Two-Stage Gas Pressure Regulator for Fast Engine Fuel Control
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Solution Overview
Problem
Existing pressure regulator assemblies for gaseous fuel supply to internal combustion engines lack precision and responsiveness, particularly in handling sudden engine speed variations due to mechanical spring inertia and high thrust forces, making precise control of fuel flow rate difficult.
Innovation Solution
A pressure regulator assembly featuring a first mechanical pressure reducer and a second electrically actuated pressure reducer in series, with an intermediate sealed chamber and a communication duct, allowing for precise control of fuel flow rate through a servo and closed-loop mechanism, reducing the reliance on high-force mechanical springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical spring is used in the mechanical pressure reducer to open the interception shutter, then the shutter opens reliably against gas pressure, but the high inertia of the spring reduces the response time of the regulator assembly
Solution Approach 1:
The regulator assembly is divided into two independent stages: a mechanical pressure reducer with interception shutter and a solenoid valve with shutter body. The mechanical spring only needs to overcome downstream pressure in the first stage, not the full inlet pressure, reducing spring inertia and improving response time while maintaining reliable shutter opening.
Solution Approach 2:
A sealed intermediate chamber is introduced between the mechanical pressure reducer and solenoid valve. This chamber acts as an intermediary that decouples the mechanical spring from the high inlet pressure, allowing the spring to operate with reduced force requirements and lower inertia, thereby improving response time.
2Device complexity
If the outlet of the mechanical pressure reducer communicates directly with the inlet of the solenoid valve, then the structure is simple, but the high pressure at the solenoid valve inlet requires high-thrust springs for precise control
Solution Approach 1:
The sealed intermediate chamber serves as an intermediary between the mechanical pressure reducer outlet and solenoid valve inlet. It allows pressure regulation to occur in two stages, reducing the force required by the solenoid valve spring while maintaining structural simplicity through integrated design.
Solution Approach 2:
The high-pressure communication path is extracted from the direct connection between pressure reducer and solenoid valve. By routing gas through the sealed intermediate chamber instead, the system separates the high-pressure mechanical reduction function from the low-pressure electronic control function, reducing required spring thrust.
3Extent of automation
If a two-stage electromechanical regulator assembly is used with mechanical pressure reducer and solenoid valve, then the flow rate can be controlled electronically, but precise regulation of outlet pressure remains difficult due to mechanical reducer characteristics
Solution Approach 1:
The sealed intermediate chamber acts as a mediator that decouples the mechanical pressure reduction from electronic control. This allows the solenoid valve to operate in a lower pressure environment, enabling precise electronic regulation of outlet pressure without being constrained by mechanical reducer characteristics.
Solution Approach 2:
The system replaces direct mechanical pressure control with an electromechanical approach. The mechanical pressure reducer provides coarse pressure reduction, while the solenoid valve with electronic control provides precise outlet pressure regulation, overcoming the limitations of purely mechanical systems.
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
Enables precise variation of fuel flow rates over a wide range with reduced mechanical spring force, improved responsiveness, and easier control, achieving better engine performance without increased encumbrance or cost.
Implementation Method 1
a mechanical opening spring housed in said intermediate chamber and thrusting the separation member toward said outlet chamber
Implementation Method 2
a second pressure reducer arranged in series with the first reducer and comprising an electric actuator and a mechanical return spring for regulating the pressure/flow rate of gaseous fuel
Implementation Method 3
comprising an electric actuator and a mechanical return spring for regulating the pressure/flow rate of gaseous fuel
Implementation Method 4
a pressure regulator assembly inserted between the tank and the injectors to vary the pressure of the gas directed to the injectors
Data Source
Figure 1
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Figure 3
AI summary
A pressure regulator assembly (5) for a system (1) for supplying a gaseous fuel to an internal combustion engine (2) having a first pressure reducer (7) adapted to be connected to a fuel tank (3) and a second pressure reducer (8) driven by an electric actuator (42), and having an inlet port (38) connected to an outlet port (27) of the first reducer (7) and an outlet chamber (39) of the reduced- pressure gaseous fuel directed to the engine (2); an interception member (22) of the first reducer (7) being moved by a piston (25) that separates the outlet port (27) of the first reducer (7) from an intermediate chamber (28) housing a mechanical spring (29) for thrusting the piston (25), and pressurized with a pressure value equal to that of the outlet chamber (39) of the second reducer (8).