Gas Valve Unit with Rotating Disc for Precise Multi-Level Flow Control
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Solution Overview
Problem
Existing gas valve units for burners are complex, expensive, and lack precision in adjusting gas flow levels, leading to issues with miniaturization, compatibility, wear, and safety, as well as inadequate sealing and customization options.
Innovation Solution
A compact gas valve unit with a disc-shaped element and a control linkage system that allows precise modulation of gas flow through a series of through openings, ensuring tight sealing and easy customization, featuring a safety valve with a flat shutter and an electromagnet for reliable operation, and a bypass circuit for gas type changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rotating disc with direct contact sliding mechanism is used to regulate gas flow, then continuous adjustment between power levels is enabled, but wear of the disc increases and cycles of use are reduced
Solution Approach 1:
The continuous rotation of the disc is segmented into discrete angular positions using a crown wheel with notches and a pusher mechanism. This allows the disc to snap between predetermined positions rather than sliding continuously, eliminating wear from continuous contact while maintaining the ability to adjust between multiple power levels.
Solution Approach 2:
The direct contact sliding mechanism is replaced with a magnetic coupling system where a magnet on the control rod interacts with a magnet on the disc without physical contact. This eliminates mechanical wear while transmitting rotational motion to regulate gas flow.
2Manufacturing precision
If multiple on-off valves with cylindrical shutters are used to control gas passages, then precise gas flow regulation is achieved, but device complexity and size increase
Solution Approach 1:
Multiple on-off valves are merged into a single rotating disc mechanism with multiple through-openings. By rotating the disc to different angular positions, different combinations of openings align with gas passages, enabling precise control of gas flow to multiple burners simultaneously with a single actuator.
Solution Approach 2:
The single rotating disc serves multiple functions: it controls gas flow to different burners, adjusts power levels for each burner, and can be actuated by a single control rod. This multi-functionality reduces the number of components needed while maintaining precise regulation capability.
3Reliability
If a rotating disc directly contacts the valve body surface to prevent gas leakage, then sealing is improved, but thermal expansion effects and wear increase
Solution Approach 1:
A seal ring made of elastomeric material is introduced as an intermediary between the rotating disc and the valve body. This seal ring maintains gas-tightness through its elastic properties while accommodating thermal expansion and reducing wear compared to direct metal-to-metal contact.
4Volume of stationary object
If the disc rests on the same wall as the gas inlet connection to enable rotation, then device compactness is achieved, but safety is compromised due to overpressure lifting risk
Solution Approach 1:
Instead of having the gas inlet push the disc against the sealing surface (which could cause lifting under overpressure), the design uses a spring to push the disc against the seal ring. The spring force acts in the opposite direction to gas pressure, ensuring the disc remains sealed even when gas pressure increases.
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 provides a compact, cost-effective, and highly customizable valve unit with precise and repeatable gas flow adjustment, enhanced safety, and compatibility with various gas types, ensuring effective sealing and reduced wear, while allowing easy switching between gas types.
Implementation Method 1
on-off valves can be electromagnetically operated, e.g. individually controlled, by means of an electronic control unit, an electromagnet which is associated with each on-off valve
Implementation Method 2
an elastic element which pushes the disc-shaped element towards the seal so as to ensure a tight sealing of the valve unit
Data Source
Figure 1~2
Figure 3A~4
Figure 5~7
AI summary
An improved gas valve unit, characterized in that it comprises: a body (4) provided with an inlet (9), fluidically connectable to a gas source and to at least one outlet (10), a main chamber (28), defined at least in part in said body (4), put into fluid communication with said gas inlet (9) and provided with main outlet hole (27) put into fluid communication with said outlet (10), a disc-shaped element (40) which is housed in said main chamber (28), is provided with at least one through opening (42, 49) defining at least two zones, having a mutually different passage section in order to put said main chamber (28) into communication with said main outlet hole (27), said disc-shaped element (40) is movable in rotation within said chamber (28) between at least one closing position, in which said main outlet hole (27) is entirely covered by a full portion of said disc-shaped element (40), and at least two distinct opening positions in each of which a corresponding and distinct passage zone defined by said at least one through opening (42, 49) of said disc-shaped element (40) faces, at least in part, said main outlet hole (27) so as to allow the passage of the gas from said chamber (28) to said main outlet hole (27) through said passage zone (42, 49), a control unit (3) associated with said body (4) and provided with means for causing the snapping rotation of said disc-shaped element (40) between said closing position and an opening position, and to cause the snapping rotation of said disc-shaped element (40) between said at least two distinct opening positions.