Compressed Gas Fill Rate Control via Pressure Feedback
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Solution Overview
Problem
Existing compressed gas filling systems lack effective means to detect and prevent excessively fast or slow fill rates without feedback instrumentation on the receiving tank, leading to potential overheating or prolonged filling times, which can result in unsafe conditions.
Innovation Solution
A self-diagnostic method and apparatus that determines a desired ramp rate for filling a gas-receiving vessel, continuously monitors the pressure, and discontinues gas flow if the pressure deviates by an undesired amount from the intended pressure at the desired ramp rate, using a programmable logic controller and pressure monitors to ensure safe filling conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the filling rate is increased to reduce fill time, then productivity is improved, but the receiving tank overheats due to adiabatic compression
Solution Approach 1:
The patent implements a feedback control system that continuously monitors the actual fill rate and compares it to the desired fill rate. When the actual fill rate deviates from the desired rate (indicating potential overheating), the system automatically adjusts the control valve to correct the deviation. This closed-loop feedback mechanism enables the system to maintain safe temperatures while optimizing fill time.
Solution Approach 2:
The patent dynamically adjusts the fill rate based on real-time conditions. The control system continuously modifies the gas flow rate in response to measured pressure and temperature variations, transitioning from a static fill process to a dynamic adaptive process that prevents overheating while maintaining high productivity.
2Temperature
If the filling rate is decreased to prevent overheating, then temperature control is improved, but the fill time becomes excessively long
Solution Approach 1:
The patent employs periodic monitoring and adjustment of the fill rate. The control system continuously measures pressure and temperature, compares actual values to desired values, and makes periodic corrections to the fill rate. This periodic control action ensures temperature remains within safe limits while minimizing interruptions to the filling process, thus maintaining acceptable fill times.
Solution Approach 2:
The patent changes the fill rate parameter dynamically during the filling process based on measured conditions. By adjusting the gas flow rate parameter in response to temperature and pressure measurements, the system prevents overheating while avoiding excessively long fill times through optimized parameter management.
3Measurement precision
If feedback instrumentation is installed on the receiving tank to monitor pressure and temperature, then control precision is improved, but device complexity increases
Solution Approach 1:
The patent designs the control system to perform multiple functions: monitoring pressure, monitoring temperature, calculating fill rate, comparing with desired values, and controlling the valve. By creating a multi-functional control system, the patent reduces the need for separate dedicated devices for each function, thereby managing complexity while maintaining high measurement and control precision.
Solution Approach 2:
The patent introduces a control system as an intermediary that processes information from pressure and temperature sensors and translates it into valve control actions. This intermediary layer coordinates the various system components, managing complexity by providing a centralized control logic that integrates sensing, calculation, and actuation functions.
4Productivity
If the control valve opens more than required to establish desired fill rate, then fill time is reduced, but excessive temperature rise occurs creating unsafe conditions
Solution Approach 1:
The patent implements beforehand cushioning by establishing a desired fill rate that is predetermined to prevent excessive temperature rise. The control system uses this pre-calculated reference value as a safety threshold, comparing actual fill rate against it and taking corrective action before dangerous temperature increases can occur. This proactive approach cushions against the harmful effect of overheating.
Solution Approach 2:
The patent uses feedback control to detect when the actual fill rate exceeds the desired rate and automatically reduces the valve opening to correct the deviation. This real-time feedback mechanism prevents excessive temperature rise by continuously monitoring and adjusting the fill rate, thereby maintaining safe operating conditions while optimizing fill time.
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
Prevents overheating by maintaining a controlled fill rate, ensuring the fill process is safe and efficient by automatically shutting off the gas supply when an undesired pressure deviation is detected, thus optimizing the filling process and preventing damage to the receiving tank.
Implementation Method 1
Overheating occurs as a result of both adiabatic compression of the gas
Implementation Method 2
when the gas is hydrogen or helium, by the reverse Joule-Thompson effect
Data Source
AI summary
A diagnostic method for a gas supply system includes: determining a desired ramp rate for filling a vessel from a supply of compressed gas; monitoring the actual pressure of gas entering the vessel; and discontinuing the flow of gas into the vessel when the actual pressure deviates from the intended pressure at the desired ramp rate by an undesired amount. A system for carrying out the method includes a flow controller for controlling operation of the supply system to deliver compressed gas from a source to a vessel through a supply line at a desired ramp rate. The system employs a pressure monitor downstream of a control valve for measuring the pressure of gas directed into the vessel and transmitting pressure-related data to the flow controller, which closes the control valve to discontinue filling of the vessel if the actual pressure exceeds a permissible deviation from the intended pressure.