Gas control valve for electronic pressure control of a gas heater
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Solution Overview
Problem
Existing gas control valves for boilers rely on external sensors connected via long pressure lines, leading to errors and costly, time-consuming installations, and require manual calibration of differential pressure sensors for accurate flow rate determination.
Innovation Solution
A modular gas control valve design with integrated sensor modules directly on the central module, allowing for redundant sensing and automatic calibration, reducing cable lengths and response times, and incorporating dust filters and condensate drains for enhanced robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external sensors are connected via long pressure lines to measure pressure difference, then pressure control can be implemented, but installation becomes time-consuming and expensive, and additional sources of error are introduced
Solution Approach 1:
The sensor module is integrated directly onto the central module of the gas control valve, merging the sensing function with the control valve body. This eliminates the need for separate external sensors and long pressure lines, thereby reducing installation complexity while maintaining measurement precision through direct pressure tapping at the valve outlet.
Solution Approach 2:
The central module serves as an intermediary structure that provides direct pressure access to the sensor module. By incorporating pressure ports in the central module, the system establishes a direct measurement path between the gas flow and the sensor, eliminating the need for external pressure lines and reducing installation complexity.
2Measurement precision
If differential pressure sensors are used to determine gas flow rate, then pressure control can be achieved, but manual calibration is required which increases maintenance needs
Solution Approach 1:
The sensor module is designed to detect pressure difference directly at the valve outlet without requiring external calibration equipment or procedures. The integrated design allows the sensor to automatically reference the outlet pressure, enabling self-calibration functionality that eliminates manual calibration requirements and reduces maintenance needs.
Solution Approach 2:
The sensor module continuously monitors the pressure difference between the inlet and outlet of the central module and provides real-time feedback to the control system. This feedback mechanism enables automatic adjustment and validation of measurements, reducing the need for manual calibration while maintaining accurate gas flow rate determination.
3Adaptability or versatility
If sensors are arranged outside the gas control valve, then modular design is simplified, but cable lengths increase and response times are delayed
Solution Approach 1:
The sensor module is nested within or directly mounted on the central module of the gas control valve, creating a compact integrated assembly. This nested arrangement minimizes the distance between the pressure measurement point and the sensor, reducing cable lengths and signal transmission delays while maintaining modular replaceability of the sensor module as a complete unit.
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 integrated sensor modules provide accurate, reliable pressure control with reduced installation complexity and maintenance needs, enhancing safety and reducing calibration requirements.
Implementation Method 1
detect a pressure difference between the gas flowing through the central module and air having a reference pressure, for example as differential pressure or as mass flow
Data Source
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AI summary
The invention relates to a gas control valve (1) for electronic pressure control of a gas-air mixture at a gas boiler, wherein the gas control valve (1) comprises a central module (40), a control module (20), and a sensor module (30), wherein the central module (40) is permeable to gas flow from a valve inlet (41) to a valve outlet (42), wherein the control module (20) can be arranged directly on the central module (40) and is configured to control the flow of gas through the central module (40) with a throttle element (23) arranged fluidically between the valve inlet (41) and the valve outlet (42), wherein the sensor module (30) can be arranged directly on the central module (40) and comprises at least one sensor (31, 32) which is operatively connected to the gas flowing through the central module (40) via a gas inlet (44) arranged fluidically between the throttle element (23) and the valve outlet (42). and which is trainedFor pressure control, a pressure difference between the gas flowing through the central module (40) and air having a reference pressure is to be detected.