Instability analysis and improvement of a high-pressure and high-flow air pressure-reducing regulator

Abstract

This study is concerned with the instability analysis and improvement of a high-pressure and high-flow air pressure-reducing regulator (HPHFPRR). The outlet pressure of HPHFPRR abruptly exceeds the initial set pressure value under high-pressure and high-flow conditions. To address this instability issue of HPHFPRR during practical usage, this study conducted simulations to analyze the transient flow field characteristics under varying valve opening degrees, unlike most studies that focused on unsteady turbulent behaviors at fixed valve openings. The investigation examined variations in the internal flow field and air force acting on the valve spool at different degrees of valve opening for HPHFPRR. Moreover, a dynamic model was established to deeply analyze the motion process and forces experienced by the valve spool and piston in HPHFPRR, and an optimized spool structure was experimentally verified. Results demonstrated that the gas flow force acting on the valve spool was responsible for sudden outlet pressure rise in HPHFPRR. After design optimizations, the maximum gas flow force on the newly designed valve spool decreased by 32.7% during HPHFPRR opening, effectively resolving abnormal instability issues under high-pressure conditions encountered in projects.

Graphical abstract

Keywords

high pressure / high flow / pressure-reducing regulator / instability / optimal design

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