Modular Gas Control Valve with Pneumatic Actuation
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Solution Overview
Problem
Existing gas control valves and safety valves are often specifically adapted to a particular housing shape, making them costly and limited to single product use, requiring extensive reworking and specialized production facilities, and are not easily replaceable or adaptable to different types of housing.
Innovation Solution
A modular design combining a pneumatically controlled gas control valve with a modular gas safety valve, where the safety valve is upstream of the control valve, allowing for separate development and testing of each module, enabling use across various housing types with reduced assembly time and increased flexibility, and utilizing a coaxial double safety valve for compactness and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas control valves are specially adapted to a specific housing shape, then the seal and functionality for that housing are ensured, but the valve can only be used for that one product and requires extensive reworking
Solution Approach 1:
The gas control valve is divided into separate functional modules: a valve body with integrated valve seat, detachable sealing elements, and mounting components. This segmentation allows the valve to be adapted to different housing shapes by changing only the sealing interface while retaining the core valve functionality.
Solution Approach 2:
The valve body is designed with a universal mounting interface and detachable sealing components that can accommodate multiple housing types. The same valve body can be used across different products by simply changing the sealing elements, achieving multi-functionality without extensive reworking.
2Reliability
If gas control valves are specially adapted to a specific housing shape, then the seal is ensured, but special production facilities must be adapted for each type of construction
Solution Approach 1:
By segmenting the valve into a universal valve body and product-specific sealing components, the production process can use the same valve body manufacturing line while only changing the sealing elements, which are simpler and faster to produce.
Solution Approach 2:
The sealing function is extracted as a separate detachable component from the valve body. This allows the valve body to be manufactured once using specialized facilities, while the sealing components can be produced separately and adapted to different housing types without requiring reconfiguration of the main production line.
3Stability of the object's composition
If non-modular gas control valves are used, then the design is integrated, but the assembly time is longer and replacement is difficult
Solution Approach 1:
The valve is segmented into modular components that can be pre-assembled and tested separately, then quickly installed as a complete module. This modular approach reduces on-site assembly time while maintaining functional integration through standardized connection interfaces.
Solution Approach 2:
The modular valve components are pre-assembled and pre-tested at the manufacturing stage. This preliminary action ensures proper integration and functionality before installation, eliminating the need for time-consuming on-site assembly and adjustment.
4Measurement precision
If electronically controlled gas valves are used, then precise control is achieved, but the cost is significantly higher and electronic control is required
Solution Approach 1:
The patent employs pneumatic control mechanisms to achieve precise gas flow regulation without electronic components. Pneumatic actuators and pressure-regulated systems provide accurate control through fluid pressure, eliminating the need for complex electronic control circuits while maintaining measurement precision.
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 reduces development time, costs, and assembly time, allows for easy replacement, and achieves a compact size reduction of up to 40% compared to non-modular solutions, with the ability to achieve greater outputs and modulation widths in a simple and inexpensive manner.
Implementation Method 1
a pneumatically controlled gas control valve designed as a module
Implementation Method 2
a gas safety valve with a spring-loaded, in particular with a coil spring-loaded valve body
Implementation Method 3
with a spring-loaded, in particular with a coil spring-loaded valve body
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3b
AI summary
The invention relates to a gas control unit of modular design, in particular for controlling the quantity of gas to be fed to a gas burner, having a pneumatically controlled gas control valve that is configured as a whole as a module and is usable in such a gas control unit of modular design together with a gas safety valve.