Pressure Reducer With Integrated Leak Detection and Auto Shutoff
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Solution Overview
Problem
Existing pressure reducers in water supply systems struggle to reliably detect leaks downstream, which can cause significant damage, and require separate leakage detection devices that need to be installed externally.
Innovation Solution
Integration of a sensor for leakage detection within the pressure reducer, specifically in the non-fluid-conducting region, which can detect micrometer-range movements of the spring plate associated with the diaphragm, coupled with a control unit to automatically close the valve in case of a leak exceeding a limit value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate leakage detection device is installed externally, then leakage detection capability is provided, but device complexity and installation requirements increase
Solution Approach 1:
The patent combines the leakage detection function with the existing pressure reducer by integrating a sensor into the non-fluid-conducting region. This merging eliminates the need for separate external leakage detection devices, reducing overall system complexity while maintaining reliable leakage detection capability through the sensor's ability to detect tappet movement.
Solution Approach 2:
The pressure reducer is transformed into a multi-functional device that simultaneously performs pressure reduction and leakage detection. The sensor integrated into the non-fluid-conducting region enables the pressure reducer to monitor leakage conditions without requiring additional dedicated equipment, thereby achieving universality.
2Reliability
If the sensor is integrated into the non-fluid-conducting region, then leakage detection is enabled without interfering with fluid flow, but manufacturing precision requirements increase
Solution Approach 1:
The pressure reducer is divided into fluid-conducting and non-fluid-conducting regions. The sensor is specifically placed in the non-fluid-conducting region where it can detect tappet movement without being exposed to fluid pressure variations, thereby enabling reliable leakage detection while minimizing interference with fluid flow and reducing manufacturing precision requirements.
Solution Approach 2:
The tappet serves as an intermediary element that transmits leakage information to the sensor. The sensor detects the movement of the tappet, which is mechanically coupled to the valve mechanism, thereby indirectly detecting leakage conditions without requiring direct exposure to fluid streams or high-precision positioning in the fluid path.
3Object-affected harmful factors
If automatic valve closing is implemented upon leakage detection, then damage prevention is improved, but control system complexity increases
Solution Approach 1:
The system implements a feedback mechanism where the sensor continuously monitors tappet position and provides real-time information to the control unit. When leakage is detected through tappet movement, the control unit automatically responds by closing the valve, thereby preventing further damage. This closed-loop feedback system achieves effective damage prevention with minimal additional control complexity.
Solution Approach 2:
The pressure reducer system performs self-protection by automatically detecting leakage conditions and closing the valve without requiring external intervention. The integrated sensor and control unit enable the system to monitor its own operational state and take corrective action, thereby serving itself to prevent damage from leakage.
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
Enables the pressure reducer to perform both pressure reduction and leakage detection functions without a separate device, preventing damage by automatically closing the valve upon detecting a leakage, thus ensuring constant water pressure and system integrity.
Implementation Method 1
In particular, a capacitive sensor or inductive sensor is used which detects a leakage-induced movement of the spring plate facing the diaphragm in the micrometer range
Implementation Method 2
In particular, a capacitive sensor or inductive sensor is used which detects a leakage-induced movement of the spring plate facing the diaphragm in the micrometer range
Implementation Method 3
A force that is a function of the pressure prevailing in the outlet pressure chamber acts in the closing direction of the valve
Implementation Method 4
a spring force of a spring element acting in the opening direction of the valve acts on the one hand
Data Source
AI summary
Pressure reducer (10) having a housing (11) with a valve (12) positioned in said housing (11), wherein in closed position the valve (12) separates an inlet pressure chamber (13) of the housing (11) from an outlet pressure chamber (14) of the housing (11), and in open position connects the inlet pressure chamber (13) and the outlet pressure chamber (14), wherein the valve (12) has a diaphragm (16) acting on a valve tappet (15), on which diaphragm, by providing a pressure reducing function, a spring force of a spring element (17) acting in the opening direction of the valve (12) acts on the one hand and a force that is a function of the pressure prevailing in the outlet pressure chamber (14) acting in the closing direction of the valve (12) acts on the other hand, wherein the valve (12) has, attached to the valve tappet (15), a valve body (21) which, in closed position, bears against a valve seat (22) in a sealing manner and which in open position is raised off the valve seat (22), and wherein the spring element (17) is arranged between spring plates (18, 19), namely between a spring plate (18) facing the diaphragm (16) and a spring plate (19) facing away from the diaphragm (16). A sensor (27) for detecting leakage is integrated into the pressure reducer.