Pressure Regulator Pilot Control for Transient Flow Stability
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Solution Overview
Problem
Industrial systems face challenges in controlling fluid pressure and flow rate during transient conditions, leading to over- or under-dispensing of materials due to fluctuations, which are not accounted for in traditional control schemes, resulting in increased manufacturing costs and workflow disruptions.
Innovation Solution
A method involving a pressure control system that adjusts the pilot pressure of a control fluid in a pressure regulator to maintain target system pressures and flow rates by using a controller to send signals to a pressure control valve, actively compensating for hysteresis and initial pressure drops, even during transient conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional control schemes are used to control transient periods by segregating system operating conditions and performing calibration routines, then system pressure and flow rate can be controlled, but manufacturing costs increase and manufacturing workflow is disrupted due to production pauses during calibration
Solution Approach 1:
The system performs preliminary calibration actions by establishing lookup tables that store pre-calculated pressure and flow rate relationships for multiple operating conditions. This preliminary action allows the control system to quickly retrieve appropriate calibration data during transient periods without pausing production, thereby maintaining pressure control reliability while avoiding workflow disruptions
Solution Approach 2:
The control system dynamically adapts to transient conditions by using a controller that continuously monitors system state and selects appropriate calibration data from lookup tables based on current operating conditions. This dynamic adaptation allows the system to maintain accurate pressure and flow rate control throughout transient periods without requiring manual recalibration or production pauses
2Reliability
If traditional control schemes control transient periods by dispensing excess material until steady state is reached, then pressure and flow rate can be controlled, but material costs increase
Solution Approach 1:
The system pre-calculates and stores the relationship between pressure set points and corresponding flow rates in lookup tables during system setup. This preliminary action eliminates the need to dispense excess material during transient periods, as the controller can immediately determine the correct flow rate settings from the lookup tables, maintaining control reliability while preventing material waste
Solution Approach 2:
The control system serves itself by using the stored lookup table data to automatically adjust flow rate settings during transient conditions. The system retrieves appropriate calibration data and adjusts parameters without requiring external intervention or excess material dispensing, thereby maintaining reliable control while avoiding material loss
3Measurement precision
If conventional control schemes monitor parameters critical to system performance, then gradual changes in the system can be detected and counteracted, but transient pressure and flow rate changes during short duration operations cannot be properly controlled
Solution Approach 1:
The control system dynamically adapts its response based on the duration and nature of operating conditions. For transient conditions, the controller quickly retrieves pre-calibrated data from lookup tables and adjusts pressure and flow rate settings accordingly, rather than relying solely on gradual parameter monitoring. This dynamic approach enables reliable control during both transient and steady-state operations
4Adaptability or versatility
If the system operates at multiple pressure and flow rate combinations with short duration conditions, then system versatility is improved, but pressure and flow rate do not reach steady state causing control problems
Solution Approach 1:
The system performs preliminary calibration for multiple operating conditions and stores the results in lookup tables. This preliminary action enables the system to handle multiple pressure and flow rate combinations reliably, even during short duration transient conditions, by quickly retrieving appropriate calibration data without requiring steady state to be reached
Solution Approach 2:
The control system dynamically selects appropriate calibration parameters from lookup tables based on current operating conditions. This dynamic selection allows the system to maintain reliable pressure and flow rate control across multiple operating modes, adapting instantly to transient conditions without requiring steady state
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 allows for cost-effective adaptation to multiple operating conditions and environmental changes, reducing material waste and manufacturing costs by precisely regulating system pressures and flow rates without the need for repeated calibration routines.
Implementation Method 1
actuating the pressure control valve to vary a pilot pressure of a control fluid contained within a pressure control line that is fluidly connected to a pressure regulator
Implementation Method 2
A diaphragm of the pressure regulator is disposed between the pressure control line and a system line and acts on a fluid with the system line to modify the system pressure
Data Source
AI summary
A method for controlling a system pressure within a closed system includes sending a signal to a pressure control valve corresponding to a pressure set point and actuating the pressure control valve to vary a pilot pressure of a control fluid contained within a pressure control line that is fluidly connected to a pressure regulator. A diaphragm of the pressure regulator is disposed between the pressure control line and a system line and acts on a fluid with the system line to modify the system pressure.