Gas Flow Controller Valve Layout for Safe Pilot Ignition

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Solution Overview

Problem

Existing gas flow controllers for gas fired apparatus lack redundancy during pilot lighting and are prone to hazardous ignition conditions due to potential software failures and the use of large, complex, and costly electronically controlled valves.

Innovation Solution

A gas flow controller design that includes a pilot valve, a main burner valve, and a flow controller valve, actuated by a manual or electronic actuator, which maintains the main burner valve in a closed position during pilot ignition by providing selective fluid communication between the gas inlet and the back side of the main burner valve, preventing gas flow to the main burner.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

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

Engineering Contradiction:

Improvesafety during pilot lightingVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces electronically controlled valves with a purely mechanical valve system actuated by a manual actuator. The mechanical linkage directly connects the actuator to both the pilot valve and main burner valve, eliminating the need for electronic controls while maintaining safety through mechanical interdependence of the valve operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses simple, inexpensive mechanical components such as a manual actuator, mechanical linkages, and basic valve mechanisms instead of expensive electronic controlled valves. These mechanical components are more reliable and cost-effective while achieving the same safety function during pilot lighting.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If large valves are used as safety features, then safety during pilot lighting is improved, but device size and cost increase

Engineering Contradiction:

Improvesafety during pilot lightingVSAvoiddevice size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent divides the gas flow control into separate pilot valve and main burner valve components, each controlled by the same manual actuator through mechanical linkages. This segmentation allows for smaller, more compact valve components compared to using a single large valve, reducing overall device size while maintaining safety functionality.

Inventive Principle:

Principle #1Segmentation

3Reliability

If redundancy is added during pilot lighting sequence, then safety is improved, but device complexity increases

Engineering Contradiction:

Improvesafety during pilot lightingVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the control of the pilot valve and main burner valve into a single manual actuator mechanism. The mechanical linkage system integrates both valve controls into one unified actuation system, providing redundant safety control without adding separate electronic systems or complex control logic.

Inventive Principle:

Principle #5Merging (Combining)

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 safety by preventing hazardous ignition conditions during pilot lighting and reduces the size, complexity, and cost of the gas flow controller by ensuring the main burner valve remains closed when the pilot valve is open, thereby inhibiting gas flow to the main burner.

Implementation Method 1

The flow controller valve is moveable from a closed position to an open position by actuation of the actuator to provide selective fluid communication between the gas inlet and a back side of the main burner valve to maintain the main burner valve in a closed position when the pilot valve is in the open position

Methodology Applied

Scientific EffectFluid flow pressure: Pressure Gradient

Data Source

PatentUS9618205B2Gas flow controller for use in gas fired apparatus

Publication Date: 2017.04.11 SIT MFG N AS A DE CV

AI summary

A gas flow controller for use in a gas fired apparatus includes an actuator, a pilot valve operably connected to the actuator, a main burner valve, and a flow controller valve operably connected to the actuator. The pilot valve is moveable from a closed position to an open position by actuation of the actuator to provide selective fluid communication between a gas inlet and a first fluid chamber. The main burner valve provides selective fluid communication between the first fluid chamber and a main burner outlet. The flow controller valve is moveable from a closed position to an open position by actuation of the actuator to provide selective fluid communication between the gas inlet and a back side of the main burner valve to maintain the main burner valve in a closed position when the pilot valve is in the open position.