CO2 Control Valve Remote Filling and Pressure Regulation
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Solution Overview
Problem
Existing CO2 system pressure control valves require frequent tank changes, leading to inconvenient and time-consuming processes, especially during non-business hours, and can result in overfilling and pressure hazards due to inefficient liquid carbon dioxide delivery methods.
Innovation Solution
A control valve system that allows for remote filling of CO2 systems without interrupting service, using a diverter valve design with adjustable pressure regulation and pressure relief valves to manage pressure and ensure continuous operation during filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If liquid carbon dioxide tanks are manually changed, then the system can be refilled, but service must be shut down and time is lost
Solution Approach 1:
The system pre-charges the headspace of liquid CO2 tanks with gaseous CO2 before disconnecting them from the service line. This preliminary action ensures that when tanks are replaced, the new tanks are already pressurized and ready for immediate service, eliminating downtime during the tank change process
Solution Approach 2:
A remote control valve system acts as an intermediary between the operator and the tank filling process. The valve assembly with multiple positions (filling, charging, service) allows remote operation of the filling process without requiring manual intervention in the patron area, enabling continuous operation during tank changes
2Quantity of substance
If delivery personnel fill the system manually, then liquid carbon dioxide can be delivered, but overfilling and pressure hazards occur
Solution Approach 1:
Pressure sensors and flow meters provide real-time feedback during the filling process, monitoring tank pressure and liquid CO2 flow rate. The system automatically adjusts or stops filling when predetermined pressure thresholds are reached, preventing overfilling and pressure hazards while ensuring complete tank utilization
Solution Approach 2:
The system performs self-regulation during the filling process through automated pressure control valves and sensors. The filling mechanism automatically manages its own operation, controlling liquid CO2 flow and headspace charging based on real-time pressure measurements, eliminating the need for manual monitoring and reducing pressure hazards
3Loss of time
If multiple liquid tanks are used, then tank change frequency is reduced, but space requirements and monitoring complexity increase
Solution Approach 1:
The remote control valve assembly serves multiple functions: it controls filling operations, charges headspace pressure, manages service line connections, and coordinates tank replacement sequences. This multi-functional design allows the system to handle multiple tanks efficiently without proportionally increasing control complexity
Solution Approach 2:
Manual monitoring and physical tank management are replaced with an automated electronic control system. The remote valve assembly with electronic controls and sensors automates the complex coordination required for multi-tank operation, reducing the burden on operators while managing space and monitoring requirements
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
Enables continuous CO2 delivery and reduces the need for frequent tank changes, minimizing downtime and pressure hazards by allowing remote filling and precise pressure control, enhancing system efficiency and user convenience.
Implementation Method 1
at least one pressure relief valve is provided in the control valve
Implementation Method 2
a predetermined pressure set by an adjustable pressure regulating valve in the control unit
Data Source
AI summary
An apparatus and method for filling a CO2 system that provides carbonation and delivery of beverages to a user is provided together with a control valve for performing this method. The steps include: attaching a hose and pumping liquid carbon dioxide through an inlet fitting housed in a control valve assembly; causing the translation of a valve stem to isolate a gas port and a tank and a user port and directing the liquid carbon dioxide to a liquid port and a tank; and stopping the pumping of the liquid carbon dioxide upon reaching a pre-determined pressure and removing the hose allowing the translation of the valve stem to close the valve assembly from the atmosphere and allowing the liquid to boil to a gas to provide delivery and carbonation to the beverage.