Electromechanical Pressure Regulator Feedback Control
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Solution Overview
Problem
Existing pressure regulators in gas-fired appliances are sensitive to pressure surges, have limited turndown capability, and suffer from oscillation/stability issues, flow-dependent drift, and hysteresis, which affect the accuracy of pressure regulation.
Innovation Solution
A pressure regulator assembly that includes a housing, a spring, a diaphragm, a stem, a position sensor, and a controller, where the controller adjusts the valve actuator to maintain a constant pressure by sensing the diaphragm's position and balancing bias forces with counter forces, independent of flow rates and input pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a traditional pressure regulator is used, then the structure is simple, but the pressure regulation accuracy is poor due to sensitivity to pressure surges, oscillation, and flow-dependent drift
Solution Approach 1:
The patent implements a feedback control system where a position sensor continuously monitors the stem position and feeds this information to a controller. The controller adjusts the valve actuator based on the feedback signal to maintain the diaphragm at its setpoint position, thereby achieving accurate pressure regulation while compensating for pressure surges and flow-dependent drift.
Solution Approach 2:
The patent replaces traditional purely mechanical pressure regulation mechanisms with an electro-mechanical system. The controller receives signals from the position sensor and actuates the valve through an electro-mechanical actuator, substituting complex mechanical linkages with electronic control to improve regulation accuracy while reducing mechanical complexity.
2Adaptability or versatility
If a traditional pressure regulator is used, then the device is simple, but the turndown capability is limited
Solution Approach 1:
The patent employs a dynamic control system where the valve position is continuously adjusted based on real-time feedback from the position sensor. This dynamic adjustment capability allows the regulator to adapt to a wide range of flow rates and pressure conditions, significantly improving turndown capability compared to static traditional regulators.
Solution Approach 2:
The patent changes the operating parameters of the valve by using an electronically controlled actuator that can precisely adjust the valve opening position across a wide range. This allows the regulator to maintain accurate pressure control under varying flow conditions, enhancing adaptability and turndown capability.
3Stability of the object's composition
If a traditional pressure regulator is used, then the structure is simple, but stability is poor due to oscillation and hysteresis
Solution Approach 1:
The feedback control system continuously monitors stem position and makes real-time corrections to counteract oscillations and hysteresis effects. The controller processes the feedback signal and adjusts the valve actuator to maintain stable pressure regulation, eliminating the stability issues inherent in traditional mechanical regulators.
Solution Approach 2:
By replacing mechanical feedback linkages with an electronic sensor and controller system, the patent eliminates mechanical play and hysteresis in the feedback path. The electronic control system provides precise, repeatable adjustments that improve stability and eliminate oscillation problems associated with mechanical systems.
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 achieves a constant or substantially constant pressure output over a range of flow rates and input pressures, reducing flow-dependent errors and hysteresis, thereby enhancing the stability and accuracy of pressure regulation.
Implementation Method 1
The position sensor may be configured to sense a longitudinal position of the stem and a longitudinal translation of the stem in response to movement of the diaphragm
Implementation Method 2
The bias mechanism may apply a bias force to the diaphragm toward the pressure sensing chamber, such that a pressure differential between the pressure sensing chamber and the reference chamber may provide a counter force to the bias force
Implementation Method 3
a pressure differential between the pressure sensing chamber and the reference chamber may provide a counter force to the bias force
Data Source
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AI summary
The disclosure relates generally to pressure regulators, and more particularly, to pressure regulating valves. In one illustrative but non-limiting example, a pressure in a flow channel is translated into a position of a diaphragm, wherein the position of the diaphragm is dependent on the pressure in the flow channel. The position of the diaphragm is then sensed. A position of a valve in the flow channel is then controlled to adjust the pressure in the flow channel acting on the diaphragm so that the sensed position of the diaphragm is driven toward a predetermined position. This may result in regulated pressure in the fluid channel.