Gas Flow Controller Decoupling for Safe Pilot Valve Opening

Solution Overview

Problem

Gas flow controllers in gas fired apparatus lack redundancy during pilot lighting, are prone to software failure, and utilize complex, costly electronically controlled valves, which can lead to hazardous ignition conditions and excessive strain on components due to abnormal operating pressures.

Innovation Solution

A gas flow controller with a decoupling mechanism that limits the opening force of the pilot valve and connects the actuator to the pilot valve only under normal pressure conditions, preventing excessive gas flow and stress on components, and includes a flow controller valve to maintain the main burner valve closed during pilot ignition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electronically controlled valves are used as safety features, then safety is improved, but device complexity and cost increase

Engineering Contradiction:

ImprovesafetyVSAvoidcomplexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces electronically controlled valves with a purely mechanical decoupling mechanism that uses pressure differential and mechanical linkages to prevent pilot valve opening under abnormal conditions. This eliminates the need for electronic controls while maintaining safety functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses simple, inexpensive mechanical components such as springs, levers, and pressure-sensitive elements instead of expensive electronic valves. These mechanical components are robust and eliminate the need for complex electronic control systems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If electronically controlled valves are used as safety features, then safety is improved, but cost increases

Engineering Contradiction:

ImprovesafetyVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses simple, inexpensive mechanical components such as springs, levers, and pressure-sensitive elements instead of expensive electronic valves. These mechanical components are robust and eliminate the need for complex electronic control systems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If the actuator is connected to open the pilot valve under abnormal pressure conditions, then gas flow to pilot burner increases, but hazardous ignition conditions and excessive component stress occur

Engineering Contradiction:

Improvegas flowVSAvoidhazardous ignition conditions

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The decoupling mechanism is designed to detect abnormal pressure conditions before the pilot valve can open, and preemptively prevents valve opening by disconnecting the actuator from the valve. This prevents hazardous conditions rather than responding to them after they occur.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The patent introduces a mechanical intermediary (the decoupling mechanism) between the actuator and the pilot valve. This intermediary monitors pressure conditions and selectively transmits or blocks actuator force based on whether pressure is within safe limits, preventing direct actuation under abnormal conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Productivity

If the actuator is connected to open the pilot valve under abnormal pressure conditions, then gas flow to pilot burner increases, but excessive strain on interconnecting components occurs

Engineering Contradiction:

Improvegas flowVSAvoidcomponent stress

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The decoupling mechanism is designed to detect abnormal pressure conditions before the pilot valve can open, and preemptively prevents valve opening by disconnecting the actuator from the valve. This prevents hazardous conditions rather than responding to them after they occur.

Inventive Principle:

Principle #9Preliminary anti-action

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 solution prevents hazardous ignition conditions and reduces component stress by limiting the opening force of the pilot valve under abnormal pressures and ensuring the main burner valve remains closed during pilot ignition, enhancing safety and reducing complexity and cost.

Implementation Method 1

a decoupling mechanism configured to connect the actuator to the pilot valve and to selectively disconnect the actuator from the pilot valve when the actuator is actuated and a pressure differential across the pilot valve exceeds a threshold pressure limit

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS9945583B2Gas flow controller including valve decoupling mechanism

Publication Date: 2018.04.17 COPELAND COMFORT CONTROL LP

AI summary

Gas flow controllers for use in gas fired apparatus including a pilot burner and a main burner are described. A controller includes a pilot valve moveable between a closed position and an open position to provide selective fluid communication between a gas inlet and the pilot burner, a main burner valve providing selective fluid communication between the gas inlet and the main burner, an actuator configured to open the pilot valve, a flow controller valve operable to open and close a fluid flow path between the gas inlet and a back side of the main burner valve upon actuation of the actuator, and a decoupling mechanism. The decoupling mechanism is configured to connect the actuator to the pilot valve and to selectively disconnect the actuator from the pilot valve when the actuator is actuated and a pressure differential across the pilot valve exceeds a threshold pressure limit.