Modular Flow-Rate Controller with Detachable Orifice Unit
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Solution Overview
Problem
Conventional flow-rate controllers with integrated structures are bulky, difficult to maintain, and suffer from instability due to fluctuations in pressure and flow rate, leading to issues like overshoots and increased response times, especially when handling fluids with low fluidity like slurry.
Innovation Solution
A modular flow-rate controller design comprising a regulator unit, a valve unit, and an orifice unit, each with integrated components and detachable connections, reducing the number of joints and allowing for easier maintenance and adjustment of the orifice unit to suit specific applications, thereby stabilizing fluid pressure and improving control accuracy and response time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If components are integrated into a single structure, then the footprint is reduced, but maintenance becomes complicated and clogging is difficult to address
Solution Approach 1:
The flow-rate controller is divided into three detachable units: a regulator unit, a valve unit, and an orifice unit. This segmentation allows individual components to be accessed, removed, and maintained independently while maintaining a compact overall structure when assembled together.
2Ease of repair
If components are individually provided, then maintenance is easier, but connection structures occupy large space
Solution Approach 1:
The system segments components into modular units that can be easily assembled and disassembled, providing maintenance accessibility while minimizing the space occupied by connection structures through optimized joint designs.
3Measurement precision
If feedback control is used to stabilize flow rate, then control accuracy is improved, but response time increases when pressure changes are great
Solution Approach 1:
The regulator unit performs preliminary pressure stabilization before fluid enters the valve unit, pre-conditioning the fluid to reduce pressure fluctuations. This preliminary action allows the feedback control system to respond more quickly and accurately without excessive overshoot or delay.
4Stability of the object's composition
If the orifice unit is fixed, then structural stability is improved, but adaptability to different applications is reduced
Solution Approach 1:
The orifice unit is designed as a detachable module that can be easily swapped between different configurations. This segmentation maintains structural stability when assembled while enabling adaptability to different applications through component interchangeability.
Solution Approach 2:
The standardized interface design allows the same basic unit structure to serve multiple functions and applications by simply changing the orifice component, providing both structural consistency and application-specific adaptability.
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 modular design enhances ease of handling and maintenance, reduces the overall size of the apparatus, and improves control accuracy and response time by stabilizing fluid pressure, even under turbulent conditions, while allowing for flexible configuration based on intended use.
Implementation Method 1
a regulator for controlling the pressure of fluid supplied from the upstream side
Implementation Method 2
a flow-rate control valve for controlling the flow rate of fluid
Implementation Method 3
a differential-pressure flow meter for measuring the flow rate of fluid
Data Source
AI summary
A highly versatile flow-rate controller that is easy to handle and a regulator unit and a valve unit used for the same are provided. The flow-rate controller includes a regulator unit having a regulator and a first pressure sensor, a valve unit having a second pressure sensor and a flow-rate control valve, and an orifice unit that is connected to the regulator unit and the valve unit in a detachable manner and that has a fluid channel and an orifice that connect to the regulator unit and the valve unit.