Flow Control Valve With Feedback Orifice Adjustment
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Solution Overview
Problem
Existing flow control systems for pipe systems are limited in their ability to provide accurate, pressure-independent control of medium flow, particularly in non-residential buildings where pressure variations are common, restricting their applicability range and accuracy.
Innovation Solution
A flow control system comprising a flow sensor with a static measurement principle, such as ultrasonic sensors, and an orifice adjusting system with an equal-percentage characteristic curve, allowing for precise control of medium flow independent of pressure variations, using a controller to adjust the orifice based on actual and set flow values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical drive mechanism is used to compensate pressure loss variations, then pressure independent flow control is achieved, but only minor medium flow variations can be compensated
Solution Approach 1:
The patent replaces the mechanical drive mechanism with an electronic control system comprising a controller that receives signals from flow sensors and actuates an adjustable orifice accordingly. This substitution enables a wider range of flow variations to be compensated while maintaining pressure independence, as the electronic system can respond more precisely and over a broader operating range compared to the mechanical system.
Solution Approach 2:
The patent introduces an adjustable orifice whose opening area can be dynamically changed based on detected flow variations. By actively modifying the orifice parameter in response to pressure loss changes, the system compensates for a wider range of flow variations than the mechanical system, which had fixed compensation characteristics.
2Measurement precision
If characteristic values of the control valve are used to determine actual flow rate, then flow measurement is possible, but only a narrow range of pressure variations can be accurately compensated for
Solution Approach 1:
The patent employs a feedback control system where flow sensors continuously monitor the actual medium flow and send signals to a controller. The controller compares the measured flow with the desired flow and adjusts the adjustable orifice accordingly. This closed-loop feedback enables accurate flow measurement and compensation over a wide pressure variation range, overcoming the limitation of using fixed characteristic values.
Solution Approach 2:
The patent transitions from static characteristic values to dynamic flow control by continuously adjusting the orifice opening based on real-time flow measurements. The system adapts its operation to varying pressure conditions, enabling accurate compensation across a broad pressure range rather than being limited to a single calibrated pressure point.
3Ease of operation
If control valves with adjustable orifice are used, then flow control is possible, but pressure variations cause unwanted changes in medium flow rate
Solution Approach 1:
The patent uses flow sensors to continuously monitor the actual medium flow and feeds this information back to a controller. The controller adjusts the adjustable orifice to maintain the desired flow rate despite pressure variations, achieving pressure-independent flow control while preserving the ease of operation provided by the adjustable orifice.
Solution Approach 2:
The patent introduces a counteracting control mechanism that opposes the unwanted flow changes caused by pressure variations. The controller detects flow deviations and adjusts the orifice to compensate for pressure effects, effectively counterbalancing the harmful influence of pressure variations on flow stability.
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 accurate and wide-range flow control, capable of compensating large pressure differences and maintaining performance across various pressure conditions without the need for calibration, ensuring consistent medium delivery to consumer devices.
Implementation Method 1
a flow sensor (1) for sensing an actual medium flow through the pipe part (6) and outputting an electrical signal indicative of the sensed actual medium flow, wherein the flow sensor (1) is arranged outside the flow chamber (11) and has a static measurement principle based on a wave propagating in the medium
Data Source
AI summary
The present invention relates to methods for operating and controlling flow control systems. The method includes sensing an actual medium flow through a pipe part and outputting an electrical signal indicative of the sensed actual medium flow; comparing the sensed medium flow with a set medium flow and outputting a control signal; using an orifice adjusting system to adjust an adjustable orifice in a pipe part in response to the control signal; and performing a correction of a characteristic curve. The method can include setting an upper limit for medium flow to Vmax wherein Vmax is less than a maximum medium flow.