Smoke Generator Valve Control for Consistent Output
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Solution Overview
Problem
Smoke generators face issues with uneven smoke output due to variations in gas pressure and backpressure, leading to quality fluctuations and potential blockages, especially at low smoke outputs, which are economically and environmentally undesirable.
Innovation Solution
A method of controlling a smoke generator using a valve to regulate gas pressure and a fluid driving means to control smoke liquid flow, with a mixing unit and heat exchanger to vaporize the smoke liquid, and a pressure sensor for feedback control, ensuring a consistent smoke output and reduced gas consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high gas pressure is used to drive smoke liquid through the heat exchanger, then complete vaporization and sufficient smoke liquid flow is ensured, but gas consumption increases and blockages occur at low smoke outputs
Solution Approach 1:
The system dynamically adjusts gas pressure based on the required smoke output level. At low smoke outputs, reduced pressure prevents blockages and lowers gas consumption. At high smoke outputs, increased pressure ensures complete vaporization and sufficient flow. This dynamic adaptation resolves the contradiction between maintaining reliable vaporization and reducing gas consumption.
Solution Approach 2:
The system changes the operating pressure parameter according to the smoke generation demand. By varying pressure from low to high levels based on operational requirements, the system avoids constant high pressure that causes blockages and waste, while ensuring adequate pressure is available when needed for complete vaporization.
2Stability of the object's composition
If high gas pressure is maintained to prevent blockages at low smoke outputs, then flow stability is improved, but gas consumption and environmental impact worsen
Solution Approach 1:
The system implements dynamic pressure adjustment that adapts to smoke output requirements. At low outputs, lower pressure is used which still maintains adequate flow stability through proportional control, while significantly reducing gas consumption and environmental impact. This dynamic approach eliminates the need for continuously high pressure.
Solution Approach 2:
The system uses feedback from smoke density sensors and pressure measurements to automatically adjust gas pressure to the minimum level required for stable operation. This self-regulating mechanism ensures flow stability is maintained through intelligent control rather than brute-force high pressure, reducing unnecessary gas consumption and environmental harm.
3Ease of operation
If manual pressure control is used to allow variation in output, then operational flexibility is improved, but smoke output uniformity deteriorates due to backpressure variations
Solution Approach 1:
The system incorporates feedback control using smoke density parameters and pressure sensor measurements. The controller continuously monitors actual smoke output and gas pressure, then adjusts the pressure control valve to maintain uniform smoke generation. This feedback mechanism compensates for backpressure variations and ensures consistent output while preserving manual override capability for operational flexibility.
Solution Approach 2:
The system replaces manual mechanical pressure control with an electronically controlled pressure control valve that responds to feedback signals. This substitution enables precise, rapid adjustments to maintain uniform smoke output while preserving the ability to manually set desired output levels, combining the benefits of automated uniformity control with operational flexibility.
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 method achieves a stable and controllable smoke output with reduced gas and energy consumption, enhanced safety, and improved environmental sustainability by maintaining consistent pressure and flow, even at low smoke outputs, and detecting potential gas pressure losses.
Implementation Method 1
a heat exchanger to heat the mixture of the pressurized gas and the smoke liquid to vaporize the smoke liquid and form a smoke upon ejection into surrounding air
Implementation Method 2
measuring a gas pressure at a position between the valve and the heat exchanger
Data Source
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AI summary
The invention relates to a method of controlling a smoke generator. The smoke generator is adapted to be connected to a supply of a pressurized gas and a supply of a smoke liquid and further comprises a valve to regulate the pressure of the gas, a fluid driving means, a mixing unit for mixing the smoke liquid and the gas, and a heat exchanger heating the mixture of the pressurized gas and the smoke liquid to vaporize the smoke liquid and form a smoke upon ejection into surrounding air. The control method according to the invention then comprises the steps of receiving a smoke density parameter indicative of a desired amount of smoke to be generated by the smoke generator, measuring a gas pressure at a position between the valve and the heat exchanger, and using these parameters in controlling the valve. The invention further relates to a smoke generator arranged for performing the control method.