Expandable Pilot Assembly With Modular Manifold for Pressure Accuracy
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Solution Overview
Problem
Pressure regulators in industrial applications face challenges in maintaining accurate control of downstream pressure, especially under high inlet pressures and varying demand conditions, often requiring robust designs that are costly and time-consuming to construct, while also needing to accommodate different applications and environments.
Innovation Solution
A modular pilot assembly with an expandable manifold and internal variable orifice is introduced, allowing for additional pilot valves to be added, providing improved accuracy and response time, and is compatible with other flow control devices, enabling better pressure regulation and adaptability across various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robust and sturdy design is adopted to withstand high pressures and caustic environments, then reliability and operating pressure capability are improved, but manufacturing cost and construction time increase
Solution Approach 1:
The pressure regulator is divided into modular components including a valve body, pilot assembly, diaphragm chamber, and seat assembly. Each module can be manufactured separately using appropriate materials and techniques, then assembled together. This segmentation allows critical high-pressure components to be robust while other parts can be simpler, reducing overall manufacturing cost and time.
Solution Approach 2:
The patent employs different materials for different components based on their specific requirements. For example, the valve body and seat are made from materials suitable for high-pressure and caustic environments, while other components use materials optimized for their specific functions. This selective material usage achieves the required reliability without unnecessarily increasing manufacturing costs across all components.
2Measurement precision
If additional pilot valves are added to improve pressure control accuracy, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The pilot assembly is designed as a separate, self-contained module that can be easily added or removed from the main valve body. This segmentation allows the system to start with a simple single-pilot configuration and expand to multi-pilot configurations as needed, improving pressure control accuracy without initially increasing complexity. Each pilot valve functions independently to control specific aspects of pressure regulation.
Solution Approach 2:
The pilot assembly is designed with universal mounting interfaces and standardized connections that allow the same basic module to be used in single-pilot or multi-pilot configurations. The expandable manifold can accommodate one or more pilot valves using the same mounting approach, reducing the complexity increase that would normally accompany additional components.
3Adaptability or versatility
If an expandable manifold design is used to accommodate additional pilot valves, then adaptability is improved, but device complexity increases
Solution Approach 1:
The pilot valves are designed to be nested within or mounted on the expandable manifold structure. The manifold provides a centralized mounting platform with integrated fluid passages that can accommodate one or more pilot valves in a compact arrangement. This nesting approach allows adaptability for different configurations without proportionally increasing the overall device volume or complexity.
Solution Approach 2:
The expandable manifold is designed with universal mounting interfaces and standardized fluid connections that work the same way regardless of how many pilot valves are installed. This universality allows the same basic manifold structure to support single-pilot, dual-pilot, or multi-pilot configurations without requiring different hardware designs, thereby improving adaptability while minimizing the increase in device complexity.
4Ease of operation
If a spring-operated valve design is used to maintain downstream pressure, then ease of operation is improved, but response time and accuracy deteriorate under rapid demand changes
Solution Approach 1:
The pilot valve acts as an intermediary that controls the main valve operation. Instead of the spring-operated valve directly responding to downstream pressure changes, the pilot valve senses pressure changes and modulates the control signal to the main valve. This intermediary approach allows the main valve to respond more quickly and accurately to demand changes while the spring mechanism continues to provide ease of operation and fail-safe functionality.
Solution Approach 2:
The system incorporates feedback through the pilot valve that continuously monitors downstream pressure and adjusts the main valve position accordingly. The pilot valve receives feedback about actual downstream pressure conditions and modulates the control signal to the main valve to maintain the desired setpoint, enabling rapid response to demand changes while preserving the simple spring-operated mechanism for baseline operation.
Data Source
AI summary
A pilot assembly is configured for use with various types of flow controls. These configurations include a manifold with an internal flow network that connects pilot valves and an adjustable orifice. The pilot valves may have a fixed and variable differential pressure. In one implementation, the manifold comprises a pair of separable blocks, one each that includes part of the internal flow network. This construction also permits the manifold to expand with, for example, and additional block for an additional pilot valve. This feature configures the manifold for use in working monitor systems or those systems that deploy multi-stage pressure regulation.