Brazing Flame Preset Control for Consistent Gas Flow
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Solution Overview
Problem
Existing brazing systems face challenges in achieving consistent and reproducible gas flow rates due to manual adjustments of needle valves, which are influenced by external temperature changes and gas cylinder variations, leading to inconsistent flame quality and difficulty in setting the oxygen-to-fuel ratio.
Innovation Solution
A brazing system with a controller circuit board and mass flow controllers that automatically adjust and monitor gas flow rates, allowing for precise control of flame settings through a touch screen interface and foot pedal operation, and supports single or multiple torch configurations with wireless data communication for real-time monitoring and analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual needle metering valves are used to control gas flow rates, then the system is simple and easy to operate, but the gas flow rates become inconsistent due to external temperature changes and gas cylinder variations
Solution Approach 1:
The patent replaces manual mechanical needle metering valves with an automated electronic control system that includes mass flow controllers, pressure transducers, and a microprocessor-based controller. This substitution eliminates manual adjustment errors and provides consistent, reproducible gas flow rates by using electronic sensors and actuators to automatically regulate fuel and oxidant flows based on real-time pressure and flow measurements.
Solution Approach 2:
The system implements feedback control by continuously monitoring gas pressures and flow rates using pressure transducers and mass flow controllers, then automatically adjusting the gas valve positions based on this feedback. The microprocessor compares actual measurements with target values and dynamically adjusts valve actuator positions to maintain consistent gas flow ratios, compensating for external temperature changes and cylinder variations.
2Manufacturing precision
If automated mass flow controllers are used to precisely control gas flow rates, then flame quality consistency is improved, but the device complexity and initial cost increase
Solution Approach 1:
The patent replaces manual mechanical needle metering valves with an automated electronic control system that includes mass flow controllers, pressure transducers, and a microprocessor-based controller. This substitution eliminates manual adjustment errors and provides consistent, reproducible gas flow rates by using electronic sensors and actuators to automatically regulate fuel and oxidant flows based on real-time pressure and flow measurements.
Solution Approach 2:
The system performs self-adjustment by automatically monitoring its own operational parameters (gas pressures and flow rates) and making real-time corrections without external intervention. The microprocessor-controlled valves continuously adjust gas flows to maintain optimal flame settings, enabling the system to self-correct for changing conditions such as temperature variations or gas cylinder pressure changes.
3Adaptability or versatility
If multiple adjustment valves are provided for different gas flows, then the ability to control oxygen-to-fuel ratio is improved, but the difficulty in setting and determining acceptable flame settings increases
Solution Approach 1:
The system implements feedback control by continuously monitoring gas pressures and flow rates using pressure transducers and mass flow controllers, then automatically adjusting the gas valve positions based on this feedback. The microprocessor compares actual measurements with target values and dynamically adjusts valve actuator positions to maintain consistent gas flow ratios, compensating for external temperature changes and cylinder variations.
Solution Approach 2:
The patent introduces a microprocessor-based control system as an intermediary between the operator and the multiple gas valves. This intermediary automatically manages the complex coordination of multiple valves by receiving high-level commands from the operator and translating them into precise valve actuator positions, eliminating the need for operators to manually coordinate multiple adjustments while maintaining accurate oxygen-to-fuel ratios.
4Reliability
If manual valve adjustment is used, then the system is easier to operate, but operator variability leads to inconsistent flame quality
Solution Approach 1:
The system performs self-adjustment by automatically monitoring its own operational parameters (gas pressures and flow rates) and making real-time corrections without external intervention. The microprocessor-controlled valves continuously adjust gas flows to maintain optimal flame settings, enabling the system to self-correct for changing conditions such as temperature variations or gas cylinder pressure changes.
Solution Approach 2:
The patent replaces manual mechanical needle metering valves with an automated electronic control system that includes mass flow controllers, pressure transducers, and a microprocessor-based controller. This substitution eliminates manual adjustment errors and provides consistent, reproducible gas flow rates by using electronic sensors and actuators to automatically regulate fuel and oxidant flows based on real-time pressure and flow measurements.
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 system ensures consistent and reproducible flame quality by automating gas flow adjustments, reducing operator variability, and providing real-time data analysis for improved brazing processes.
Implementation Method 1
a mass flow controller operatively connected to the controller circuit board and between the fuel gas input and the fuel gas output. The mass flow controller is configured to monitor and adjust at least the flow rate of the fuel gas under the control of the controller circuit board
Implementation Method 2
a mass flow controller operatively connected to the controller circuit board and between the oxygen/air gas input and the oxygen/air gas output. The mass flow controller is configured to monitor and adjust at least the flow rate of the oxygen/air gas under the control of the controller circuit board
Implementation Method 3
One of the gases will include a flammable fuel gas such as LP gas, natural gas, acetylene gas, methane, propane, butane, hydrogen and mixtures and combinations thereof, while the other gas will include a combustion-assisting gas such as oxygen or air
Data Source
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AI summary
Embodiments of brazing systems are disclosed. In one embodiment, a brazing system (100) includes a controller circuit board (controller) (260) having a processor (264) and a memory (262). The system also includes a fuel gas input (222), a fuel gas output (224), an oxygen/air gas input (216), and an oxygen/air gas output (218). The system further includes a touch screen display (202) and a foot pedal (610), each operatively connected to the controller (260). The controller (260) is configured to store multiple jobs of flame presets in the memory (262). Any job can be called up from the controller (260) and the flame presets can be cycled through in response to tapping the foot pedal (610). Each job corresponds to a sequence of joint brazings to be performed on a braze assembly and includes a plurality of selectable flame presets. Each flame preset defines a flame setting based on a flow rate of a fuel gas and a flow rate of an oxygen/air gas.