High-Pressure Gas Mixing Without Buffer Tanks
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Solution Overview
Problem
Existing gas-mixing devices for high-pressure applications are complex and costly, requiring buffer tanks for gas mixture storage and adjustment of mixing ratios, which complicates operation and increases equipment costs.
Innovation Solution
A gas-mixing device with two gas-carrying branches, each equipped with a pilot valve, a proportional valve, and a flow sensor, allowing for simultaneous regulation of pressure and flow to achieve a constant output pressure and adjustable mixing ratio of two high-pressure gases without the need for a buffer tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gas mixing is performed at high pressure using conventional devices, then the desired gas mixture with adjustable mixing ratio is achieved, but the device construction becomes complex and expensive requiring buffer tanks
Solution Approach 1:
The invention extracts and removes the buffer tank component from the conventional high-pressure gas mixing system. By directly mixing gases at the point of use without intermediate storage, the system eliminates the complex buffer tank infrastructure while maintaining precise mixing ratio control through electronic regulation of gas flow rates.
Solution Approach 2:
The invention replaces the mechanical buffer tank-based mixing system with an electronically controlled direct mixing system. Electronic proportional valves and flow meters substitute for mechanical pressure regulation and storage mechanisms, enabling precise mixing ratio control through electronic signals rather than mechanical adjustments.
2Adaptability or versatility
If buffer tanks are used for gas mixture storage and adjustment, then gas mixing is achieved, but equipment costs and operational complexity increase
Solution Approach 1:
The invention extracts the buffer tank from the system entirely, replacing it with direct electronic control of gas flows. This eliminates the need for expensive high-pressure storage vessels and their associated safety infrastructure, reducing equipment costs while maintaining full adaptability for mixing ratio adjustment through electronic valve control.
Solution Approach 2:
The invention changes the control parameter from mechanical pressure regulation in buffer tanks to electronic flow rate regulation. By controlling the flow rates of individual gases through electronic proportional valves and measuring them with flow meters, the system achieves precise mixing ratio adjustability without requiring expensive buffer tank infrastructure.
3Reliability
If conventional high-pressure gas mixing devices are used, then gas mixture is produced, but the system requires complex construction with multiple components including buffer tanks
Solution Approach 1:
The invention removes the buffer tank component from the system, eliminating the intermediate storage step. By mixing gases directly at the point of use with electronic flow control, the system maintains reliable and consistent gas mixture production while reducing the number of components and potential failure points associated with buffer tanks and their pressure regulation mechanisms.
Solution Approach 2:
The invention implements electronic feedback control using flow meters to monitor the actual flow rates of individual gases. This feedback information is used by the electronic control system to adjust proportional valves and maintain precise mixing ratios, ensuring gas mixture consistency without requiring the complex mechanical feedback mechanisms of conventional buffer tank 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
The device enables the generation of a gas mixture with constant output pressure and precisely adjustable mixing ratio, reducing equipment complexity and costs while allowing for efficient operation and rapid adjustment of gas mixtures.
Implementation Method 1
the piezo-proportional valve of the second branch functions as a flow regulator
Implementation Method 2
the proportional valve of the first branch functions as a pressure regulator
Implementation Method 3
A pilot valve, a proportional valve and a flow sensor are disposed in each of these branches
Data Source
AI summary
A gas-mixing device is provided for the controlled mixing of two different gases. The gas-mixing device has a first inlet for a first gas which is under pressure, a second inlet for a second gas which is under pressure, and an outlet for the mixed gas. The gas-mixing device also has two gas-conducting lines. The first line connects the first inlet to the outlet, and the second line connects the second inlet to the outlet. In each line, an upstream valve, a proportional valve and a flow sensor are provided. The gas-mixing device additionally has at least one electronic control unit for controlling the two proportional valves and is designed such that the proportional valve of the first line acts as a pressure regulator and the proportional valve of the second line acts as a flow regulator.