Low-power-consumption high-permeability air compressor non-contact electromagnetic valve

Abstract

The application discloses a low-power-consumption high-permeability air compressor contactless electromagnetic valve, and belongs to the technical field of air compressor accessories. The electromagnetic valve system is based on the energy generated by an electromagnetic coil in a switching process, converts the energy through an energy recovery module, and stores the energy in a capacitor, thereby realizing cyclic utilization of the energy. A sensor monitors the state and performance of the electromagnetic valve, feeds back the information to a feedback controller, intelligently adjusts the output frequency and voltage of a frequency converter, and further adjusts the working frequency and voltage of electromagnetic driving, thereby improving control efficiency and stability. A power factor correction circuit optimizes the phase relationship between current and voltage, reduces reactive power loss, and improves energy utilization efficiency. An integrated protector not only provides multiple protection, but also feeds back state and control information, organically combines protection and intelligent control, and enhances the stability and safety of the system. High-permeability materials and fast switching elements are applied to improve the electromagnetic field strength, realize efficient energy conversion, and improve the response speed.

Description

Technical Field

[0001] This invention belongs to the technical field of air compressor accessories, specifically, it relates to a contactless solenoid valve for low-power, high-permeability air compressors. Background Technology

[0002] Solenoid valves play a crucial role in fluid control systems; however, traditional solenoid valves suffer from slow response times and high energy consumption, which limits the efficiency and performance of industrial applications. These problems become increasingly prominent under the demands of high-speed, high-efficiency fluid control, requiring innovative technologies to solve them.

[0003] Traditional solenoid valves suffer from insufficient response speed, leading to lag and delay in fluid control processes, which affects production efficiency and accuracy. High energy consumption increases system operating costs, not only increasing energy consumption but also potentially generating unnecessary heat and noise, reducing the comfort of the working environment.

[0004] Furthermore, the inefficient use of energy generated by the movement of the solenoid valve leads to energy waste. The lack of intelligent control means the solenoid valve cannot be flexibly adjusted according to actual needs, resulting in unstable control and potential malfunctions under complex operating conditions, increasing maintenance costs and safety risks.

[0005] In view of this, the present invention is proposed. Summary of the Invention

[0006] To solve the above-mentioned technical problems, the basic concept of the technical solution adopted by the present invention is as follows:

[0007] A low-power, high-permeability contactless solenoid valve for air compressors, comprising:

[0008] Electromagnetic drive module;

[0009] This includes the control motherboard, drive circuit, and electromagnetic coil;

[0010] The output terminal of the control motherboard is electrically connected to the input terminal of the drive circuit, and the output terminal of the drive circuit is electrically connected to the input terminal of the electromagnetic coil.

[0011] Variable frequency speed control module;

[0012] Includes sensors, feedback controllers, and frequency converters;

[0013] The output terminal of the sensor is electrically connected to the input terminal of the feedback controller, and the output terminal of the feedback controller is electrically connected to the input terminal of the frequency converter.

[0014] The sensor's output is communicatively connected to the input of the control motherboard;

[0015] Energy recovery module;

[0016] Includes rectifier circuits and capacitor energy storage;

[0017] The input terminal of the rectifier circuit is electrically connected to the output terminal of the electromagnetic drive module, and the output terminal of the rectifier circuit is electrically connected to the input terminal of the capacitor energy storage.

[0018] Power factor correction circuit;

[0019] The input terminal of the power factor correction circuit is connected to the power supply and the capacitor for energy storage, and the output terminal of the power factor correction circuit is electrically connected to the input terminal of the frequency converter.

[0020] The output terminal of the frequency converter is electrically connected to an integrated protector, and the output terminal of the integrated protector is electrically connected to the input terminal of the electromagnetic drive module.

[0021] As a further embodiment of the present invention: the output terminal of the integrated protector is electrically connected to the input terminal of the control motherboard, and the integrated protector includes overcurrent protection, short circuit protection, overtemperature protection, start-stop smooth control, current frequency monitoring, remote control, status indication, fault diagnosis and filter.

[0022] As a further aspect of the present invention: the electromagnetic drive module is bidirectionally electrically connected to a low-power electronic device, the input terminal of the low-power electronic device is electrically connected to the output terminal of the control motherboard, and the output terminal of the low-power electronic device is electrically connected to the input terminal of the drive circuit.

[0023] As a further aspect of the present invention: the electromagnetic coil is made of a high permeability material, the switching element of the driving circuit includes a MOSFET, and the control motherboard monitors sensor feedback data in real time and dynamically adjusts the driving frequency and voltage of the driving circuit.

[0024] As a further aspect of the present invention: the rectifier circuit converts the AC energy generated during the movement of the solenoid valve into DC energy, and transmits it to the capacitor for storage, for energy supply in subsequent cycles.

[0025] As a further aspect of the present invention: the sensor includes a position sensor and a current sensor to monitor the operating status and performance of the solenoid valve in real time; the feedback controller analyzes the sensor feedback and sends the optimal output frequency and voltage signal to the frequency converter; the frequency converter adjusts the operating frequency and voltage of the electromagnetic drive according to the instructions of the feedback controller.

[0026] As a further aspect of the present invention: the power factor correction circuit optimizes the current and voltage phase relationship and reduces reactive power loss input.

[0027] As a further aspect of the present invention: the low-power electronic device employs a low-power microcontroller or power management chip to manage the power supply and control of the solenoid valve.

[0028] Beneficial effects:

[0029] In the electromagnetic drive module, the electromagnetic coil generates energy during the opening and closing of the solenoid valve. This energy is captured by the rectifier circuit in the energy recovery module and then transferred to a capacitor for storage. In subsequent cycles, the energy recovery module can release the stored energy and supply it to the electromagnetic drive module again, achieving efficient energy recycling.

[0030] Sensors monitor the status and performance of the solenoid valve and feed this information back to the feedback controller. This information is used to adjust the output frequency and voltage of the frequency converter, which in turn adjusts the operating frequency and voltage of the electromagnetic drive module. This intelligent feedback control mechanism ensures that the solenoid valve can quickly adjust according to actual needs, achieving higher control efficiency and performance stability.

[0031] The power factor correction circuit optimizes the phase relationship between current and voltage, reducing reactive power loss. This means the system can more effectively transfer the actual usable power to the solenoid valve, reducing unnecessary energy consumption and thus improving energy efficiency.

[0032] By using low-power electronics, such as low-power microcontrollers and power management chips, the control motherboard can more intelligently manage the power supply and control of the solenoid valves. This optimization allows the system to maintain performance while reducing both static and dynamic power consumption, achieving higher energy efficiency.

[0033] The integrated protector not only provides multiple protection functions for the electromagnetic drive module, but also feeds back the status and control information of the solenoid valve to the control motherboard, realizing a close integration of protection functions and intelligent system control, thereby enhancing the stability and safety of the system.

[0034] The electromagnetic coil uses a high-permeability material, which enhances the electromagnetic field strength and improves energy conversion efficiency. Meanwhile, the MOSFET in the drive circuit acts as a fast-switching element, enabling high-frequency drive of the electromagnetic drive module and ensuring a faster response speed.

[0035] The specific embodiments of the present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0036] In the attached diagram:

[0037] Figure 1 This is a schematic diagram of the contactless solenoid valve structure for the low-power, high-permeability air compressor of the present invention.

[0038] Figure 2This is a flowchart illustrating the operation of this invention.

[0039] In the diagram: 1. Control motherboard; 2. Drive circuit; 3. Integrated protector; 4. Frequency converter; 5. Feedback controller; 6. Sensor; 7. Electromagnetic coil; 8. Rectifier circuit; 9. Capacitor energy storage; 10. Power factor correction circuit; 11. Low-power electronic devices. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate the present invention.

[0041] like Figures 1 to 2 As shown, a low-power, high-permeability air compressor contactless solenoid valve includes:

[0042] Electromagnetic drive module;

[0043] Includes a control motherboard 1, a drive circuit 2, and an electromagnetic coil 7;

[0044] The output terminal of the control motherboard 1 is electrically connected to the input terminal of the drive circuit 2, and the output terminal of the drive circuit 2 is electrically connected to the input terminal of the electromagnetic coil 7.

[0045] Variable frequency speed control module;

[0046] Includes sensor 6, feedback controller 5, and frequency converter 4;

[0047] The output terminal of sensor 6 is electrically connected to the input terminal of feedback controller 5, and the output terminal of feedback controller 5 is electrically connected to the input terminal of frequency converter 4.

[0048] The output of sensor 6 is connected to the input of control motherboard 1.

[0049] Energy recovery module;

[0050] Includes rectifier circuit 8 and capacitor energy storage 9;

[0051] The input terminal of rectifier circuit 8 is electrically connected to the output terminal of electromagnetic drive module, and the output terminal of rectifier circuit 8 is electrically connected to the input terminal of capacitor energy storage 9.

[0052] Power factor correction circuit 10;

[0053] The input terminal of the power factor correction circuit 10 is connected to the power supply and the energy storage capacitor 9, and the output terminal of the power factor correction circuit 10 is electrically connected to the input terminal of the frequency converter 4.

[0054] The output terminal of the frequency converter 4 is electrically connected to the integrated protector 3, and the output terminal of the integrated protector 3 is electrically connected to the input terminal of the electromagnetic drive module.

[0055] These components work closely together to achieve efficient operation of the solenoid valve system. The energy recovery module provides electrical energy through energy storage elements to power the electromagnetic drive module, reducing external energy requirements. The variable frequency speed control module, through intelligent feedback control, ensures that the solenoid valve achieves optimal performance under different workloads, improving system control efficiency and performance stability. The application of power factor correction and low-power modules reduces energy consumption and optimizes energy utilization efficiency. The multiple protection functions of the integrated protector 3 enhance the stability and safety of the system, while simultaneously feeding back status and control information to the control motherboard 1, achieving an organic combination of protection functions and intelligent control.

[0056] Overall, the close integration of these components has resulted in significant improvements in the solenoid valve system, including high efficiency, low power consumption, and intelligent control. Through energy recycling, intelligent control mechanisms, and reduced energy consumption, the system meets practical needs while improving energy efficiency and reducing operating costs, thus positively impacting applications in the air compressor field.

[0057] The synergistic effect of high-speed electromagnetic drive and intelligent variable frequency speed control technology significantly improves the response speed of the solenoid valve. In the electromagnetic drive module, fast-switching elements enable high-frequency drive, allowing the solenoid valve to respond quickly to signals and reducing lag in the fluid control process.

[0058] Energy recovery technology captures the energy generated by the movement of the solenoid valve and converts it into stored DC energy. This reduces external energy demand, lowers system energy consumption, and improves energy efficiency. Power factor correction and low-power modules effectively reduce reactive power losses, further reducing energy consumption.

[0059] The variable frequency speed control module intelligently adjusts the operating frequency and voltage by monitoring the solenoid valve's status in real time, ensuring that the solenoid valve can flexibly adapt to actual needs. This intelligent control mechanism achieves higher control efficiency and performance stability.

[0060] The application of the energy recovery module enables the capture and storage of the solenoid valve's kinetic energy, which can then be reused by the electromagnetic drive module in subsequent cycles. This recycling mechanism reduces energy waste and improves energy efficiency.

[0061] The integrated protector 3 not only provides multiple protection functions for the electromagnetic drive module, but also feeds back status and control information to the system, enhancing system stability and safety. The intelligent feedback mechanism of the variable frequency speed control module also enables the solenoid valve to operate stably under complex conditions.

[0062] High-speed electromagnetic drive devices achieve high-frequency drive through fast switching elements, improving response speed and ensuring that the solenoid valve responds to signals quickly, thereby achieving faster switching actions.

[0063] The rectifier circuit 8 captures the energy from the solenoid valve's movement and converts it into stored DC energy. This energy recycling reduces energy waste and lowers the demand for external energy.

[0064] Sensor 6 provides real-time feedback on the status, and the variable frequency speed control module intelligently adjusts the frequency and voltage, enabling the solenoid valve to dynamically adjust according to actual needs, thereby improving control efficiency and stability.

[0065] Optimize the phase relationship between current and voltage to reduce reactive power loss and improve energy transmission efficiency. Low-power electronic devices reduce energy consumption and enhance system energy efficiency.

[0066] The output terminal of the integrated protector 3 is electrically connected to the input terminal of the control motherboard 1. The integrated protector 3 includes overcurrent protection, short circuit protection, overtemperature protection, start-stop smooth control, current frequency monitoring, remote control, status indication, fault diagnosis and filter.

[0067] Overcurrent protection: An overcurrent protection circuit is added to automatically cut off the current when an abnormal current occurs in the electromagnetic coil 7, so as to avoid coil overload.

[0068] Short circuit protection: An integrated short circuit protection circuit is provided to detect and isolate any short circuits that may occur in the electromagnetic coil 7, preventing circuit damage.

[0069] Over-temperature protection is implemented by adding a temperature sensor 6 to monitor the temperature of the solenoid coil 7. When the temperature exceeds the safe range, the frequency is automatically reduced or the solenoid valve operation is stopped to prevent overheating.

[0070] Smooth start-stop control integrates soft start and stop functions, gradually increasing or decreasing the current and frequency of the electromagnetic coil 7 to reduce shock and vibration.

[0071] Current and frequency monitoring: Add current and frequency sensors 6 to monitor the solenoid valve's operation in real time. You can set thresholds to detect abnormalities promptly.

[0072] Remote control with integrated communication interfaces such as Modbus and CAN allows for remote monitoring and control of the solenoid valve system, enabling remote maintenance and operation.

[0073] Status indicators can be added, such as LED indicators or LCD screens, to display information such as the operating status, frequency, and current of the solenoid valve, allowing users to monitor it in real time.

[0074] Fault diagnosis: Integrates fault diagnosis functions, automatically detects and provides fault information and possible solutions when a system fault occurs.

[0075] Add a power supply filter to reduce electromagnetic interference and noise, and ensure system stability.

[0076] The electromagnetic drive module is bidirectionally electrically connected to a low-power electronic device 11. The input terminal of the low-power electronic device 11 is electrically connected to the output terminal of the control motherboard 1, and the output terminal of the low-power electronic device 11 is electrically connected to the input terminal of the drive circuit 2.

[0077] The electromagnetic coil 7 is made of a high permeability material. The switching element of the drive circuit 2 includes a MOSFET. The control motherboard 1 monitors the feedback data from the sensor 6 in real time and dynamically adjusts the drive frequency and voltage of the drive circuit 2.

[0078] The rectifier circuit 8 converts the AC energy generated during the movement of the solenoid valve into DC energy and transmits it to the capacitor energy storage 9 for storage, which is then used for energy supply in subsequent cycles.

[0079] Sensor 6 includes position sensor 6 and current sensor 6, which monitor the operating status and performance of the solenoid valve in real time. Feedback controller 5 analyzes the feedback from sensor 6 and sends the optimal output frequency and voltage signal to frequency converter 4. Frequency converter 4 adjusts the operating frequency and voltage of the electromagnetic drive according to the instructions of feedback controller 5.

[0080] The power factor correction circuit optimizes the current and voltage phase relationship, reducing reactive power loss input.

[0081] The low-power electronic device 11 uses a low-power microcontroller or power management chip to manage the power supply and control of the solenoid valve.

[0082] Working principle:

[0083] The solenoid valve achieves its switching process through an electromagnetic drive module. A high-permeability electromagnetic coil 7 generates a strong electromagnetic field, and signals generated by the control board 1 are transmitted to the electromagnetic coil 7 via the drive circuit 2. Fast-switching elements such as MOSFETs in the drive circuit 2 ensure high-frequency drive, enabling the solenoid valve to respond quickly to input signals and achieve rapid valve opening and closing.

[0084] The energy generated during the switching process of the solenoid valve is captured by the rectifier circuit 8, converted into DC power, and stored in the capacitor. This energy recovery mechanism effectively utilizes energy and achieves energy recycling. The stored DC power can be supplied to the electromagnetic drive module in subsequent cycles, reducing the demand for external energy and improving the system's energy efficiency.

[0085] Sensor 6 monitors the solenoid valve's status in real time and transmits the information to the feedback controller 5. Based on the feedback, the frequency converter 4 adjusts its output frequency and voltage to control the operating frequency and voltage of the electromagnetic drive module. This intelligent feedback mechanism enables the solenoid valve to dynamically adjust according to actual needs, achieving optimal control efficiency and performance stability.

[0086] The power factor correction circuit 10 optimizes the phase relationship between current and voltage, reducing reactive power loss and improving energy transmission efficiency. Low-power electronic devices 11, such as microcontrollers and power management chips, manage the power supply and control of the solenoid valves, reducing system energy consumption. The integrated protector 3 not only provides multiple protection functions but also feeds back status and control information to the system, enhancing system stability and safety.

[0087] Through comprehensive operation, this solution optimizes the solenoid valve drive, energy recovery, intelligent control, and energy consumption optimization, achieving efficient and low-power operation of the solenoid valve system and meeting the requirements of modern fluid control for performance, efficiency, and sustainability.

[0088] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A low-power, high-permeability contactless solenoid valve for an air compressor, characterized in that, include: Electromagnetic drive module; It includes a control motherboard (1), a drive circuit (2), and an electromagnetic coil (7); The output terminal of the control motherboard (1) is electrically connected to the input terminal of the drive circuit (2), and the output terminal of the drive circuit (2) is electrically connected to the input terminal of the electromagnetic coil (7). Variable frequency speed control module; Includes a sensor (6), a feedback controller (5), and a frequency converter (4); The output terminal of the sensor (6) is electrically connected to the input terminal of the feedback controller (5), and the output terminal of the feedback controller (5) is electrically connected to the input terminal of the frequency converter (4). The output terminal of the sensor (6) is communicatively connected to the input terminal of the control motherboard (1); Energy recovery module; Includes a rectifier circuit (8) and a capacitor for energy storage (9); The input terminal of the rectifier circuit (8) is electrically connected to the output terminal of the electromagnetic drive module, and the output terminal of the rectifier circuit (8) is electrically connected to the input terminal of the capacitor energy storage (9). Power factor correction circuit (10); The input terminal of the power factor correction circuit (10) is connected to the power supply and the capacitor energy storage (9), and the output terminal of the power factor correction circuit (10) is electrically connected to the input terminal of the frequency converter (4). The output terminal of the frequency converter (4) is electrically connected to an integrated protector (3), and the output terminal of the integrated protector (3) is electrically connected to the input terminal of the electromagnetic drive module.

2. The contactless solenoid valve for a low-power, high-permeability air compressor according to claim 1, characterized in that, The output terminal of the integrated protector (3) is electrically connected to the input terminal of the control motherboard (1). The integrated protector (3) includes overcurrent protection, short circuit protection, overtemperature protection, start-stop smooth control, current frequency monitoring, remote control, status indication, fault diagnosis and filter.

3. The contactless solenoid valve for a low-power, high-permeability air compressor according to claim 1, characterized in that, The electromagnetic drive module is bidirectionally electrically connected to a low-power electronic device (11). The input terminal of the low-power electronic device (11) is electrically connected to the output terminal of the control motherboard (1), and the output terminal of the low-power electronic device (11) is electrically connected to the input terminal of the drive circuit (2).

4. The contactless solenoid valve for a low-power, high-permeability air compressor according to claim 1, characterized in that, The electromagnetic coil (7) is made of a high permeability material, the switching element of the drive circuit (2) includes a MOSFET, and the control motherboard (1) monitors the feedback data from the sensor (6) in real time and dynamically adjusts the drive frequency and voltage of the drive circuit (2).

5. The contactless solenoid valve for a low-power, high-permeability air compressor according to claim 2, characterized in that, The rectifier circuit (8) converts the AC energy generated during the movement of the solenoid valve into DC energy and transmits it to the capacitor energy storage (9) for storage, so as to supply energy for subsequent cycles.

6. The contactless solenoid valve for a low-power, high-permeability air compressor according to claim 4, characterized in that, The sensor (6) includes a position sensor (6) and a current sensor (6) to monitor the operating status and performance of the solenoid valve in real time. The feedback controller (5) analyzes the feedback from the sensor (6) and sends the optimal output frequency and voltage signal to the frequency converter (4). The frequency converter (4) adjusts the operating frequency and voltage of the electromagnetic drive according to the instructions of the feedback controller (5).

7. The contactless solenoid valve for a low-power, high-permeability air compressor according to claim 5, characterized in that, The power factor correction circuit (10) optimizes the current and voltage phase relationship and reduces reactive power loss input.

8. The contactless solenoid valve for a low-power, high-permeability air compressor according to claim 3, characterized in that, The low-power electronic device (11) employs a low-power microcontroller or power management chip to manage the power supply and control of the solenoid valve.

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