Field Adjustable Gas Valve with Magnetic Control
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Solution Overview
Problem
Two-stage gas-fired furnaces lack the ability to provide adjustable gas flow rates, as their gas valves are typically set at fixed high and low settings, not allowing for field adjustments, which limits their operational flexibility and efficiency.
Innovation Solution
A gas valve unit with a valve member that moves in response to a magnetic field generated by a coil, controlled by a stepper-motor or solenoid, and a setting adjustment device that allows for calibration of desired gas flow rates, enabling field adjustment of gas flow rates through a valve controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-stage gas valve with fixed high and low settings is used, then the furnace operates with increased performance and comfort compared to single-stage, but the gas flow rates are not adjustable in the field, limiting operational flexibility
Solution Approach 1:
The patent applies the dynamics principle by replacing fixed gas flow rate settings with a dynamic adjustment mechanism. The gas valve incorporates a movable component that can be positioned at different locations along a flow path, allowing the gas flow rate to be dynamically adjusted between minimum and maximum settings. This enables the system to adapt to different operational requirements while maintaining the reliability benefits of two-stage operation.
Solution Approach 2:
The patent implements parameter changes by providing field-adjustable gas flow rate settings. The adjustment mechanism allows technicians to modify the gas flow rate parameters directly in the field without requiring factory reconfiguration. This is achieved through a mechanical adjustment device that changes the physical configuration of the valve to alter the flow characteristics, enabling customization of operating parameters to match specific application requirements.
2Adaptability or versatility
If a modulating gas valve with adjustable capacity levels is used, then the furnace controller can request operation at various capacity levels from full capacity down to 30 percent, but the gas flow rate settings are typically set at the factory and not field adjustable
Solution Approach 1:
The patent applies the self-service principle by enabling field technicians to independently adjust gas flow rate settings using an integrated adjustment mechanism. The device includes accessible adjustment components that allow on-site modification of operating parameters without requiring factory service or specialized tools. This self-service capability empowers local technicians to optimize system performance directly at the installation site.
Solution Approach 2:
The patent implements segmentation by dividing the gas valve into distinct functional sections, including a separate adjustment mechanism that can be independently operated. The valve body is segmented to allow access to internal adjustment components, and the flow control mechanism is divided into adjustable segments that can be repositioned to achieve different flow rates. This segmentation enables flexible field adjustment while maintaining overall valve integrity.
3Device complexity
If fixed gas flow rate settings are used in two-stage furnaces, then the valve structure is simpler, but the furnace lacks the ability to provide adjustable gas flow rates for optimized performance
Solution Approach 1:
The patent applies dynamics by introducing a movable adjustment component within the valve structure. This component can be repositioned to change the effective flow area, providing adjustable gas flow rates. The dynamic element is integrated into the existing valve body in a space-efficient manner, adding functionality without substantially increasing overall device complexity or requiring complete valve redesign.
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 adjustable gas flow rates between high and low capacity settings, allowing for precise control and flexibility in operation, improving the performance and comfort of gas-fired appliances.
Implementation Method 1
a valve member that moves relative to a valve seat in response to a magnetic field generated by a coil
Implementation Method 2
The coil may be part of a stepper-motor having one or more coils, which displace the valve member based on activation of the coils
Implementation Method 3
the coil may be a part of a solenoid that is configured to move the valve member based on the magnitude of the magnetic field generated by the coil
Data Source
AI summary
A valve unit includes a valve member that moves relative to a valve seat in response to a magnetic field generated by a coil. An input signal to the coil controls the extent of movement of the valve member relative to the valve seat, to control a gas flow rate therethrough. The gas valve unit also includes a setting adjustment device that provides a setting adjustment input utilized for calibrating or adjusting at least one gas flow rate. A valve controller is configured to receive an activation signal and to responsively send an input signal to the coil to move the valve member and establish at least one desired gas flow rate corresponding to the activation signal, wherein the valve controller is configured to adjust the input signal to the coil based on the setting adjustment input, to thereby enable field adjustment of at least one gas flow rate.