Master-Slave Flow Ratio Controller Parallel Architecture

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Solution Overview

Problem

Existing multiple-channel flow ratio controllers (MCFRCs) face challenges with high pressure drop, large footprint, and high costs when implemented in cascaded configurations, limiting flexibility and constraining the number of flow channels to N=2n, which is not suitable for applications requiring more than two secondary flows.

Innovation Solution

A system comprising a master FRC and one or more slave FRCs connected through a digital communication network, allowing for a flexible configuration of N secondary flow channels, where the master FRC receives preselected ratio setpoints and command signals to maintain desired flow ratios between individual and total flow rates, enabling efficient distribution of a single mass flow into multiple secondary flows.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a cascaded configuration of DCFRCs is used to create an MCFRC, then the system can split a single mass flow into multiple secondary flows, but the pressure drop across the MCFRC becomes high

Engineering Contradiction:

Improveability to split flow into multiple channelsVSAvoidpressure drop

Core Design Contradiction:

Adaptability or versatilityVSStress or pressure

Solution Approach 1:

The system segments the flow control function into independent parallel DCFRC modules, each handling a portion of the total flow split. This allows multiple secondary flows to be generated without cascading, thereby reducing cumulative pressure drop while maintaining the ability to divide flow into N channels.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from a one-dimensional cascaded arrangement (series connection of DCFRCs) to a two-dimensional parallel architecture where multiple DCFRCs operate simultaneously. This dimensional change eliminates the cumulative pressure drop inherent in series configurations while achieving the same multi-channel flow splitting function.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If a cascaded configuration of DCFRCs is used to create an MCFRC, then the system can split a single mass flow into multiple secondary flows, but the footprint becomes large

Engineering Contradiction:

Improveability to split flow into multiple channelsVSAvoidfootprint

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The patent merges multiple DCFRC functions into a single integrated MCFRC device where multiple secondary flow channels share common components (inlet, outlet, housing). This consolidation reduces the overall footprint compared to cascaded configurations while maintaining the capability to split flow into multiple channels.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If a cascaded configuration of DCFRCs is used to create an MCFRC, then the system can split a single mass flow into multiple secondary flows, but the cost increases

Engineering Contradiction:

Improveability to split flow into multiple channelsVSAvoidcost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The MCFRC is designed as a universal device that can split flow into any number of secondary channels (N channels) using a standardized architecture of parallel DCFRC modules. This multi-functionality eliminates the need for custom cascaded configurations for different channel counts, reducing development and manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Adaptability or versatility

If a cascaded configuration of DCFRCs is used to create an MCFRC, then the system can split a single mass flow into multiple secondary flows, but the number of flow channels is constrained to N=2n

Engineering Contradiction:

Improveflexibility in number of channelsVSAvoidconstraint on channel number

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system employs dynamic configurability where the number of active secondary flow channels can be adjusted independently of the total module count. Each parallel DCFRC module can be individually activated or deactivated, allowing flexible adaptation to different channel requirements (any N from 2 to 2n) without being locked into fixed cascaded configurations.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS8997791B2Multiple-channel flow ratio controller

Publication Date: 2015.04.07 MKS INSTR INC

AI summary

A system for dividing a single mass flow into a plurality N of secondary flows includes an inlet configured to receive the single mass flow, a master FRC (flow ratio controller), and one or more slave FRCs. Each FRC is connected to the inlet and including at least one flow channel. The master FRC and the slave FRCs include in combination a total of N flow channels. Each flow channel i (i=1, . . . , N) is connected to carry a corresponding one of the N secondary flows. In response to preselected ratio setpoints received from a host controller, the master FRC and the slave FRCs maintain ratios Qi/QT (i=1, . . . , N) between individual flow rates Qi (i=1, . . . , N) and a total flow rate QT at the preselected ratio set points.