Electronic pressure regulators have many advantages over mechanical ones. The mechanical regulator maintains the downstream pressure. However, optimally with a constant flow rate, the flow rate and downstream pressure tend to fluctuate in most applications. Pumps and compressors send pulses. and the pressure will fluctuate according to demand. When the mechanical electric pressure regulator is inaccurate or does not respond quickly enough, the result is uneven output voltage. This simple device may be good enough when accuracy is not that important. However, digital/electronic air regulator provide better accuracy and dynamic regulation of outlet pressure by using control signals and feedback to create a force check. You can visit the website in order to know other uses and working process of electric pressure regulator at Gennidh.

pressure control

What Does an Electronic Pressure Regulator Do

An electronic pressure regulator maintains a constant output voltage within a pressurized system. Although there are fluctuations in the input voltage to the electric pressure regulator. Generally, mechanical pressure regulators are adjustable only by hand. This limits its usability in high-tech applications. When using electronic pressure controllers with a digital control system The precise output voltage can be controlled with the slightest adjustment of the control signal.

An internal pressure transducer forms a true closed-loop control device and provides a feedback voltage of the current output voltage. reading the feedback signal from the electric pressure regulator. The control system can make adjustments in real time. Dramatically improves consistent pressure control in the most demanding applications.

How the Electronic Pressure Regulator Functions

The electric pressure regulator is a vast improvement over the mechanical regulator. It’s quite simple and very effective in helping you get better control. They use a fill valve and a vent valve to maintain the outlet pressure at the required set point. A small internal pressure sensor monitors the output voltage. And the digital controller internally adjusts the valve output current to maintain the desired set point (eg, closed-loop control). The electronic pressure regulator maintains this pressure. Although the flow rate through the system has changed. Internal pressure transducers provide instant feedback to adjust flow from fill valves or relief valves. to keep the output voltage constant.

When the control signal increases the internal proportional valve will work. The increased pressure goes to the internal pilot chamber. When this happens Inlet pressure flows proportionally through the fill valve and into the cabin. The pressure in the cabin increases and the upper surface of the diaphragm is activated, as a result, the air supply valve connected to the diaphragm opens. and part of the supply voltage becomes the output voltage. This output voltage is fed back to the control circuit using a pressure sensor of the electric pressure regulator. The fill valve of the electronic water pressure regulator will continue to adjust slightly until the outlet pressure equals the desired control signal setpoint.

Applications for Electronic Pressure Regulators

There  are numerous applications of electric pressure regulator devices and the reason for its various applications is, it provides closed loop pressure control. They are usually used in many industries as well as domestically. Below listed are a few of the common applications of digital pressure regulator.

  • Direct control of pressurized air and inert gasses.
  • Operation of small bore cylinders.
  • Medical/analytical applications.
  • Leak testing.
  • Packaging.

Uses of a Pressure Regulator

The pressure controlling regulator is considered to be a common tool, which is used in many industries with different applications. The most common use of electric pressure regulator is in the air compressors. Here it is used to manage the outgoing pressure of an air receiver to meet the required need for that particular task. Electric air pressure regulator plays an important role in the propulsion pressurant control for many systems in the aerospace industry. It also includes the reaction control systems and altitude control system due to its corrosive fluids, temperature extremes, and presence of high vibration.

Basic Elements of a Pressure Regulator:

The commonly used electric pressure regulator is consisted on the below listed elements:

Pressure Reducing Element

Spring loaded poppet valves of the electronic air regulator are usually utilized as a pressure decreasing element. The poppet valve has the elastomeric sealing in the regular applications & thermoplastic sealing in the application of high pressure. It helps to seal the valve of the electric pressure regulator against the gas and fluid leakage. The poppet valve is being controlled by the spring force for opening the valve of the regulator. And let the flow of medium from inlet to outlet. When the output pressure rises, the poppet valve gets closed because of the force generated by the sensing element that overcomes the force of the spring.  

Load the Parts

The load element is used to force the sensor element to open the valve. The amount of spring force can be variable, which determines the amount of output pressure obtained.

Sensory Element:

Pistons are commonly used in high pressure, uneven, and high pressure output applications. They tend to be lazy due to the friction between the pinion seal and the adjusting body.

For higher accuracy, aperture-type sensor elements are suitable. They are made of elastomers or thin disc-shaped materials that are sensitive to pressure changes. Diaphragms have less friction than piston designs. They also offer a higher sensor area for a specific electric air pressure regulator size.

Types of Pressure Regulators:

Pressure regulators can be generally divided into the following categories:

  • Direct or autonomous
  • Pilot operation

Direct Operated Regulators

They are the simplest form of electro pneumatic pressure regulator. They usually operate at set pressures below 0.07 bar (1 psi) and can be more accurate. At higher pressures up to 35 bar (500 psi) they can be 10 to 20% accurate.

Directly operated electric pressure regulator are self-sufficient, meaning they do not require an external output line to operate effectively. They consist of an active spring-loaded valve directly controlled by a diaphragm assembly. Energy or pressure from the flow medium is used to activate the diaphragm. Increased downstream pressure affects the diaphragm, which closes the valve plug using a compression spring. This causes the valve to close. As the downstream pressure decreases, the spring force now exceeds the ambient force at the diaphragm and the valve opens.

A Regulator Operated by a Pilot

These electronic fuel pressure regulator are ideal for applications with high flow changes, oscillating inlet pressure or inlet pressure drop, conditions that typically occur with gas stored in cylinders or small inlet tanks. Provides precise pressure control. This type of electric pressure regulator is usually a primary or secondary device. Single-stage regulators are ideal for relatively small pressure drops. They are not suitable for large changes in inlet pressure or flow.

Two-phase regulators are the most common regulators operated by the pilot. The first stage consists of a spring pilot that controls the pressure in the main adjusting valve diaphragm. There is no downstream flow as long as the medium pressure in the spring pilot is low. As the pressure increases, the spring is compressed and the pilot valve is opened, creating a pressure difference between the inlet side of the main control valve and the outlet valve. This differential pressure drives the main operating valve and the flow under reduced pressure occurs through the outlet valve.

Need le Valve Regulator

Another control method uses two precision-machined needle valves made of durable ceramic material that use small ports and threaded pistons. One valve supplies pressure and the other supplies exhaust pressure from the regulated downstream system. The valves are designed to provide fast and precise control. The modulating valve is controlled by an algorithm that continuously monitors the difference between the downstream pressure, the setpoint, and the rate at which the pressure approaches the setpoint. The algorithm controls the needle valve to achieve a precise ramp at a set point and constant stability. This type of electric pressure regulator has a high degree of stability in the voltage output. This can be affected by temperature changes in the system or any fluctuations downstream. The Mensor CPC8000 uses this method which allows the product to provide precise and stable control at pressures up to 6000 psi.

Piston Actuator Regulator

They are generally used in hydraulic systems. The piston regulator works similarly to a deadweight tester by applying a force over the cross-sectional area of ​​the piston inside the cylinder. Pressure equals force divided by piston area, which is the definition of pressure P=F/A. The higher the pressure, the higher the pressure. The Mensor CPC8000-H uses this method to provide precise pressure control up to 23,000 psi. The benefit of this type of electric pressure regulator is its ability to achieve very high pressures. This is achieved by reducing the cross-sectional area of ​​the piston.”

Final Words

In this article, we have mentioned how the electric pressure regulator works and what it does. Basically, this pressure controlling device manages the fluid pressure when the pressure of liquids or gasses is not high or too low. Electronic pressure controllers are the best when there are fluctuations in the pressure or flow of regulators. 

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