Balanced Port Pilot-Operated Regulator for Droop Mitigation
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Solution Overview
Problem
Conventional pressure regulating valves suffer from 'droop' due to reduced force from expanding control springs, leading to decreased outlet pressure and reduced fluid transfer capacity, while unbalanced valves face issues with high inlet pressures and inlet pressure sensitivity, necessitating different designs for various global markets.
Innovation Solution
A pilot-operated balanced port gas regulator with a balancing diaphragm and pilot regulator valve assembly that maintains equal forces on the valve plug, compensating for upstream pressure and ensuring consistent downstream pressure control, incorporating a pilot regulator to adjust loading pressure and mitigate 'droop' effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional control spring is used to regulate outlet pressure, then the outlet pressure can be controlled, but the control spring loses force as it expands, causing outlet pressure to decrease and rated capacity to reduce
Solution Approach 1:
The control spring is segmented into multiple smaller springs arranged in parallel. Each spring provides a portion of the total force, and as they expand, the distributed design maintains more consistent combined force output compared to a single spring, reducing the droop effect and maintaining rated capacity.
Solution Approach 2:
A counterweight mechanism is introduced to compensate for the force loss in the control spring as it expands. The counterweight system provides additional force to balance the decreasing spring force, maintaining consistent outlet pressure control and preventing rated capacity reduction.
2Ease of operation
If the control spring expands to open the valve, then the valve opens to allow fluid flow, but the diaphragm area increases and control spring force decreases, causing force imbalance and droop
Solution Approach 1:
The system transitions from a static spring force to a dynamic force balance mechanism. As the diaphragm moves and area changes, the counterweight and segmented spring system dynamically adjusts to maintain force equilibrium, ensuring the valve opens properly while preventing droop through continuous force balancing.
Solution Approach 2:
The physical parameters of the spring system are changed by using multiple smaller springs with different characteristics rather than one large spring. This parameter change allows the system to maintain more consistent force output across the range of diaphragm movement, preserving force balance during valve operation.
3Reliability
If unbalanced regulator valves are used, then pilot regulators can control loading pressure, but the valves suffer from high inlet pressure sensitivity and crushing issues
Solution Approach 1:
A balanced port design is introduced as an intermediary mechanism between the inlet pressure and the valve components. This balanced port equalizes pressure distribution, preventing the high inlet pressure sensitivity and crushing issues while allowing the pilot regulator to effectively control loading pressure through the diaphragm.
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
The solution provides accurate and consistent downstream pressure control, increased capacity, and reduced sensitivity to inlet pressure variations, enhancing the regulator's ability to maintain setpoint pressure even under high inlet pressures and varying demands.
Implementation Method 1
a control spring (30) disposed in the atmospheric cavity (25) and in engagement with a top-side of the diaphragm (24) to offset the outlet pressure sensed by the diaphragm (24)
Implementation Method 2
The control pressure cavity (27) is in fluid communication with the outlet (18) of the regulator valve (14) such that a bottom side of the diaphragm (24) senses the outlet pressure
Data Source
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AI summary
A fluid regulating device includes a regulator valve, an actuator and a pilot regulator valve assembly. The pilot regulator valve assembly provides a pressure load to a surface of a diaphragm of the actuator in response to changes in downstream pressure being applied to the opposite surface of the diaphragm. An upper cavity of the pilot regulator valve assembly is in fluid communication with a control cavity of the actuator, allowing both the actuator diaphragm and the pilot regulator valve assembly diaphragm to simultaneously sense pressure variations within the cavities. As the downstream pressure varies, the diaphragms of both the actuator and the pilot regulator valve assembly displace to regulate the downstream pressure and the pilot regulator valve assembly maintains a load pressure. The regulator further includes a balanced regulator valve applying a balancing force to offset a force of upstream pressure on a balanced valve plug.