Two-Stage Gas Pressure Regulator for Stable Outlet Pressure
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Solution Overview
Problem
Existing gas pressure regulators for outdoor combustion furnaces face challenges in maintaining stable output performance and safety due to fluctuations in inlet pressure, leading to potential combustion issues and safety hazards from gas leakage.
Innovation Solution
A gas pressure regulator design incorporating a valve body with a valve cover, featuring a primary and secondary pressure regulating cavity partitioned by a high pressure diaphragm and lever pressure regulating assembly, which integrates the complementary effects of valve core and lever pressure regulation to ensure stable output and safety under varying inlet pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a valve core single-stage pressure regulator is used, then the structure is simple and air tightness is good, but the output pressure increases when inlet pressure decreases, making combustion control difficult
Solution Approach 1:
The single-stage pressure regulator is divided into two independent pressure regulating assemblies (valve core assembly and lever assembly) that work in sequence. The valve core assembly performs primary pressure reduction while the lever assembly performs secondary pressure regulation, allowing each stage to operate independently and compensate for inlet pressure fluctuations.
Solution Approach 2:
A diaphragm is introduced as an intermediary component between the two pressure regulating assemblies. The diaphragm transmits pressure changes from the first stage to the second stage, enabling the lever assembly to respond to and compensate for inlet pressure variations, thus stabilizing the output pressure.
2Device complexity
If a lever-type single-stage pressure regulator is used, then the structure is simple, but the output pressure decreases when inlet pressure decreases, causing combustion failure and explosion risk
Solution Approach 1:
The pressure regulation function is segmented into two stages: the valve core assembly handles primary pressure reduction and the lever assembly handles secondary fine-tuning. This segmentation allows the system to maintain stable output pressure even when inlet pressure fluctuates, ensuring reliable combustion.
Solution Approach 2:
The lever assembly acts as a feedback mechanism that responds to output pressure changes. When inlet pressure decreases causing output pressure to drop, the lever assembly automatically adjusts to increase the opening, compensating for the pressure loss and maintaining stable combustion.
3Device complexity
If lever pad parts are directly impacted by high pressure gas, then the structure is simple, but gas leakage occurs easily under maximum pressure, creating safety hazards
Solution Approach 1:
The high pressure gas flow is segmented into two stages: the valve core assembly handles the initial high pressure reduction, and the lever assembly handles the final low pressure regulation. This segmentation protects the lever pad parts from direct exposure to maximum pressure, preventing leakage while maintaining structural simplicity.
Solution Approach 2:
The valve core assembly provides beforehand cushioning by reducing the pressure before the gas reaches the lever assembly. This pre-pressure-reduction protects the lever pad sealing surfaces from the full force of high pressure gas, preventing leakage under maximum pressure conditions.
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 integrated pressure regulation system provides stable output performance and enhanced safety by maintaining controlled gas pressure, preventing leakage, and ensuring consistent combustion, even with fluctuations in inlet pressure.
Implementation Method 1
The valve cavity includes a primary pressure regulating cavity and a secondary pressure regulating cavity
Implementation Method 2
a valve core pressure regulating assembly is disposed between the primary pressure regulating cavity and the air inlet channel
Implementation Method 3
A lever pressure regulating assembly is disposed between the valve port and the secondary pressure regulating cavity
Implementation Method 4
When the inlet pressure rises or decreases, complementary effects may be generated between the two pressure regulating assemblies. Therefore, under different inlet pressures, the gas pressure regulator performs very well in safety regarding leakage and stable output performance
Data Source
AI summary
A gas pressure regulator includes a valve body and a valve cover. The valve cover is covered on the valve body. The valve body is provided with a valve cavity, and the valve cavity is connected to an air inlet channel and an air outlet channel. The valve cavity includes a primary pressure regulating cavity and a secondary pressure regulating cavity, and the primary pressure regulating cavity and the secondary pressure regulating cavity are communicated with each other through a valve port. The primary pressure regulating cavity is communicated with the air inlet channel, and a valve core pressure regulating assembly is disposed between the primary pressure regulating cavity and the air inlet channel. The secondary pressure regulating cavity is communicated with the air outlet channel. A lever pressure regulating assembly is disposed between the valve port and the secondary pressure regulating cavity.