a lower part (08) and an upper part (09), between which is squeezed a membrane (22). On the upper and lower side of membrane (22) is placed on each side one plate (33) which are in the central part connected by a support (34) and a tightener (35), and in the center of which the piston (12) is fixed with a performed choking channel (11) in the axis. The piston (12) is by its lower end slidingly movably placed, through a guide (36) and gaskets (24), in lower part (08) of the second housing (21), and by the upper end, through a guide (37) and gaskets (24), it is placed in the upper part (09) of the second housing (21). The piston (12) leans on roller (13) which is by an axle (17) rotatably placed at the end of a first lever (14), which is by its other end articulately connected with a support (30), and by its middle is articulately connected to a second lever (15). The second lever (15) is at its lower end articulately connected to a third lever (16), which is by an axle (18) is slidigly movably placed in the lower part of the carrier (30), while archly bended legs (161) of the third lever (16) comprise the nozzle (02) and, via plates (38), are slidingly movably connected to it.