Multi-Valve Pressure Controller for Overshoot-Free Output Control
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Solution Overview
Problem
Proportional pressure controllers face issues with weight, cost, electrical current consumption, system pressure undershoot or overshoot, 'motor-boating', difficulty in achieving zero pressure at the outlet port, and backflow contamination, which affect the operation and performance of pressure-controlled devices.
Innovation Solution
A valve assembly with a housing, fluid inlet, outlet, and exhaust, featuring a plurality of fill and dump valves, a pressure sensor, and a controller that dynamically controls the valves to achieve desired pressure by selectively opening and closing them, using high-flow and low-flow valves to prevent overshooting and undershooting, and isolating the pressure sensor from contaminated fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solenoid actuators are used to reposition main valves, then pressure control function is achieved, but weight and expense increase
Solution Approach 1:
The patent divides the single main valve into multiple smaller valves (first valve, second valve, third valve, fourth valve). Each valve is controlled by simpler actuators rather than a single large solenoid actuator. This segmentation reduces the weight and complexity of the actuation system while maintaining pressure control functionality through coordinated operation of multiple valves.
2Reliability
If solenoid actuators are used to reposition main valves, then pressure control function is achieved, but electrical current consumption increases
Solution Approach 1:
The patent segments the pressure control function across multiple smaller valves, each requiring less electrical current to actuate compared to a single large main valve. The controller coordinates these smaller valves to achieve the desired pressure control with reduced overall power consumption.
3Reliability
If main valves with mass are used, then pressure control is achieved, but system pressure undershoot or overshoot occurs
Solution Approach 1:
The patent uses multiple lighter valves instead of a single heavy main valve. The coordinated opening and closing of these segmented valves allows for finer control of pressure changes, reducing the mass-related inertia that causes overshoot and undershoot while maintaining effective pressure control.
Solution Approach 2:
The controller implements periodic or sequential actuation of the multiple valves rather than single abrupt movements. This staged approach to valve operation allows the system to respond more smoothly to pressure changes, preventing the oscillations and inaccuracies caused by the sudden movement of heavy main valves.
4Speed
If rapid opening and closing sequence is used to control pressure, then pressure control response is improved, but wear and operating costs increase
Solution Approach 1:
The patent distributes the control action across multiple valves, allowing the controller to achieve rapid pressure response by coordinating several lighter valves rather than rapidly actuating a single heavy valve. This reduces the mechanical stress and wear on each individual valve while maintaining fast response capability.
Data Source
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AI summary
A valve assembly having a plurality of fill valves that permit a fluid to flow from a fluid inlet into an interior flow path to increase a pressure of the fluid output from a fluid outlet, and a plurality of dump valves that permit the fluid to flow from the interior flow path to an exhaust to reduce the pressure of the fluid output from the fluid outlet. The valve assembly includes a controller that is configured for receipt of a command signal including a desired pressure of the fluid to be output from the fluid outlet, and is configured for receipt of a signal from a pressure sensor that is indicative of an actual pressure of the fluid output from the fluid outlet, wherein based on a comparison of the command signal with the signal indicative of the actual pressure, the controller is configured to selectively open and close each of the fill valves and each of the dump valves until the actual pressure is equal to the desired pressure.