Energy-saving pressure-maintaining vacuum generating equipment
By designing a pressure-holding air tank and a vacuum control system, the problem of vacuum generator consuming compressed air from the air compressor was solved, achieving energy-saving vacuum clamp adsorption, reducing electricity costs and equipment costs, and extending the life of the air compressor system.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-30
- Publication Date
- 2026-03-17
AI Technical Summary
Existing vacuum generators consume a large amount of compressed air from air compressors, resulting in high electricity costs and frequent operation of the air compressor system, which increases equipment costs and maintenance expenses.
A pressure-holding gas tank and a vacuum control system were designed. By storing negative pressure gas and automatically replenishing it, the compressed air consumption of the air compressor is reduced, and stable adsorption of the vacuum clamp is achieved.
It significantly reduces the electricity and equipment costs of air compressors, extends the lifespan of air compressor systems, and reduces maintenance costs.
Smart Images
Figure 1
Abstract
Description
Technical Field
[0001] This utility model relates to the field of automatic control technology for vacuum gas, and in particular to an energy-saving pressure-maintaining vacuum generating device. Background Technology
[0002] Vacuum chucks and vacuum clamps are a common type of tooling and fixture used in the machining industry. These fixtures require vacuum gas as their working power. In the machining industry, 100% of factories use air compressors (positive pressure compressed air sources) because machining equipment requires compressed air. If a factory needs vacuum chucks or vacuum clamps, 80% of factories will spend around 50 yuan to purchase a device called a vacuum generator. The working principle is as follows: the E inlet port connects to the compressed air from the air compressor, and the P outlet port exhausts the air. During operation, a large amount of air enters through E port, while a large amount of air is exhausted through P port. Through the eddy current effect, the V vacuum port forms an intake port, generating vacuum gas, which is then supplied to the vacuum chucks and vacuum clamps.
[0003] The existing products that convert the positive pressure air source of the workshop air compressor into the negative pressure vacuum air source required by the fixtures by using a vacuum generator costing around 50 yuan seem to create a vacuum gas for only 50 yuan, which can drive tooling fixtures with low vacuum requirements. However, the positive pressure air source of the workshop air compressor needs to be generated by a compressed air system. This system ranges from a few kilowatts to hundreds of kilowatts, and the cost ranges from several thousand to millions of yuan. Factories generally purchase according to their own air consumption needs. The power consumption of this system also ranges from a few kilowatt-hours to hundreds of kilowatt-hours per hour. The existing structure uses a vacuum generator to convert the positive pressure air source of the workshop air compressor into a negative pressure vacuum air source. To continuously generate a negative pressure vacuum air source, the positive pressure air source of the air compressor must be continuously consumed to produce a continuous vacuum, because the vacuum required by vacuum clamps cannot be interrupted. For example, the EV-25 vacuum generator commonly used in factories (EV-10, EV-15, and EV-20 also exist, but they generate negative pressure too slowly for many vacuum clamps) consumes 265L of air per minute. A 7.5kW air compressor (compressed air system) produces 1100L of compressed air per minute. Four EV-25 vacuum generators could keep a 7.5kW air compressor running continuously without stopping. Each EV-25 vacuum generator consumes 7.5 kWh of electricity per hour, or 1.9 kWh per hour, totaling 45 kWh per day. Given the current national average industrial electricity price of 1 yuan per kWh, the daily electricity cost for each EV-25 vacuum generator is 45 yuan, and the monthly cost is 30 * 45 = 1350 yuan. If calculated based on 12 hours of operation per day, the monthly electricity cost for each EV-25 vacuum generator is 1350 * 0.5 = 675 yuan, and the annual cost is 7800 yuan. In many processing plants with dozens or even hundreds of machining centers, 20 sealing strip vacuum suction cups operating 12 hours a day would cost 675 * 20 = 13500 yuan per month, or 162,000 yuan per year.
[0004] Meanwhile, when the air compressor (compressed air system) in the workshop is running normally, if there is no load consuming its positive pressure gas, or it only occasionally needs to drive the machining center, it will mostly be in a pressure-maintaining state and will not consume electricity. The air compressor will only start consuming electricity again when the gas pressure drops below a certain level. The more compressed air the load, the higher the operating frequency of the air compressor, or the larger and more expensive air stations (costing hundreds of thousands or even millions) need to be purchased because factories require a large number of compressed air-consuming devices.
[0005] Therefore, those skilled in the art have provided an energy-saving pressure-holding vacuum generating device to solve the problems mentioned in the background art. Utility Model Content
[0006] The purpose of this invention is to address the shortcomings of existing technologies by proposing an energy-saving pressure-holding vacuum generating device. By designing a pressure-holding gas tank, the lower limit of the negative pressure generated is lower than that generated directly by a vacuum generator, which is more conducive to the adsorption of vacuum clamps. At the same time, the pressure-holding gas tank can store a certain capacity of negative pressure gas. When the load requires a certain amount of vacuum, the vacuum negative pressure in the gas tank can be replenished in time, preventing the adsorbed workpiece from falling off due to sudden pressure drop.
[0007] To achieve the above objectives, the present invention provides the following technical solution:
[0008] An energy-saving pressure-maintaining vacuum generating device includes a compressor, a gas storage tank connected to one side of the compressor via a pipeline, and a compressed air dryer connected to one side of the gas storage tank via a pipeline.
[0009] One side of the compressed air dryer is connected to an energy-saving pressure-maintaining vacuum control system via a pipeline, and the other side of the energy-saving pressure-maintaining vacuum control system is connected to a vacuum clamp via a pipeline.
[0010] Furthermore, the energy-saving pressure-holding vacuum control system includes a pressure-holding gas tank, and a negative pressure gauge is fixedly installed on one side of the upper end of the pressure-holding gas tank.
[0011] Furthermore, an air outlet is fixedly provided at the middle position of the upper end of the pressure-holding gas tank, and a liquid drain outlet is fixedly provided at the middle position of the bottom surface of the pressure-holding gas tank.
[0012] Furthermore, a one-way valve is fixedly installed at the middle position on one side of the upper surface of the pressure-holding gas tank, and a vacuum generator is fixedly installed at the upper end of the one-way valve.
[0013] Furthermore, a vacuum generator exhaust port is fixedly provided at one end of the vacuum generator, and a solenoid valve is fixedly provided at the other end of the vacuum generator.
[0014] Furthermore, an air inlet is fixedly connected to one end of the solenoid valve.
[0015] Furthermore, a power junction box is fixedly installed on one side of the outer surface of the vacuum generator.
[0016] Furthermore, two mounting brackets are fixedly installed on the bottom surface of the pressure-holding gas tank.
[0017] This utility model has the following beneficial effects:
[0018] 1. This utility model proposes an energy-saving pressure-holding vacuum generating device. Through the design of a vacuum pressure-holding and automatic system, the compressed air consumed by the air compressor is less than 1 / 10 of that consumed by using a vacuum generator alone. If a factory only has 20 sealing strip vacuum suction cups, and the original vacuum generator produces a vacuum, working 12 hours a day, the monthly electricity cost is 675 yuan, which is 675 * 20 = 13,500 yuan per month, and 162,000 yuan per year. If it is replaced with this energy-saving pressure-holding vacuum generating device, the electricity cost for this project alone will be reduced from 162,000 yuan / year to 16,000 yuan / year. At the same time, due to the reduction in air consumption, the factory's air compressor system can be reduced from the original air compressor system that required hundreds of thousands of yuan to one that only requires tens of thousands of yuan. Even without replacing the equipment, the reduction in air consumption greatly reduces the operating frequency of the air compressor system, extends the life of the air compressor system, and reduces the maintenance cost of the air compressor system. Attached Figure Description
[0019] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0020] Figure 2 This is a schematic diagram of the structure of the energy-saving pressure-holding vacuum control system of this utility model. Figure 1 ;
[0021] Figure 3 This is a schematic diagram of the structure of the energy-saving pressure-holding vacuum control system of this utility model. Figure 2 ;
[0022] Figure 4 This is a schematic diagram of the structure of the energy-saving pressure-holding vacuum control system of this utility model. Figure 3 .
[0023] Legend:
[0024] 1. Energy-saving pressure-holding vacuum control system; 2. Vacuum clamp; 3. Compressed air dryer; 4. Air tank; 5. Compressor; 101. Vacuum generator exhaust port; 102. Negative pressure gauge; 103. Pressure-holding air tank; 104. Mounting bracket; 105. Vacuum generator; 106. Solenoid valve; 107. Air inlet; 108. Check valve; 109. Air outlet; 110. Drain port; 111. Power junction box. Detailed Implementation
[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0026] Reference Figure 1-4 One embodiment provided by this utility model:
[0027] An energy-saving pressure-holding vacuum generating device includes a compressor 5, an air storage tank 4 connected to one side of the compressor 5 via a pipeline, a compressed air dryer 3 connected to one side of the air storage tank 4 via a pipeline, an energy-saving pressure-holding vacuum control system 1 connected to one side of the compressed air dryer 3 via a pipeline, and a vacuum clamp 2 connected to one side of the energy-saving pressure-holding vacuum control system 1 via a pipeline.
[0028] Specifically, the compressor 5 compresses air into high-pressure gas, increasing the pressure of ambient air to provide the necessary high-pressure gas source for subsequent vacuum generation. The air storage tank 4 stores the high-pressure air generated by the compressor 5, acting as a buffer and stabilizing the air pressure to ensure that the air pressure in the system remains stable within a certain range. The compressed air dryer 3 removes moisture and impurities from the compressed air. The vacuum clamp 2 enables the basic functions of the device. The energy-saving pressure-maintaining vacuum control system 1 achieves efficient vacuum generation and maintenance while minimizing compressed air consumption.
[0029] The energy-saving pressure-holding vacuum control system 1 includes a pressure-holding gas tank 103. A negative pressure gauge 102 is fixedly installed on one side of the upper end of the pressure-holding gas tank 103. An air outlet 109 is fixedly installed at the middle position of the upper end of the pressure-holding gas tank 103. A drain outlet 110 is fixedly installed at the middle position of the bottom surface of the pressure-holding gas tank 103. A one-way valve 108 is fixedly installed at the middle position of one side of the upper surface of the pressure-holding gas tank 103. A vacuum generator 105 is fixedly installed at the upper end of the one-way valve 108. A vacuum generator exhaust port 101 is fixedly installed at one end of the vacuum generator 105. A solenoid valve 106 is fixedly installed at the other end of the vacuum generator 105. An air inlet 107 is fixedly connected to one end of the solenoid valve 106. A power junction box 111 is fixedly installed on the outer surface of one side of the vacuum generator 105. Two mounting brackets 104 are fixedly installed on the bottom surface of the pressure-holding gas tank 103.
[0030] Specifically, the pressure-holding gas tank 103 is a key component of the entire system, used to store vacuum negative pressure gas. It can replenish the vacuum negative pressure in a timely manner when the load requires it, preventing workpieces from falling off due to sudden pressure drops. The negative pressure gauge 102 is used to monitor the negative pressure value in the pressure-holding gas tank in real time and issue control signals according to the set pressure range. The outlet 109 is the connection point between the pressure-holding gas tank and the vacuum clamp or other loads, used to transfer the vacuum negative pressure in the pressure-holding gas tank to the load. The drain port 110 is used to discharge liquid impurities from the pressure-holding gas tank. When compressed air enters the system, it may carry moisture or other impurities, which need to be discharged periodically to ensure the normal operation of the system. The one-way valve 108 is used to prevent gas backflow, ensuring that the gas can only flow in one direction. The vacuum generator 105 is a key component that converts compressed air into vacuum negative pressure. It generates negative pressure at the vacuum port through the eddy current effect. The vacuum generator exhaust port 101 is used to discharge the waste gas generated by the vacuum generator during operation. The solenoid valve 106 is used to control the on and off of compressed air, thereby controlling the working state of the vacuum generator 105. The air inlet 107 is the channel for compressed air to enter the vacuum generator 105. The power junction box 111 is used to connect the power supply and provide power support for the entire energy-saving pressure-holding vacuum control system 1. The mounting bracket 104 is used to fix the pressure-holding gas tank 103 to ensure its stability during operation.
[0031] Working principle: When using this device, place it as follows... Figure 1As shown, after connecting the air hose and turning on the 220V power supply, the negative pressure gauge 102 in the system will detect and display the current negative pressure value of the pressure-holding gas tank 103. For example, if the required working pressure of the vacuum clamp 2 is between -0.6 MPa and -0.85 MPa, the user can set the working range of the negative pressure gauge 102 to the upper limit of -0.6 MPa and the lower limit of -0.85 MPa. When the negative pressure gauge 102 detects a negative pressure value in the pressure-holding gas tank 103 that is higher than -0.6 MPa... When the pressure reaches a certain level (e.g., MPa), the negative pressure gauge 102 will give a conduction signal, the solenoid valve 106 will open, and the compressed air from the air compressor will enter the vacuum generator 105 through the air pipe – solenoid valve 106 – the vacuum port of the vacuum generator 105 will then draw air out of the pressure-holding tank 103, thereby increasing the vacuum level in the pressure-holding tank 103. Generally, after about 15 seconds, the negative pressure in the pressure-holding tank 103 will drop to the set lower limit of -0.85 MPa. At this point, the negative pressure gauge 102 will give a signal. When a disconnect signal is issued, solenoid valve 106 closes, stopping the consumption of compressed air from the air compressor. The pressure holding control system will then be in a pressure holding state. As long as there is no air leakage from the load suction cup or other negative pressure device, the pressure will be maintained indefinitely without consuming the negative pressure value or the compressed air from the air compressor. If there is a load leak, the negative pressure value will be gradually consumed. For example, after ten minutes, when the negative pressure value rises from the lower limit of -0.85 MPa to -0.6 MPa, the negative pressure gauge 102 will issue a conduction signal again, solenoid valve 106 will open, and the compressed air from the air compressor will again flow through the air pipe – solenoid valve 106 – into the vacuum generator 105 – evacuate – and reach the set lower limit of -0.85 MPa in about ten seconds. At this time, the negative pressure gauge 102 will issue a disconnect signal again, and solenoid valve 106 will close, stopping the consumption of compressed air from the air compressor. This cycle continues. As long as the air leakage problem of the load suction cup or other negative pressure device is resolved, the compressed air from the air compressor will not be consumed. Even if there is a slight, unavoidable leak, the amount of compressed air required from the air compressor is very small.
[0032] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.
Claims
1. An energy-saving pressure-maintaining vacuum generating apparatus comprising a compressor (5), characterized by: The compressor (5) is connected with a gas storage tank (4) through a pipeline, and the gas storage tank (4) is connected with a compressed air dryer (3) through a pipeline; The compressed air dryer (3) is connected with an energy-saving pressure maintaining vacuum control system (1) through a pipeline, and the energy-saving pressure maintaining vacuum control system (1) is connected with a vacuum clamp (2) through a pipeline.
2. The energy-saving pressure-maintaining vacuum generating apparatus according to claim 1, characterized by: The energy-saving pressure maintaining vacuum control system (1) comprises a pressure maintaining tank (103), and a negative pressure gauge (102) is fixedly arranged on one side of the upper end of the pressure maintaining tank (103).
3. The energy-saving pressure-maintaining vacuum generating apparatus according to claim 2, characterized by: An air outlet (109) is fixedly arranged at the middle position of the upper end of the pressure maintaining tank (103), and a liquid discharge port (110) is fixedly arranged at the middle position of the bottom surface of the pressure maintaining tank (103).
4. The energy-saving pressure-maintaining vacuum generating apparatus according to claim 2, characterized by: A one-way valve (108) is fixedly arranged at the middle position of one side of the upper surface of the pressure maintaining tank (103), and a vacuum generator (105) is fixedly arranged at the upper end of the one-way valve (108).
5. The energy-saving pressure-maintaining vacuum generating apparatus according to claim 4, characterized by: A vacuum generator exhaust port (101) is fixedly arranged at one end of the vacuum generator (105), and an electromagnetic valve (106) is fixedly arranged at the other end of the vacuum generator (105).
6. The energy-saving pressure-maintaining vacuum generating apparatus according to claim 5, characterized by: An air inlet (107) is fixedly connected to one end of the electromagnetic valve (106).
7. The energy-saving pressure-maintaining vacuum generating apparatus according to claim 4, characterized by: A power supply junction box (111) is fixedly arranged on the outer surface of one side of the vacuum generator (105).
8. The energy-saving pressure-maintaining vacuum generating apparatus according to claim 2, characterized by: Two mounting racks (104) are fixedly arranged on the bottom surface of the pressure maintaining tank (103).