Gas Flow Shutoff Circuit for Stuck Injector Detection

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Solution Overview

Problem

In mixing systems, if the injector gets stuck in the open position, gas flow continues longer than intended, leading to excessive consumption, energy waste, and potentially adverse mixing effects on liquids or materials.

Innovation Solution

A control circuit comprising a valve, sensor, and controller that monitors gas flow parameters and automatically stops the gas flow if it falls outside a predetermined range, preventing excessive gas consumption and mixing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the injector is allowed to remain open for extended periods, then gas flow continues to mix the liquid or material, but excessive gas is consumed and energy is wasted

Engineering Contradiction:

Improvemixing effectivenessVSAvoidgas consumption

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The control circuit continuously monitors the injector position through sensors and provides feedback to the controller. When the injector is detected to be stuck in the open position, the controller receives this feedback and automatically closes the control valve to stop gas flow, thereby preventing excessive gas consumption and energy waste while maintaining reliable mixing operation.

Inventive Principle:

Principle #23Feedback

2Reliability

If the injector gets stuck in the open position, then gas flow continues longer than intended, but this causes excessive mixing and adverse effects on the liquid or material

Engineering Contradiction:

Improveinjector operationVSAvoidexcessive mixing effects

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The control circuit uses sensors to provide continuous feedback on injector position to the controller. When the injector is detected to be stuck open, the controller automatically closes the control valve to stop gas flow, preventing excessive mixing and harmful effects on the liquid or material while maintaining reliable injector operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control circuit is designed to detect injector malfunction and take corrective action by closing the control valve before excessive mixing can occur. This preliminary anti-action prevents the harmful effects of prolonged gas flow on the liquid or material.

Inventive Principle:

Principle #9Preliminary anti-action

3Loss of energy

If a control circuit is added to monitor and stop gas flow, then gas consumption is reduced, but device complexity increases

Engineering Contradiction:

Improvegas consumptionVSAvoidcontrol circuit components

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The control circuit is designed to be self-monitoring and self-correcting. The sensors automatically detect injector position, the controller processes this information, and the control valve automatically adjusts gas flow without requiring external intervention. This self-service capability reduces gas consumption while keeping the added complexity manageable through automation.

Inventive Principle:

Principle #25Self-service

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

Effectively prevents excessive gas consumption and energy waste by detecting and addressing stuck injector issues, ensuring controlled mixing processes.

Implementation Method 1

The sensor is positionable in the primary circuit and operable to sense a parameter of the flow of the gas in the primary circuit and generate a signal that represents the sensed parameter

Methodology Applied

Scientific EffectSensor detection:

Implementation Method 2

When the valve is open the pressure of the gas at the valve's outlet equalizes with the pressure of the gas at the valve's inlet. When the valve is closed the pressure of the gas at the valve's outlet is prevented from equalizing with the pressure of the gas at the valve's inlet

Methodology Applied

Scientific EffectPressure equalization:

Implementation Method 3

The valve is couplable with a primary pressure-regulator that controls the flow of another gas in a primary circuit

Methodology Applied

Scientific EffectPressure regulation:

Data Source

PatentUS10940447B2Control circuit for stopping the flow of fluid in a primary circuit, and related methods and devices

Publication Date: 2021.03.09 PULSAIR SYSTEMS INC

AI summary

A control circuit for automatically stopping the flow of a gas in a primary circuit, includes a valve, a sensor and a controller. The valve is couplable with a primary pressure-regulator that controls the flow of another gas in a primary circuit. The valve has an inlet operable to receive a gas and an outlet operable to distribute the gas. The sensor is positionable in the primary circuit and operable to sense a parameter of the flow of the gas in the primary circuit and generate a signal that represents the sensed parameter. The controller is operable to receive the sensor's signal and, in response to the signal, direct the valve to close if the parameter of the flow of gas in the primary circuit lies outside of a predetermined range.