Electronically Controlled Regulator with Piezo-Actuated Pilot Valve
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Solution Overview
Problem
Traditional mechanical pressure regulators experience significant errors due to 'droop' and unit-to-unit variability, especially at high inlet pressures, resulting in deviations from set pressure and accumulated wear over time.
Innovation Solution
An electronically-controlled hybrid mechanical-electronic pressure regulator with a piezo-actuated pilot valve system that includes a valve with a pintle and enlarged shoulder, a dome with a piston, and a vent valve assembly, allowing for precise control of outlet pressure through electronic communication with transducers to maintain a stable equilibrium point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional mechanical regulators are used, then the device complexity is low, but the measurement precision deteriorates due to droop and unit-to-unit variability
Solution Approach 1:
The patent replaces the traditional mechanical feedback mechanism with an electronic sensing and control system. Transducers measure outlet pressure and feed signals to an electronic controller, which actuates a control valve to adjust inlet flow, eliminating the mechanical droop error while maintaining reasonable structural complexity
Solution Approach 2:
The patent introduces an electronic controller as an intermediary between the pressure sensing transducers and the control valve. This intermediary processes the pressure signals and generates appropriate actuation commands, enabling precise pressure regulation without direct mechanical coupling
2Reliability
If traditional mechanical regulators are used, then the ease of operation is good, but the reliability deteriorates due to accumulated wear and unit-to-unit variability
Solution Approach 1:
The patent substitutes wear-prone mechanical feedback components with solid-state electronic transducers and control circuitry. The electronic system has no moving parts subject to wear, eliminating accumulated wear errors while maintaining operational simplicity through automated control
Solution Approach 2:
The regulator performs self-diagnosis and self-correction through the electronic control system. The transducers continuously monitor outlet pressure, and the controller automatically adjusts the control valve to maintain setpoint pressure, eliminating the need for manual calibration and compensation for unit-to-unit variability
3Manufacturing precision
If traditional mechanical regulators are used, then the use of energy is low, but the manufacturing precision deteriorates due to droop across operating range
Solution Approach 1:
The patent replaces the passive mechanical spring-dome balance system with an active electronic control system. The electronic controller continuously adjusts the control valve based on transducer feedback, eliminating droop error across the operating range while consuming minimal power through efficient electronic circuitry
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 achieves flexible, accurate, and stable pressure regulation across a wide pressure ratio, eliminating droop and unit-to-unit variability, ensuring minimal output pressure deviation regardless of inlet conditions, and accommodating varying set points with reduced power consumption.
Implementation Method 1
The charge valve assembly may be an electronically controlled, piezo-actuated pilot valve
Data Source
AI summary
An electronically-controlled pressure regulator includes an inlet through which a gas or liquid is introduced at an inlet pressure, an outlet through which the gas or liquid exits at an outlet pressure, and a valve disposed between the inlet and the outlet, the valve defining a passage including a throat and having a pintle with an enlarged shoulder, the valve movable between a closed configuration in which the enlarged shoulder seals the throat to prevent the gas or liquid from passing from the inlet to the outlet through the valve, and an open configuration in which the gas or liquid can pass from the inlet to the outlet through the valve. In a valve flow path, the enlarged shoulder is disposed between the inlet and the throat. All of the gas or liquid that enters through the inlet can exit through the outlet.