FORM-2
THE PATENTS ACT, 1970
(39 of 1970)
& THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
DIAPHRAGM OPERATED CNG PRESSURE REGULATOR WITH MULTI-FEATURES
VANAZ ENGINEERS LTD.,
an Indian Company of 85/1, Paud Road, Pune - 400 038, Maharashtra, [ndia.
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

FIELD OF THE INVENTION
The present invention relates to the field of CNG conversion systems to be used for air cooled / water cooled engines.
In particular, this invention relates to Diaphragm operated CNG Regulators
with multi-features.
BACKGROUND OF THE INVENTION
Due to extensive use of conventional fueled engines (petrol / diesel), the pollution levels are regularly increasing to a level which is much higher than the permissible level. This increases the pollution to an alarming high level causing serious threats and health hazards. This is a matter of great concern. Further the cost of running these engines on conventional fuels i.e. Petrol and Diesel is considerably high. Reduction of pollutant emission level and reduction in running cost of fuel have become important issues for which immediate action is required.
A two-stage servo gas pressure regulator valve is disclosed in the publication WO01/20418. This two-stage fluid pressure regulating valve 10 has a solenoid operated lever 50 for moving a regulator shaft 20 between two positions. The regulator shaft 20 biases the regulator spring 14 of a flow rate control diaphragm valve. When the solenoid 25 is actuated the lever is pivoted, applying increased force to the regulator spring, to change the valve set point to its higher pressure output. A return spring 58 returns the arm to the low pressure set point when the solenoid is de-energized. A pair of adjustable stops 53, 55 are positioned for engagement by the lever and forming limits for

its motion, for independently adjusting the low and high pressure set points for the valve.
Further, a three-stage pressure reducing mechanism is disclosed in the document CN 2403970Y. The utility model relates to a compressed natural gas pressure reducing regulator which is composed of a three-stage pressure reducing mechanism and adopts an electromagnetic switch to control a natural gas path. The utility model is characterized in that all levels of regulating screws are arranged on the exterior of a device body.
Similarly, in the document MX 9703862A, a supplementary pressure regulator is provided that can be used with conventional single or multistage pressure regulators. It may also conveniently be used with a novel two-stage balanced pressure regulator to form a three-stage vacuum demand pressure regulation system which may be used to regulate the pressure of compressed gases used as fuel in engines, such as natural gas used in natural gas powered vehicles.
However, all these prior art pressure regulators are very complex in nature and not easy to use. All these require high pressure steel tubes for connection to the CNG cylinders.
The vehicles powered with 2 Stroke single cylinders or even 4 Stroke single or multi cylinder engines with various engine capacities are basically Spark Ignition (SI) type engines which can use CNG as a fuel.

Presently, for carbureted vehicles using CNG fuel,following types of CNG Kits are used.
1) CNG kit with Open Loop System
2) CNG Kit with closed loop system
For both the above types of systems, a three stage Pressure Reduction System is required as the CNG Pressure is 200 bar.
Even for MPFI Vehicles using CNG fuel, a two stage pressure reduction system is required. The above mentioned regulators are fitted near the engine.
High Pressure steel tube is used to connect these reguIators with CNG Cylinder / Cylinders. Whereas, in the present inve:ntion this high pressure steel tube is completely dispensed with, by directly connecting this inventive pressure regulator on the CNG cylinder valve, This also results in reducing number of potential leakage points, which need to be sealed effectively.
OBJECTS OF THE INVENTION:
An object of the present invention is to eliminate use of high pressure steel tube.
Another object of the present invention is to use a Diaphragm operated CNG Regulator with multi-features.
Yet another object of the present invention is related to a Diaphragm operated CNG regulator having the features of High Pressure Filter, Refueling System,

CNG Cylinder Pressure Gauge with or without electronic output, Safety Relief Valve and Micro switch operated safety device as an integral part of the regulator.
Still another object of the present invention is to provide a Diaphragm operated CNG Regulator that has simple structural sensitive configuration and a compact design.
One more object of the present invention is to provide a Diaphragm operated CNG Regulator that is cost effective.
SUMMARY OF THE INVENTION
A diaphragm operated CNG pressure regulator connected to a CNG cylinder, comprising: a bonnet, a diaphragm, a body, a junction block, a safety relief valve, a high-pressure filter, a bull-nose connector, a CNG pressure gauge and a refueling adaptor, wherein said regulator is rigidly mounted on the CNG cylinder directly at said junction block by means of a bull-nose connector and a coupling screw in a sealing manner.
Typically, CNG is filtered by means of said high-pressure filter before entry into said regulator.
Typically, CNG pressure gauge includes an electronic output device.
Typically, the electronic output device also indicates the balance volume of CNG in said CNG cylinder.

Typically, the outlet pressure of CNG can be reduced from 200 bars to any desired pressure by adjusting the spring load exerted by a spring on said diaphragm by means of an adjusting screw.
Typically, the safety relief valve actuates if the outlet pressure reaches more than 1.5 times the set pressure of said CNG pressure regulator.
Typically, a refueling adaptor is provided for filling CNG into said CNG cylinder and a non return valve is provided to prevent reverse flow of the CNG through said refueling adaptor.
Typically, a dust plug is fitted on said refueling adaptor, which is detachable before inserting the CNG filling probe for CNG refueling. When the dust plug is removed, the micro switch is operated to 'OFF' position & disconnect the electrical supply to the engine ignition system and starter motor. This ensures that the vehicle cannot start on CNG or petrol mode during CNG filling operation.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Figure 1 illustrates a schematic arrangement of a CNG Cylinder, CNG Valve & Diaphragm Operated Regulator in accordance with embodiment of the present invention, both in side and plan view.
Figure 2 illustrates the main components of the CNG Diaphragm Operated Regulator illustrated in Figure 1.

DETAILED DESCRIPTION OF ACCOMPANYING DRAWINGS:
The invention will now be described with reference to the embodiment shown in the accompanying drawings. The embodiment does not limit the scope and ambit of the invention. The description relates purely to the exemplary preferred embodiment of the invention and its suggested applications.
The figures and descriptions hereto are merely illustrative and only exemplify the invention and in no way limit the scope hereof.
The invention is related to a regulator which is directly mounted on a CNG Cylinder Valve outlet. This eliminates the use of high pressure steel tubing.
The invention is related to a regulator, which is a diaphragm type regulator having following additional features as an integral part of the regulator:
1) High Pressure Filter
2) Refueling System
3) CNG Cylinder Pressure Gauge with or without electronic output
4) Safety Relief Valve
5) Micro switch operated safety device.
6) Non Return Valve
The Diaphragm Operated CNG Regulator in accordance with the present invention will now be explained with reference to FIGURE 1 & FIGURE 2. In FIGURE 1, the Diaphragm Operated Regulator in accordance with the present invention is indicated by numeral 100.

The CNG cylinder as shown in the Figure 1 stores CNG at high pressure of 200 bar. The CNG cylinder valve as shown in FIGURE 1 is mounted rigidly on the CNG cylinder. By rotating the hand wheel of CNG Valve, the supply of CNG to downstream system can be started or stopped.
The main components of the CNG Diaphragm Operated Regulator indicated by numeral 100, as illustrated in FIGURE 2, are referenced as given below:
1. Dust Plug 101;
2. NRV Sub Assembly 102;
3. String 103;
4. Refueling Adaptor 104;
5. Mounting Plate 105;
6. Micro switch 106;
7. Screw 107;
8. Screw 108;
9. Adjusting Screw 109; 10-SpringllO;
11.Pressure Gauge with or without electronic output 111;
12.Filter Sub Assembly 112;
13. Safety Relief Valve 113;
H.Bonnet 114;
15. Diaphragm 115;
16.Body 116;
17. Junction Block 117;
18.LockNutll8;
19.Coupling Screw 119;

20.Bullnose connector 120; 21.'O' Ring 121;
The Diaphragm operated CNG regulator 100 is directly fitted on CNG cylinder valve by using Bull-nose Connector 120 and Coupling Screw 119. The regulator directly fitted to the outlet of CNG cylinder valve reduces the 200 bar CNG pressure from the cylinder to the desired outlet pressure which is low pressure. -This eliminates use of high-pressure steel tube & also reduces one high pressure joint. This makes the system safer.
To avoid leakage through the Bullnose connector of the regulator & CNG Valve outlet, O' Ring 121 is used. As O' Ring is soft sealing material, the joint becomes easily leak proof The Bullnose connector is fitted to Junction block. To remove foreign particles present in CNG, a Filter sub-assembly 112 is used. Only filtered CNG, flowing from cylinder enters to the pressure gauge 111 and regulator 100. This increases life of the regulator and Pressure Gauge.
However to enable fast filling of the CNG cylinder, the filter position is so designed that it does not obstruct the CNG flow while filling the Cylinder. The pressure gauge 111 will indicate the pressure inside the CNG cylinder to give the indication to the driver regarding the quantity of fuel balance in the cylinder. With pressure gauge having electronic output is connected to the Level indicator fitted on dashboard which is convenient for the driver to know the quantity of CNG in the cylinder. The outlet pressure of the diaphragm operated regulator can be set to desired pressure by adjusting spring load on diaphragm 115.

Load of spring 110 can be varied by using adjusting screw 109 to set outlet pressure. A Safety Relief Valve 113 is used to protect the downstream CNG system in case there is increase in outlet pressure more than 1.5 times the set pressure of CNG regulator.
CNG can be filled into CNG cylinder through refueling adaptor 104. A non return valve 102 prevents reverse flow through the refueling adaptor.
During CNG refueling, dust plug 101 fitted on the refueling adaptor 104 is required to be removed to insert the CNG filling probe. The string 103 provided on dust plug helps to retain the dust plug associated with refueling adaptor. When the dust plug is removed, the micro switch 106 is operated to 'OFF' position & disconnect the electrical supply to the engine ignition system and starter motor.
This ensures that the vehicle cannot start on CNG or petrol mode during CNG filling operation. Thus eliminates chances of any accident to occur. Once the filling is completed & filling probe is removed dust plug is reinserted which operates the micro switch to 'ON' position & enables engine to start.
TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE:
The technical advancements offered by the present invention, which add to the economic significance of the invention, include the realization of:
• a diaphragm operated CNG regulator having a simple structural configuration;

• a diaphragm operated CNG regulator that is compact in size;
• a diaphragm operated CNG regulator that is reliable and sensitive; and
• a diaphragm operated CNG regulator with multi features that reduces number of components in CNG system.
As such, number of joints in the system is reduced; use of high pressure tubing in the CNG system is eliminated; and the cost of the system is considerably reduced.
The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.
While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the invention. These and other changes in the preferred embodiment of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

WE CLAIM:
1. A diaphragm operated CNG pressure regulator (100) connected to a
CNG cylinder, comprising: a bonnet (114), a diaphragm (115), a body (116), a
junction block (117), a safety relief valve (113), a high-pressure filter (112), a
bull-nose connector (120), a CNG pressure gauge (111) and a refueling
adaptor (104), wherein said regulator (100) is rigidly mounted on the CNG
cylinder directly at said junction block (117) by means of a bull-nose
connector (120) and a coupling screw (119) in a sealing manner.
2. Diaphragm operated CNG pressure regulator as claimed in claim 1,
wherein CNG is filtered by means of said high-pressure filter (112) before
entry into said regulator (100).
3. Diaphragm operated CNG pressure regulator as claimed in claim 1, wherein said CNG pressure gauge (111) includes an electronic output device.
4. Diaphragm operated CNG pressure regulator as claimed in claim 3, wherein said electronic output device also indicates the balance volume of CNG in said CNG cylinder.
5. Diaphragm operated CNG pressure regulator as claimed in claim 1, wherein the outlet pressure of CNG can be reduced from 200 bars to any desired pressure by adjusting the spring load exerted by a spring (110) on said diaphragm (115) by means of an adjusting screw (109).

6. Diaphragm operated CNG pressure regulator as claimed in claim 1, wherein said safety relief valve (113) actuates if the outlet pressure reaches more than 1.5 times the set pressure of said CNG pressure regulator (100).
7. Diaphragm operated CNG pressure regulator as claimed in claim 1, wherein a refueling adaptor (104) is provided for filling CNG into said CNG cylinder and a non return valve (102) is provided to prevent reverse flow of the CNG through said refueling adaptor (104).
8. Diaphragm operated CNG pressure regulator as claimed in claim 7, wherein a dust plug (101) is fitted on said refueling adaptor (104), which is detachable before inserting the CNG filling probe for CNG refueling.