Series Pressure Regulators for Constant Flow Under Variable Pressure
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Solution Overview
Problem
Existing fluid flow systems struggle to maintain a consistent flow rate at specific locations, leading to inefficiencies and potential damage to equipment due to varying pressure conditions.
Innovation Solution
A flow control device comprising multiple pressure regulators connected in series or parallel configurations, where upstream and downstream regulators are set to maintain constant pressures, ensuring a constant flow rate by maintaining a pressure differential across the downstream regulator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single pressure regulator is used to control flow rate, then the device complexity is low, but the flow rate cannot be maintained at a constant level due to varying upstream pressure
Solution Approach 1:
The system divides the pressure regulation function into two separate pressure regulators: a first pressure regulator that maintains constant outlet pressure, and a second pressure regulator that maintains constant pressure differential. This segmentation allows each regulator to perform a specialized function, ensuring constant flow rate while managing complexity through functional decomposition
2Adaptability or versatility
If upstream pressure varies, then the system adapts to different operating conditions, but the flow rate becomes inconsistent and equipment may be damaged
Solution Approach 1:
The system employs negative feedback control in both pressure regulators. The first regulator uses feedback from its outlet pressure to adjust the valve position and maintain constant pressure. The second regulator uses feedback from the pressure differential across it to maintain constant flow. This feedback mechanism allows the system to adapt to varying upstream pressure while maintaining reliable, consistent flow rate
3Ease of operation
If pressure differential varies across the regulator, then the system responds to downstream pressure changes, but the flow rate cannot be kept constant
Solution Approach 1:
The system segments the pressure control function so that the first pressure regulator handles outlet pressure stabilization while the second pressure regulator specifically manages pressure differential maintenance. This segmentation enables the second regulator to respond to downstream pressure changes and maintain constant pressure differential, thereby ensuring constant flow rate
Solution Approach 2:
The first pressure regulator acts as an intermediary that stabilizes the outlet pressure before it reaches the second pressure regulator. This intermediary function isolates the second regulator from upstream pressure variations, allowing it to focus on maintaining constant pressure differential and flow rate
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 solution ensures a stable and consistent fluid flow rate at identified locations within the system, enhancing system performance and preventing equipment damage by regulating pressure differentials.
Implementation Method 1
maintaining a pressure differential across the downstream regulator
Data Source
AI summary
A method to control a flow rate in a fluid flow network is disclosed. The method includes setting the outlet port of an upstream pressure regulator in a flow control device to have a first constant pressure that is below a minimum upstream pressure delivered from a upstream portion to the inlet port of the upstream pressure regulator, setting the outlet port of a downstream pressure regulator in the flow control device to have a second constant pressure to maintain a constant pressure differential across the downstream pressure regulator, and maintaining, based on the minimum upstream pressure to the flow control device exceeding the first constant pressure and further based on the constant pressure differential maintained across the downstream pressure regulator, the flow rate of the flow control device at a constant value.