Two-Stage Pressure Regulator With Outlet Pressure Compensation
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Solution Overview
Problem
Existing two-stage electronic pressure regulators are limited in achieving high outlet pressures and are prone to gas leakage, especially at low temperatures, which affects their precision and safety compliance.
Innovation Solution
The regulator includes a further fluid duct connecting the outlet duct to the first chamber of the cylinder, maintaining the pressure in the compensation chamber equal to the outlet pressure, and using a direct-flow proportional valve to control the mechanical valve's opening, while incorporating a diaphragm to prevent gas leakage and pressure oscillations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If existing two-stage electronic pressure regulators are used, then the device can regulate pressure, but the outlet pressure is limited and gas leakage occurs especially at low temperatures
Solution Approach 1:
The pressure regulator is divided into two stages: a first mechanical valve for initial pressure reduction and a second electronic valve for precise outlet pressure control. This segmentation allows each valve to operate within optimal pressure ranges, enabling higher outlet pressures while maintaining reliability and preventing gas leakage through the coordinated action of both stages
Solution Approach 2:
The electronic valve operates based on feedback from a pressure sensor that monitors the outlet pressure. This closed-loop feedback system continuously adjusts the electronic valve position to maintain the desired outlet pressure, preventing gas leakage by ensuring the valve remains properly closed when pressure targets are achieved, especially under varying temperature conditions
2Measurement precision
If existing two-stage electronic pressure regulators are used, then pressure regulation is achieved, but precision and safety compliance are compromised due to gas leakage
Solution Approach 1:
The second stage of pressure regulation replaces pure mechanical control with an electronic proportional valve controlled by a pressure sensor and control unit. This substitution enables precise measurement of outlet pressure and accurate adjustment to maintain safety compliance, eliminating gas leakage issues that plague purely mechanical systems while achieving superior pressure regulation precision
Solution Approach 2:
The electronic proportional valve adjusts the opening degree as a variable parameter based on real-time pressure feedback, allowing continuous and precise control of outlet pressure. This dynamic parameter adjustment enables the system to maintain high precision and safety compliance across varying operating conditions, preventing gas leakage by optimizing valve position rather than relying on fixed mechanical settings
3Device complexity
If a mechanical valve is used in the first stage, then the structure is simple, but the outlet pressure cannot reach high values
Solution Approach 1:
The pressure regulation function is segmented into two stages: a simple mechanical valve handles the first stage of pressure reduction, maintaining structural simplicity, while an electronic proportional valve handles the second stage to achieve high outlet pressures. This segmentation allows the system to combine the advantages of both simple mechanical structures and advanced electronic control, achieving high outlet pressures without excessive overall complexity
Solution Approach 2:
The intermediate pressure chamber serves as a mediator between the first mechanical valve and the second electronic valve. The mechanical valve reduces inlet pressure to an intermediate level, which then serves as the input for the electronic valve that precisely controls the final outlet pressure. This intermediary stage allows the system to achieve high outlet pressures by combining the capabilities of both valve types in series
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 design allows for higher outlet pressures and prevents gas leakage, enhancing precision and safety compliance, particularly at low temperatures, and expands the range of applicable pressures from 0 bar G to approximately equal to the inlet pressure, suitable for applications like direct-injection internal combustion engines.
Implementation Method 1
a first elastic element housed in the first chamber and configured to push the piston in the direction of opening of the first mechanical valve
Implementation Method 2
the pressure in the intermediate duct pushes the piston in the direction of closing of the first mechanical valve
Implementation Method 3
incorporating a diaphragm to prevent gas leakage and pressure oscillations
Data Source
AI summary
A two-stage electronic pressure regulator includes an inlet duct, an intermediate duct, an outlet duct, a first, mechanical, valve arranged between the inlet duct and the intermediate duct, and a second, electronic, valve arranged between the intermediate duct and the outlet duct. The mechanical valve includes a regulation element rigidly connected to a piston slidably mounted in a cylinder, defining a first chamber and a second chamber that are fluidically separated by the piston. The mechanical valve includes an elastic element housed in the first chamber and configured to push the piston in the direction of opening of the mechanical valve. The mechanical valve includes a fluid duct configured to set in fluid communication the intermediate duct and the second chamber of the cylinder in such a way that the pressure in the intermediate duct pushes the piston in the direction of closing of the mechanical valve. The electronic pressure regulator has a further fluid duct configured to set in fluid communication the outlet duct and the first chamber of the cylinder in such a way that the pressure in the outlet duct pushes the piston in the direction of opening of the mechanical valve.