Welding Gas Flow Regulator Sequencing to Prevent Surge
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Solution Overview
Problem
Welding-type systems experience gas surges due to pressure buildup when the on/off solenoid valve is closed, leading to negative impacts on subsequent welding operations.
Innovation Solution
The implementation of an improved fluid supply system that includes a proportional valve upstream from the on/off solenoid valve, allowing the proportional valve to close before the on/off valve and equalizing pressure to ambient before closure, thereby preventing pressure buildup and gas surges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the on/off solenoid valve is closed during welding operations, then gas flow is stopped, but pressure buildup occurs leading to gas surges
Solution Approach 1:
The proportional valve performs preliminary action by closing before the on/off solenoid valve to equalize pressure in the flow path. This preliminary pressure equalization prevents the harmful gas surge that would otherwise occur when the main valve closes and subsequently reopens, resolving the contradiction between stopping gas flow and preventing pressure buildup.
2Ease of operation
If manual flow regulators are used to control gas flow, then flow rate adjustment is possible, but manual intervention is required and pressure equalization is not automatic
Solution Approach 1:
The patent replaces the manual mechanical flow regulator with an automated proportional valve controlled by a control circuit. This substitution eliminates the need for manual intervention while adding automatic pressure equalization functionality, resolving the contradiction between ease of operation and extent of automation.
Solution Approach 2:
The proportional valve system performs self-service by automatically equalizing pressure in the flow path before the on/off valve closes. The system monitors and adjusts pressure without external intervention, eliminating the need for manual operation while maintaining flow control capability.
3Speed
If the on/off valve closes quickly to stop gas flow, then response time is fast, but pressure surge occurs in the flow path
Solution Approach 1:
The proportional valve executes preliminary action by gradually closing before the on/off valve to equalize pressure. This preliminary pressure management allows the on/off valve to close quickly without causing surge, resolving the contradiction between fast response speed and pressure control.
Solution Approach 2:
The proportional valve provides beforehand cushioning by gradually reducing pressure in the flow path before the on/off valve closes. This cushioning effect prevents the pressure surge that would result from rapid valve closure, resolving the contradiction between speed and pressure buildup.
Data Source
AI summary
Systems and apparatus are disclosed relating to improved fluid supply systems. In some examples, the improved fluid supply systems use an electrically controllable proportional valve and a surge prevention process to prevent a surge of pressurized fluid at the end of a welding-type operation. In particular, the surge prevention process may coordinate closure of the proportional valve and an on/off solenoid valve so that pressure in the fluid flow path can equalize to an ambient pressure after a welding operation (and/or a post flow operation) has ended. This coordination ensures that there is no pressure buildup and/or associated surge of fluid when the on/off solenoid valve is next opened (e.g., at the start of the next welding operation).