Two-Stage Electronic Pressure Regulator for High-Pressure Leak Control
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Solution Overview
Problem
Existing electronic pressure regulators face limitations in achieving high outlet pressures and are prone to gas leakage, especially at low temperatures, which restrict their application in systems requiring precise pressure control and safety compliance.
Innovation Solution
A two-stage electronic pressure regulator design that includes a 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 pressure oscillations and gas leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a conventional electronic pressure regulator is used, then the structure is simple, but the outlet pressure is limited and gas leakage occurs at low temperatures
Solution Approach 1:
The pressure regulator is divided into two stages: a mechanical valve for initial pressure reduction and an electronic proportional valve for precise final pressure control. This segmentation allows each stage to operate within optimal pressure ranges, enabling high outlet pressures while maintaining reliability and preventing gas leakage through the electronic valve's precise control capabilities
Solution Approach 2:
A compensation chamber is introduced as an intermediary element between the mechanical and electronic valves. This chamber receives pressure from the mechanical valve and transmits it to the electronic valve, while also being connected to the outlet. The compensation chamber acts as a mediator that balances pressures and enables the electronic valve to maintain precision even at high outlet pressures, preventing gas leakage
2Measurement precision
If a two-stage design with compensation chamber is used, then outlet pressure precision is improved, but device complexity increases
Solution Approach 1:
The compensation chamber is fluidically integrated with both the mechanical valve system and the electronic proportional valve, merging their functions into a unified pressure control system. This integration allows the compensation chamber to simultaneously serve as pressure transmission medium for the mechanical valve and pressure reference for the electronic valve, achieving high precision outlet pressure control without proportionally increasing device complexity
Solution Approach 2:
The compensation chamber performs multiple functions: it receives pressure from the mechanical valve, transmits pressure to the electronic proportional valve, connects to the outlet, and provides pressure balancing. This multi-functionality allows a single component to address multiple control requirements, improving outlet pressure precision while minimizing the increase in device complexity
3Adaptability or versatility
If the mechanical valve is used for pressure control, then the structure is simple, but the outlet pressure depends on inlet pressure and flow rate
Solution Approach 1:
The electronic proportional valve operates with feedback control, continuously monitoring the outlet pressure and adjusting its opening to maintain the desired pressure setpoint. This feedback mechanism decouples the outlet pressure from variations in inlet pressure and flow rate, providing adaptability while achieving high manufacturing precision through electronic control
Solution Approach 2:
The conventional purely mechanical pressure control is replaced with an electronic proportional valve that uses electronic signals and feedback control algorithms. This substitution replaces mechanical linkage precision requirements with electronic control precision, enabling outlet pressure independence from inlet conditions while achieving superior pressure regulation precision
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 design enables higher outlet pressures, improved precision, and safety by preventing gas leakage, expanding the regulator's application range and ensuring compliance with international safety standards.
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
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 first mechanical valve
Implementation Method 3
the additional fluid duct comprises a diaphragm that hinders propagation of pressure oscillations between the outlet duct and the first chamber of the cylinder
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Described herein is a two-stage electronic pressure regulator (5). The regulator (5) comprises an inlet duct (31), an intermediate duct (32), an outlet duct (33), a first, mechanical, valve (10) arranged between the inlet duct and the intermediate duct, and a second, electronic, valve (20) arranged between the intermediate duct and the outlet duct. The mechanical valve (10) comprises a regulation element (402) rigidly connected to a piston (404) slidably mounted in a cylinder (406), thus defining a first chamber (406A) and a second chamber (406B) that are fluidically separated by the piston (404). The mechanical valve further comprises an elastic element (14) housed in the first chamber (406A) and configured to push the piston (404) in the direction of opening of the mechanical valve (10). The mechanical valve further comprises a fluid duct configured to set in fluid communication the intermediate duct (32) and the second chamber (406B) of the cylinder in such a way that the pressure (P32) in the intermediate duct pushes the piston (404) in the direction of closing of the mechanical valve (10). The electronic pressure regulator (5) comprises a further fluid duct (51) configured to set in fluid communication the outlet duct (33) and the first chamber (406A) of the cylinder (406) in such a way that the pressure (P33) in the outlet duct (33) pushes the piston (404) in the direction of opening of the mechanical valve (10).