Gas Mixture Packaging with Flow-Based Concentration Control
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Solution Overview
Problem
Current gas mixture packaging methods struggle with achieving high accuracy and reproducibility in concentration, especially with multiple constituents and low content levels, and are limited in efficiency and flexibility.
Innovation Solution
A plant comprising a mixer device, flow regulator circuits, and a control unit that selects appropriate regulator members based on flow setpoints to accurately mix and package gas mixtures, with features like expansion members, mass flow meters, and piezoelectric valves for enhanced accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sequential filling method is used to package gas mixtures, then the packaging process can be completed with simple equipment, but the accuracy of concentration and reproducibility deteriorate
Solution Approach 1:
The packaging process is segmented into multiple independent filling stations, each capable of handling specific gas constituents. The system divides the mixture into carrier gas and minor gas components, with dedicated flow regulator devices for each, allowing simultaneous parallel processing that maintains high concentration accuracy without excessive overall complexity
Solution Approach 2:
The system changes the control parameter from sequential time-based filling to parallel flow rate-based control. By using mass flow meters and flow regulator devices to control the flow rates of different gas constituents simultaneously, the system achieves high concentration accuracy through parameter optimization rather than complex procedural control
2Manufacturing precision
If manometric packaging by controlling pressure is used, then the packaging process is simple, but the accuracy of concentration values deteriorates
Solution Approach 1:
The system replaces the mechanical pressure-based control method with a flow-based control system using mass flow meters and flow regulator devices. This substitution allows direct control and measurement of gas flow rates, providing accurate concentration values without the limitations of pressure sensor accuracy and temperature variations inherent in manometric methods
Solution Approach 2:
The system implements feedback control through mass flow meters that continuously monitor the flow rates of carrier gas and minor gas constituents. The control unit receives feedback from these measurements and adjusts the flow regulator devices to maintain the desired concentration ratios, ensuring high accuracy through closed-loop control
3Productivity
If gravimetric packaging by weighing constituents is used, then the accuracy of mixture composition improves, but the packaging efficiency and productivity deteriorate
Solution Approach 1:
The system enables continuous packaging operation with multiple filling stations working in parallel, eliminating the need to stop and weigh cylinders between filling operations. The continuous flow-based method maintains constant productivity while achieving high composition accuracy through flow control, avoiding the intermittent pauses required by gravimetric methods
Solution Approach 2:
The system replaces the mechanical weighing process with a flow-based measurement and control system. By using mass flow meters to measure and control gas flow rates in real-time, the system achieves accurate mixture composition control without the time-consuming weighing operations, thereby maintaining high productivity
4Reliability
If analysis is carried out after filling individual cylinders, then the measurement can be performed simply, but the reproducibility of mixture contents between cylinders deteriorates
Solution Approach 1:
The system implements real-time feedback control during the filling process using mass flow meters that continuously monitor gas flow rates. The control unit processes this feedback information and adjusts flow regulator devices to maintain consistent concentration ratios across all cylinders, ensuring high reproducibility without requiring post-filling analysis of each individual cylinder
Solution Approach 2:
The system uses universal flow measurement and control devices that can be applied to all filling operations simultaneously. The mass flow meters and flow regulator devices provide consistent, standardized control across multiple filling stations, ensuring reproducible results through a unified control approach rather than individual cylinder-specific adjustments
5Productivity
If sequential filling of cylinders is performed, then the equipment requirements are simple, but the productivity and speed of filling deteriorate
Solution Approach 1:
The packaging system is segmented into multiple independent filling stations that can operate in parallel. Each station is equipped with its own flow regulator devices and mass flow meters, allowing simultaneous filling of multiple cylinders without the need for complex coordination, thereby increasing overall productivity while maintaining relatively simple individual station designs
Solution Approach 2:
The system merges multiple filling operations into a single integrated parallel processing system. By combining several filling stations that operate simultaneously with shared control logic, the system achieves high productivity through parallel execution while keeping each individual filling station relatively simple in design
6Productivity
If cylinders are filled one by one with disconnection and reconnection, then the equipment design is simple, but the time consumption and efficiency deteriorate
Solution Approach 1:
The system maintains continuous gas flow and connection throughout the filling process using a manifold structure. Cylinders can be filled sequentially or in parallel without disconnection and reconnection, as the manifold provides continuous fluidic pathways. This eliminates the time-consuming disconnect/reconnect operations while the modular circuit design keeps the overall system configuration relatively simple
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
The solution achieves greater accuracy, reproducibility, and flexibility in gas mixture composition, along with faster and more efficient filling of containers, while maintaining high homogeneity between containers.
Implementation Method 1
The first and second transfer circuits each include an expansion member. Such an expansion member makes it possible to carry out mixing at low pressure, which makes it possible to use more accurate regulator members.
Implementation Method 2
the delivery circuit comprising a second flow regulator device configured to regulate the flow of the gas mixture flowing toward the at least one container according to a second flow setpoint, the second flow regulator device comprising a pressure raising member
Data Source
AI summary
The invention relates to a plant for packaging a gas mixture in one container (10), comprising a source of a minor gas (1), a source of a carrier gas (2), a mixer device (3), a first transfer circuit (6) fluidically connecting the source of minor gas (1) to the mixer device (3) and comprising a first flow regulator device (4), a second transfer circuit (7) fluidically connecting the source of a carrier gas (2) to the mixer device (3), a delivery circuit (8) comprising a second flow regulator device (9), the first transfer circuit (6) and the second transfer circuit (7) each include an expansion member (15, 16), the second flow regulator device (9) comprising a pressure raising member (9), the first flow regulator device (4) comprising several regulator members.