Gas Control Valve Modular Design for Integrated Pressure Sensing
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Solution Overview
Problem
Existing gas control valves for pressure control in gas boilers require calibration of differential pressure sensors and often have long pressure lines, leading to errors and costly, time-consuming assembly processes.
Innovation Solution
A modular gas control valve design featuring a central module with integrated control and sensor modules, where sensors detect pressure differences directly within the valve, reducing line lengths and enabling automatic calibration and increased safety through redundant systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If differential pressure sensors are used for pressure control, then pressure control functionality is achieved, but calibration is required and assembly becomes time-consuming and expensive
Solution Approach 1:
The sensor module is integrated directly into the central module of the gas control valve, combining the pressure sensing function with the valve body. This eliminates the need for separate pressure lines and reduces assembly steps, making the manufacturing process simpler and less expensive while maintaining reliable pressure control functionality
Solution Approach 2:
A gas inlet is introduced as an intermediary element that directly connects the sensor to the gas flow path within the central module. This intermediary structure enables the sensor to measure pressure differences without requiring external pressure lines, thereby simplifying assembly while achieving accurate pressure control
2Reliability
If long pressure lines are used to connect sensors to measuring points, then sensor connection is achieved, but additional sources of error are introduced and assembly becomes more complex
Solution Approach 1:
The sensor module is merged with the central module, eliminating the need for separate pressure lines. The sensor is positioned within the central module to directly measure pressure differences at the measuring points, thereby reducing device complexity and eliminating error sources associated with long pressure lines while maintaining measurement accuracy
3Ease of manufacture
If sensors are arranged outside the gas control valve, then modular assembly is simplified, but line lengths increase and response time decreases
Solution Approach 1:
The sensor module is integrated into the central module, combining the benefits of modular assembly with short response times. The sensor is positioned within the central module to directly measure pressure differences, eliminating long pressure lines and ensuring fast pressure response while maintaining modular design principles for ease of manufacture
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
This design enhances the accuracy and reliability of pressure control, reduces assembly complexity, and increases the robustness of the gas control valve by minimizing errors and the need for manual calibration.
Implementation Method 1
designed to detect a pressure difference between the gas flowing through the central module and air having a reference pressure
Implementation Method 2
designed to control a flow of the gas through the central module with a throttle element fluidically arranged between the valve inlet and the valve outlet
Data Source
AI summary
A gas control valve (1) has a central module (40), a control module (20) and a sensor module (30). Gas can flows through the central module (40) from a valve inlet (41) to a valve outlet (42). The control module (20) is directly on the central module (40) and controls a flow of the gas through the central module (40). A throttle element (23) is fluidically arranged between the valve inlet (41) and the valve outlet (42). The sensor module (30) is arranged directly on the central module (40) and has at least one sensor (31, 32) in operative connection with the gas flowing through the central module (40) through a gas inlet (44) fluidically arranged between the throttle element (23) and the valve outlet (42). In order to control the pressure, it detects a pressure difference between the gas flowing through the central module (40) and air having a reference pressure.