Pressure Regulator Control Using Solenoid Current Sensing
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Solution Overview
Problem
Existing pressure regulators face challenges in rapidly responding to variations in inlet pressure without using an inlet pressure sensor, leading to potential delays and oscillations in controlling outlet pressure.
Innovation Solution
The pressure regulator employs an engaging current analysis circuit to detect variations in the solenoid current waveform of the electromagnetic valve, allowing for real-time monitoring and modulation of the loading and unloading electromagnetic valves to adjust for inlet pressure changes, effectively mimicking the role of an inlet pressure sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If an inlet pressure sensor is used to detect inlet pressure variations, then the responsiveness to inlet pressure fluctuations is improved, but the device complexity, dimensions and costs increase
Solution Approach 1:
The patent uses the solenoid current waveform as an intermediary indicator to indirectly detect inlet pressure variations. Instead of directly measuring inlet pressure with a sensor, the system monitors changes in the solenoid current waveform characteristics (amplitude, frequency, shape) which vary in response to inlet pressure changes. This intermediary approach provides the necessary pressure information without requiring an additional inlet pressure sensor, thus maintaining responsiveness while avoiding increased device complexity.
Solution Approach 2:
The patent replaces the mechanical/instrumental approach of using an inlet pressure sensor with an electrical/electronic approach by analyzing the solenoid current waveform. The control circuit electronically detects and analyzes current waveform characteristics to infer inlet pressure conditions, substituting a complex mechanical sensing system with a simpler electrical measurement and analysis system that uses existing components.
2Stability of the object's composition
If an inlet pressure sensor is installed, then the control stability is improved, but the dimensions and costs of the regulator increase
Solution Approach 1:
The solenoid current waveform serves as an intermediary that provides control stability information without requiring additional physical sensors. By monitoring waveform characteristics, the system achieves stable control of outlet pressure in response to inlet pressure variations while avoiding the space requirements of an inlet pressure sensor.
Solution Approach 2:
The existing solenoid, already present in the pressure regulator for valve control, is made multi-functional by also using its current waveform as a diagnostic indicator of inlet pressure conditions. This universal use of the solenoid for both actuation and sensing eliminates the need for dedicated inlet pressure sensing components, maintaining control stability without increasing regulator dimensions.
3Measurement precision
If the control circuit waits for outlet pressure feedback to detect inlet pressure variations, then the measurement is accurate, but the response time is delayed with oscillations
Solution Approach 1:
The patent performs preliminary detection of inlet pressure variations by monitoring the solenoid current waveform before these variations propagate through the system and affect outlet pressure. By detecting inlet pressure changes early through the current waveform indicator, the control circuit can take preliminary corrective action on the electromagnetic valves before outlet pressure deviations occur, eliminating delays and oscillations while maintaining accurate detection.
Solution Approach 2:
The system implements a dual feedback mechanism: the primary feedback from the outlet pressure sensor is supplemented by a secondary feedback loop that monitors solenoid current waveform characteristics. This additional feedback path provides real-time information about inlet pressure conditions, allowing the control circuit to adjust electromagnetic valve operation proactively and maintain outlet pressure stability without the delays associated with waiting for outlet pressure feedback alone.
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
This approach enables quicker and more stable control of outlet pressure, reducing oscillations and complexity by eliminating the need for an additional inlet pressure sensor, thus improving responsiveness to inlet pressure fluctuations.
Implementation Method 1
a loading electromagnetic valve (18) having a loading electromagnetic valve inlet (182) in fluid communication with the inlet passage (10) and a loading electromagnetic valve outlet (184) in fluid communication with the supply valve (14)
Data Source
AI summary
A pressure regulator includes an outlet pressure sensor, loading and unloading electromagnetic valves, and a regulator control circuit operatively connected to the loading and unloading electromagnetic valves and configured to pilot the loading and unloading electromagnetic valves to cancel an error signal given by a difference between an inlet signal corresponding to a desired outlet pressure and a feedback signal provided by the outlet pressure sensor. The pressure regulator includes an engaging current analysis circuit to detect and store reference characteristics of the engaging current of the solenoid of the loading electromagnetic valve in a stable inlet pressure condition, monitor the engaging current to detect any variation of its characteristics with respect to the corresponding reference characteristics, and, in the event of variation, provide a pilot modulation signal to at least one of the loading or unloading electromagnetic valves or a pressure variation signal to the regulator control circuit.