Reciprocating Valve Pressure Regulator for Pipe Retrofitting
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Solution Overview
Problem
Conventional pressure regulators for fluid systems are complex, large, costly, and require significant maintenance, especially for high mass flow rates, and often necessitate redesigning pipe-work layouts for installation.
Innovation Solution
A simple pressure regulator device with a reciprocally moving valve member, actuated by the difference between downstream and reference pressures, which controls the mass flow rate through valve apertures to maintain a stable output pressure without deformable parts, allowing easy retrofitting within existing pipe-work without additional space or certification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pressure regulators are used to control fluid pressure, then pressure regulation is achieved, but device complexity increases due to control circuitry and valve actuation components
Solution Approach 1:
The invention extracts and eliminates the complex control circuitry and computer components from the pressure regulator system. Instead of using electronic control systems, the patent employs a purely mechanical feedback mechanism where the output pressure directly actuates the valve through a simple diaphragm and spring assembly, achieving pressure regulation without any electronic complexity
Solution Approach 2:
The pressure regulator is designed to be self-regulating through a mechanical feedback loop. The output pressure acts on a diaphragm that automatically adjusts the valve position via a spring mechanism, eliminating the need for external control systems, sensors, or power sources. The system serves itself by using the process output to control the process input
2Reliability
If pilot operated pressure regulators are used to amplify pressure control, then pressure regulation is achieved, but device size increases and protrudes from pipe-work
Solution Approach 1:
The invention merges the pressure sensing, amplification, and valve control functions into a single compact assembly that fits within the pipe diameter. The regulator body, diaphragm chamber, and valve mechanism are integrated into one unit without separate pilot stages, eliminating the need for additional space and allowing installation within existing pipe-work without protrusion
3Reliability
If conventional pressure regulators with multiple moving components are used, then pressure control is achieved, but maintenance requirements increase due to calibration and component wear
Solution Approach 1:
The invention employs simple, robust mechanical components that are inherently resistant to wear and calibration drift. The spring-loaded diaphragm mechanism and basic valve assembly have no electronic parts, sensors, or precision adjustments requiring calibration. These simple components can be easily replaced as disposable units, eliminating complex maintenance requirements
Solution Approach 2:
The mechanical feedback mechanism automatically compensates for wear and pressure variations without requiring user intervention or calibration. The spring tension and diaphragm response self-adjust to maintain accurate pressure control, eliminating the need for periodic calibration services
4Measurement precision
If computer controlled pressure regulators are used to achieve sensitivity, then pressure regulation precision is improved, but device complexity and cost increase
Solution Approach 1:
The invention replaces electronic sensing and control systems with a direct mechanical feedback mechanism. The output pressure physically acts on a diaphragm that is connected through a spring to the valve actuator, creating an automatic balance point where the valve opens or closes based purely on pressure differential. This mechanical system achieves precise pressure regulation without electronic components
Solution Approach 2:
The system uses the process output pressure itself to control the valve position through the mechanical feedback loop. The diaphragm senses output pressure and automatically adjusts the valve to maintain the setpoint, eliminating the need for external sensors, controllers, or power sources while maintaining precision
5Ease of operation
If existing pipe-work layouts are maintained for installation, then installation complexity is reduced, but pressure regulator performance may be compromised
Solution Approach 1:
The pressure regulator is designed as a compact segmented module that can be inserted into existing pipe-work at standard flange locations or between pipe sections. The device divides the pipe flow path into upstream and downstream sections with the regulator body fitting within the available space, allowing installation without redesigning the overall pipe layout while maintaining full pressure regulation functionality
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 device provides stable pressure regulation with low maintenance costs, high mass flow rates, and flexibility for various applications, reducing installation complexity and costs by fitting within existing pipe layouts, and accommodating a wide range of pressures and flow rates.
Implementation Method 1
the valve member being acted on by the downstream pressure and the reference pressure... the valve member is simply moved by the difference in the downstream and reference pressures
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3
AI summary
A device (1; 101) for controlling the flow of a fluid through a conduit (2; 102; 402; 602; 702) from an upstream side (3; 103; 703) to a downstream side (5; 105; 405; 605; 705), the device (1; 101) comprising: a valve having a valve member (14; 114; 414; 514; 614) arranged to move reciprocally selectively to open and close one or more valve apertures (10; 110; 412; 512; 611, 612), thereby controlling flow of the fluid from the upstream side (3; 03; 703) to the downstream side (5; 105; 405; 605; 705); and means for introducing a reference pressure (24; 124; 324; 424; 524; 624); wherein said valve member (14; 114; 414; 514; 614) is acted on by the pressure of the downstream side (5; 105; 405; 605; 705) and the reference pressure so as to be moved by the difference between said pressures.