Gas Flow Regulator with Segmented Passages for Welding
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Solution Overview
Problem
Current gas flow regulation systems for welding operations require separate gas flow regulators and meters, increasing complexity and cost due to the need for multiple devices connected in the gas line, and often experience initial pressure spikes that disrupt desired flow rates.
Innovation Solution
A combined gas flow regulator assembly with a regulator body, valve assembly, pressure gauge, and flow monitoring system that ensures constant gas flow rates by controlling gas pressure and flow through a series of interconnected channels and valves, minimizing initial pressure spikes and maintaining consistent flow from startup to shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate gas flow regulator and flow meter devices are used, then each device can perform its function independently, but the device complexity and cost increase due to requiring multiple connected components
Solution Approach 1:
The patent combines the gas flow regulator and flow meter into a single integrated device with a unified body structure. The regulator body contains both the valve assembly for flow regulation and the flow monitoring assembly with its own passage, creating one device that performs both functions simultaneously, thereby reducing the number of separate components needed in the gas line.
Solution Approach 2:
The integrated regulator body serves multiple functions: it regulates gas flow through the valve assembly, monitors flow rate through the flow monitoring assembly, and provides pressure regulation. This multi-functional design eliminates the need for separate dedicated devices for each function, reducing overall system complexity while maintaining independent performance of each function within the single device.
2Device complexity
If traditional gas flow regulation systems are used, then simple device structure is maintained, but initial pressure spikes occur that disrupt desired flow rates
Solution Approach 1:
The regulator body is segmented into multiple independent passages: a first passage for pressure regulation and a second passage for flow monitoring. This segmentation allows the flow monitoring assembly to independently measure flow without being affected by pressure spikes in the main regulation passage, thereby maintaining flow rate consistency while keeping the overall device structure relatively simple.
Solution Approach 2:
The flow monitoring assembly acts as an intermediary that provides a separate, dedicated pathway for measuring gas flow. By routing a portion of the gas through this separate monitoring passage, the system can accurately monitor flow rates without the measurement being disrupted by pressure fluctuations in the main gas line, thus stabilizing flow rate consistency.
3Reliability
If multiple separate devices are connected in the gas line, then complete flow control and monitoring functions are achieved, but the cost increases
Solution Approach 1:
The patent merges the regulator and flow meter into one integrated device, reducing the quantity of separate components from two or more devices to a single unit. This consolidation maintains complete flow control and monitoring functions while reducing the number of parts that need to be manufactured, inventoried, and installed.
Solution Approach 2:
The single integrated device performs multiple functions that would traditionally require separate devices: flow regulation, pressure control, and flow rate monitoring. This multi-functionality reduces the total number of components needed in the system while ensuring all necessary flow control functions are fully implemented.
Data Source
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AI summary
A flow control regulator assembly (100) having a regulator body (101 ) with an inflow channel (141 ) that couples an inlet of the regulator body (101 ) to a flow rate port and an exit flow channel (149) which couples the flow rate port to an outlet port (113) of the regulator body (101 ). The minimal cross-sectional area of the exit flow channel (149) is larger than the maximum cross-sectional area of the inflow channel (141 ).