Multi-Gas Mixing Control for Precise Composition and Line Pressure
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Solution Overview
Problem
Existing gas blending technologies face challenges in reliably and precisely mixing gases to achieve specific compositions, particularly in maintaining line pressure and composition accuracy across varying operational conditions.
Innovation Solution
The method involves using multiple gas flow meters controlled by a mixture composition control system that adjusts gas flow rates to maintain predetermined compositions and line pressures, with embedded controllers for real-time monitoring and adjustments, allowing for precise mixing of two or more gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple flow meters and controllers are used to maintain precise gas composition and line pressure, then manufacturing precision and reliability are improved, but device complexity increases
Solution Approach 1:
The patent employs multiple flow meters to measure individual gas stream flows and a pressure sensor to monitor line pressure, with controllers that receive these measurements and adjust flow control valves to maintain desired composition and pressure. This feedback mechanism enables precise control of gas blending ratios and line pressure despite variations in inlet conditions, directly resolving the technical contradiction by achieving high manufacturing precision through active feedback control.
Solution Approach 2:
The controllers in the system perform multiple functions: they process measurements from flow meters and pressure sensors, calculate required flow adjustments based on desired composition targets, control flow control valves to achieve target compositions, and coordinate to maintain line pressure. This multi-functionality consolidates control logic into centralized units, managing device complexity while achieving precise gas blending through integrated control of composition and pressure.
2Reliability
If flow meters and controllers continuously adjust gas flows to maintain line pressure and composition, then reliability is improved, but use of energy increases
Solution Approach 1:
The system uses continuous feedback from flow meters and pressure sensors to controllers, which adjust flow control valves to maintain desired gas composition and line pressure. This feedback mechanism ensures reliable mixing by constantly monitoring and correcting deviations from target conditions, accepting increased energy consumption as necessary to maintain high reliability under varying operational conditions.
Solution Approach 2:
The gas blending system automatically monitors its own performance through embedded flow meters and pressure sensors, and self-corrects composition and pressure deviations through controller-directed valve adjustments without external intervention. This self-service capability maintains reliable mixing operation while minimizing the need for manual adjustment, though continuous automated control does consume energy for sensors, controllers, and actuators.
Data Source
AI summary
A method of mixing at least two gases is provided. This method includes providing a mixture composition control, including a predetermined composition input and a composition trim input. Providing N gas flow meters, including a N gas flows, and N desired gas flow rates determined by the mixture composition control, wherein N is 3 or more. Mixing the N gas flows, thereby producing a mixed gas flow at the predetermined composition and at a line pressure. Configuring the N flow meters to adjust the N gas flows to maintain the line pressure at a predetermined value, while maintaining the predetermined composition. And adjusting the composition trim input to vary the composition of the mixed gas, without modifying the predetermined composition input.