Gas Burner Valve Plug Geometry for Linear Flow Control
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Solution Overview
Problem
Traditional manual control valves for gas burners have limited resolution due to circular apertures, requiring large rotations to achieve peak flow rates and decreasing gas flow, which restricts precise regulation of gas fuel flow.
Innovation Solution
A control valve design featuring a non-circular inlet conduit and a plug with a slot and flow chamber, allowing for a more linear change in gas flow rate through rotation, combined with additive manufacturing to create complex shapes with precise tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If circular apertures are used in traditional control valves, then manufacturing is simpler with standard machining, but the resolution of gas flow control is limited requiring large rotations
Solution Approach 1:
The patent applies asymmetry by replacing the traditional circular aperture with a non-circular (e.g., rectangular or oval) aperture shape in the plug. This asymmetric geometry allows the aperture to align with the inlet conduit at specific angular positions, enabling more precise control of gas flow rates with smaller rotation angles. The non-circular shape creates distinct alignment positions that improve control resolution while maintaining manufacturability through additive manufacturing processes.
2Manufacturing precision
If tight tolerances and complex shapes are required for precise gas fuel flow regulation, then precision machining is needed, but this limits aperture shapes to circular cross-sections
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional circular aperture geometry to non-circular aperture geometry in the plug design. This geometric parameter change enables more precise control of gas flow characteristics while the adoption of additive manufacturing technology changes the manufacturing process parameters, allowing complex non-circular shapes to be produced with tight tolerances without being constrained by traditional machining limitations.
Solution Approach 2:
The patent applies mechanics substitution by replacing traditional precision machining processes with additive manufacturing technology. This substitution enables the creation of complex non-circular aperture shapes with precise tolerances that would be difficult or impossible to achieve through conventional mechanical machining methods, thereby improving both manufacturing flexibility and control precision.
3Productivity
If large rotations of the inner plug are required to reach peak flow rate, then the control valve can achieve full flow range, but the resolution and precision of flow regulation is reduced
Solution Approach 1:
The non-circular aperture shape creates specific angular alignment positions with the inlet conduit, allowing the plug to reach peak flow rate at defined angular positions rather than requiring large rotations. The asymmetric geometry ensures that the aperture aligns optimally with the inlet conduit at specific orientations, improving control resolution while maintaining the ability to achieve full flow range.
Data Source
AI summary
A control valve for a gas burner includes a valve body that defines an inlet conduit. The inlet conduit has a non-circular shape. A plug is positioned within a valve chamber of the valve body. The plug defines a slot on an outer surface of the plug, and the plug also defines a flow chamber within the plug. The plug further defines an aperture that extends between the slot of the plug and the flow chamber of the plug.