Pressure Regulator Floating Piston Stabilizes Outlet Pressure
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Solution Overview
Problem
Pressure regulators for compressed gases face instability due to dependence on inlet pressure changes, which affects the outlet pressure and device performance, especially in high flow capacity applications where production tolerances and size increases exacerbate this issue.
Innovation Solution
A pressure regulator design featuring a floating piston connected to a stabilizing elastic element, which compensates for inlet pressure changes by compressing a stabilizing elastic element, thereby maintaining a stable outlet pressure through a connection element that decompresses the regulating elastic element, allowing for adjustable chamber size and reduced production tolerance dependence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the regulator piston area is increased to handle high flow capacity, then the flow capacity is improved, but the force from inlet pressure increases causing greater outlet pressure instability
Solution Approach 1:
The regulator piston is divided into two separate pistons: a regulating piston for controlling outlet pressure and a floating piston for compensating inlet pressure changes. This segmentation allows each piston to have optimized area for its specific function, maintaining high flow capacity while improving pressure stability.
Solution Approach 2:
The floating piston acts as an intermediary between the inlet pressure and the regulating piston. It receives the inlet pressure changes and transmits compensated force to the regulating piston through the connection element, eliminating the direct harmful influence of inlet pressure fluctuations on outlet pressure control.
2Reliability
If production tolerances are reduced to improve precision, then manufacturing cost increases, but outlet pressure stability is improved
Solution Approach 1:
The floating piston provides automatic feedback compensation for inlet pressure changes. When inlet pressure varies, the floating piston moves accordingly and adjusts the force on the regulating piston, automatically compensating for pressure deviations without requiring precision adjustments during manufacturing.
Solution Approach 2:
The system changes the operational parameters by introducing a second piston with different area ratios. The floating piston has a larger area to efficiently sense inlet pressure changes, while the regulating piston maintains appropriate area for precise outlet pressure control, optimizing performance without tightening manufacturing tolerances.
3Reliability
If a floating piston and stabilizing elastic element are added to compensate for inlet pressure changes, then outlet pressure stability is improved, but device complexity increases
Solution Approach 1:
The floating piston and regulating piston share a common cylinder chamber and are connected through a unified connection element. The stabilizing elastic element is integrated into the same assembly, merging multiple functions (pressure sensing, force transmission, and regulation) into a compact integrated structure that minimizes overall complexity.
Solution Approach 2:
The connection element serves multiple functions: it connects the floating piston to the regulating piston, transmits force between them, and provides a mounting point for the stabilizing elastic element. This multi-functionality reduces the number of separate components needed, offsetting the added complexity of the floating piston mechanism.
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 design enhances the stability of the pressure regulator by minimizing the impact of inlet pressure changes on outlet pressure, ensuring a more consistent and reliable gas delivery without increasing the regulator's size, and allows for adjustment to a reference outlet pressure.
Implementation Method 1
a stabilizing elastic element arranged to be compressed by a force resulting from an increase in the force of the gas under inlet pressure acting on the floating piston
Implementation Method 2
the stabilizing elastic element is connected to the regulating elastic element via a connection element arranged so that the compression of the stabilizing elastic element results in a decompression of the regulating elastic element
Data Source
AI summary
A pressure regulator includes a body having a gas inlet for a gas having an inlet pressure and a gas outlet for the gas having an outlet pressure lower than the inlet pressure and a passage connecting the outlet to the inlet. A regulator piston is arranged to control the outlet pressure of the gas by moving closer to and further away from a pressure regulator seat, and a regulating elastic element is arranged to bias the regulating piston in a direction away from the pressure regulator seat, against the force of gas at outlet pressure acting on the regulator piston in a direction towards the pressure regulator seat. The passage is fluidly connected to a floating piston, arranged to move in response to increased inlet pressure by compressing a stabilizing elastic element. The stabilizing elastic element is connected to the regulating elastic element via a connection element.