Pneumatic engine with pivoting directional valve and a low-pressure start-up system, with quick filling modules and air savings

Abstract

The present invention relates to a pneumatic engine that is actuated by a pivoting directional valve with a low-pressure start-up device (1), applied to a pneumatic pump, which may be a double-membrane pneumatic pump or a piston pneumatic pump, which may incorporate either a quick air filling system (2) that improves the filling and emptying of the air chambers, reducing load losses of the filling and emptying conduits, thus increasing the performance of the pneumatic pumps and / or an air savings system (3) which reduces air consumption of the pneumatic pump during its operation. The devices can be applied in a modular manner, that is, the pneumatic engine that is actuated by a pivoting directional valve with a low-pressure start-up device may incorporate both systems, either a quick air filling system (2) or an air savings system (3) or both, as each system can be independently applied.

Description

[0001]PNEUMATIC MOTOR WITH PIVOTING DIRECTIONAL VALVE AND LOW-PRESSURE START SYSTEM, WITH FAST FILLING AND AIR SAVING MODULES. DESCRIPTION OF THE INVENTION The present invention relates to a pneumatic motor driven by a pivoting directional valve with a low-pressure start device (1), applied to a pneumatic pump, which may be a double-diaphragm pneumatic pump or a piston pneumatic pump, which may incorporate either a fast air filling system (2) that improves the filling and emptying of the air chambers, reducing pressure losses in the filling and emptying lines, thus increasing the performance of the pneumatic pumps and / or an air saving system (3) that reduces the air consumption of the pneumatic pump during its operation.The devices can be applied in a modular fashion; that is, the pneumatic motor driven by a pivoting directional valve with a low-pressure starting device can incorporate either a rapid air filling system (2) or an air-saving system (3), or both, as each system can be applied independently. The rapid air filling system (2) consists of a slide valve with air inlets and outlets that alternately closes one of its two air inlets / outlets, allowing unrestricted air to enter the air chambers (5A, 5B) without passing through the pneumatic sensors (4A, 4B).The air-saving system (3) consists of an air-saving slide valve (3) with its corresponding inlet and outlet channels. This valve interrupts the air supply to the air chambers before they complete their stroke, allowing the final part of the stroke to be completed by inertia without requiring compressed air. This action results in air consumption savings during each operating cycle of the air motor, leading to improved performance of the pneumatic pump-motor assembly.The pneumatic motor driven by a pivoting directional valve with a low-pressure starting device, which can include a rapid air filling system and / or an air-saving system, or both, and which is the subject of this invention, also incorporates pneumatic sensors (4A, 4B) whose sole function is to serve as limit switches and send the pneumatic cycle change signal to the pivoting directional valve when the rapid air filling system is included in the pneumatic motor. These air sensors, when applied to the pneumatic motor with a pivoting directional valve, low-pressure starting device, and the rapid air filling system, eliminate the dead spot that occurs with the motor's existing sensors during the cycle change.With current sensors, it is not possible to simultaneously supply air to the air chamber and initiate the filling cycle when the pneumatic cycle change signal is sent from the pneumatic sensors (4A, 4B). This is why these sensors are said to have a dead spot when the air chamber begins to fill. The air sensors developed in this patent and the rapid air filling system eliminate this dead spot because the filling is carried out through a different and independent conduit from the one used to send the pneumatic cycle change signal from the air sensors (4A, 4B).The pneumatic motor with a pivoting directional valve and low-pressure starting device can be combined with an air-saving system using standard sensors that have the dual function of sending the stroke change signal while also serving as the air inlet to the pump's air chamber. FIELD OF THE INVENTION This invention is applicable within the industry of pneumatically driven pumps for supplying pressurized fluids such as hydrocarbons, chlorinated hydrocarbons, acids, bases, oils, greases, paints, varnishes, sealants, silicones, adhesives, and other chemical products used in industrial processes.The invention of the pneumatic motor driven by a pivoting directional valve with a low-pressure starting system and / or a rapid filling system and / or an air-saving system has applications in any system driven by compressed air or gas, in pneumatic actuators of all types, piston and diaphragm pumps, motors, and pneumatic circuits, as it can be incorporated into such systems to improve performance and reduce air consumption. BACKGROUND OF THE INVENTION Most pneumatically driven double-diaphragm or piston pumps for fluid transfer currently on the market have pneumatic motors driven by spool and / or pilot valves, but pneumatic motors driven by pivoting directional valves can also be used (1).The present invention relates to pneumatic motors applied to double-diaphragm or piston pneumatic pumps with reciprocating operation and equipped with a pivoting directional valve. The applicant company holds Patent No. ES2380260 for a center-flow double-diaphragm pump. The pneumatic motor driven by a pivoting directional valve described in that patent has air sensors that serve the dual function of acting as limit switches and regulating the air intake into the air chambers of the diaphragm pump.The present invention represents a substantial improvement to the pneumatic motor driven by a pivoting directional valve with a low-pressure starting device. This device can be modularly enhanced with pneumatic sensors that function solely as limit switches, a rapid air filling system that reduces air pressure losses when air enters and exits the air chambers of the pneumatic pump, and / or an air-saving system that reduces the air consumption of the pneumatic pump, thus improving its performance. The applicant company also holds patent no. ES2774427 for the low-pressure starting device for pneumatic motors with a pivoting directional valve applied to pneumatic pumps.The present patent substantially improves upon the aforementioned patent by applying both the rapid air filling system and the air-saving system to the pneumatic motor with a pivoting directional valve and a low-pressure starting device, thereby reducing its air consumption and increasing its performance. DESCRIPTION OF THE INVENTION The present invention is applicable to the drive of pneumatic piston or diaphragm pumps or any other pneumatic device with reciprocating motion. The drive fluid can be compressed air or any other inert gaseous fluid, such as nitrogen. In the following descriptions, references to compressed air will always be made to either compressed air or the inert gaseous fluid.The pneumatic motor with a pivoting actuating valve and low-pressure starting device (1) can be fitted with a rapid air filling system (2) and / or an air saving system (3) to operate the pneumatic pump, or both simultaneously. These systems fill the air chambers of the pneumatic pump with compressed air or any other inert gaseous fluid. When the compressed air enters one of the air chambers (5A), it causes the diaphragm or piston (6A) to move in one direction, creating the pump's suction.Once the end of its stroke is reached, the pneumatic limit switch (4B), designed for this purpose, sends a pneumatic signal to the pivoting directional valve (1), which changes position, directing the air to the other air chamber (5B). This connects the air chamber (5A), filled with compressed air, to the pneumatic pump's exhaust system (10) via the pivoting actuating valve (1). Simultaneously, the actuating valve empties as the other air chamber (5B) fills, thus causing the reciprocating linear motion of the diaphragms or pistons that operate the pneumatic pump. When installed on a pneumatic pump, the described pneumatic motor interacts with the pump's components, such as the diaphragms / pistons (6A, 6B), air sensors (4A, 4B), diaphragm rupture sensors (13A, 13B), cycle sensor (11), and the exhaust system (10), as described below.The installation of the rapid air filling system (2) and / or the air saving system (3), or both, on the pneumatic motor can be carried out on the main body of the pneumatic pump or on a separate module connected to the pneumatic pump via a manifold or set of air passages. The rapid air filling and air saving systems can be installed directly on the pneumatic motor or modularly on the pneumatic pump, forming interconnected, independent systems. When the rapid air filling system is connected to the pneumatic motor, the main air inlet (8) directs the compressed air to the pivoting actuator valve (1). This valve redirects the airflow to one air chamber (5A) or the other alternately.After passing through the pivoting actuator valve (1), the air reaches the rapid air filling system (2), which has a slide valve that allows unrestricted air to enter the air chambers (5A, 5B) without pressure loss and without passing through the pneumatic limit switches (4A, 4B). The combination of the rapid actuation of the pivoting actuator valve (1) and the unrestricted rapid air filling system (2) ensures that the air chambers (5A, 5B) are filled instantaneously without having to pass through the limit switches (4A, 4B).If an air saving system is added to the pneumatic motor with a fast air filling system, when the travel of the diaphragms or pistons (6A,6B) are very close to the end of their stroke, the air saving system (3) which has a shut-off device or slide valve, designed for this purpose, interrupts the entry of compressed air to the air chambers (5A,5B) so that the last part of the travel of the corresponding diaphragms or pistons (6A,6B) is carried out by inertia, in this way, the end point of the travel of the diaphragms (6A,6B) is reached and the consumption of air is avoided during this last part of the travel of the same.When one of the pistons or diaphragms (6A, 6B) reaches the end of its stroke, it activates the pneumatic sensors (4A, 4B), whose sole function is to send a pneumatic signal to the pivoting actuator valve (1). This reverses its position, closing the air inlet to the air chamber (5A) that was being filled and opening the air inlet to the other air chamber (5B) alternately. Simultaneously, it opens the exhaust valve of the first air chamber (5A), allowing the air to escape quickly and without restriction to the outside through the pneumatic pump's exhaust system (10). When the other diaphragm or piston (6B) reaches the end of its stroke, the other pneumatic sensor (4A) is activated, and the movement of the pistons or diaphragms (6A, 6B) is repeated, this time in the opposite direction, thus causing the pneumatic pump to reciprocate.The existing pneumatic sensors (4A, 4B) of a pneumatic motor equipped with a pivoting valve (1) have a dual function: on the one hand, they allow air to enter the pump's air chambers (5A, 5B) in each cycle, and on the other hand, they send the pneumatic signal that changes the position of the pivoting directional valve (1) to begin a new work cycle. However, the sensors developed in this patent for the application of the pneumatic motor with a rapid air filling system (2) have only one function: to send the pneumatic signal that changes the position of the pivoting directional valve (1). This is because the air entering the air chambers (5A, 5B) does so through the rapid air filling system (2) provided by the slide valve, which directs the compressed air to the air chambers (5A, 5B) unrestricted and instantaneously, increasing the performance of the pneumatic pump.The rapid air filling system allows us to redirect the incoming air to the chamber through larger diameter ducts. Furthermore, the limit switch and filling functions can be performed simultaneously, eliminating dead spots. The rapid air filling system (2), which can be installed in conjunction with the air saving system or independently, consists of a slide valve (2.1) that alternately closes the air inlets (2.3) to the pump's air chamber (5). Air enters the air filling system (2) alternately through the air inlets (2.2) of the rapid air filling system.The installation of the rapid air filling system on the pneumatic motor with a pivoting actuator valve and low-pressure starting system must be done in conjunction with the air sensors (4A, 4B), which have the sole function of sending a pneumatic signal to the pneumatic motor (1) to initiate the cycle change. Incorporating both the rapid air filling system (2) and the air saving system (3) results in superior pumping performance with optimized air consumption. If only the rapid air filling system (2) is incorporated into the pump, better pumping performance is achieved, but with higher consumption. Conversely, incorporating only the air saving system (3) provides the same pumping performance but with lower air consumption. The air sensors, with the sole function of sending a pneumatic signal to the pneumatic motor (1) to initiate the cycle change, consist of a housing or sleeve (4.1) that includes a non-return valve (4).2) which maintains the pilot pressure until it is released by the slide valve (4.3) when the diaphragm or piston (6) moves said slide valve (4.3) against the check valve (4.1). The pilot air arrives through the conduit (4.6) from the pneumatic motor (1). In turn, some of the air entering the air chamber (5) passes through the sensor inlet (4.5) and the outlet port (4.4) of the slide valve (4.3) of the pneumatic sensor. The air-saving system (3) can be applied directly to the pneumatic slide motor with a pivoting actuator and low-pressure starting system, or to the pneumatic motor assembly with a pivoting actuator and low-pressure starting system with a rapid air filling system. The air saving system(3) consists of a housing or sleeve (3.4) that houses the slide valve (3.1) and the air inlets (3.2) and the air outlets (3.3) with the end caps (3.5) and (3.6). The end caps (3.5) and (3.6) limit the stroke of the spool valve (3.1), and it is through these caps that the spool comes into contact with the pistons or diaphragms (6A, 6B) of the pneumatic pump at the end of its stroke. Pneumatic pumps driven by a pneumatic motor with a pivoting actuating valve, a low-pressure starting system, and rapid air filling systems (2), as well as the option of including an air-saving system (3), can be equipped with a cycle sensor and piston or diaphragm rupture sensors that monitor the operating variables of these pumps and send the values ​​of these variables to an external control system via cable or wireless communication. The cycle sensor (11) can be magnetic, optical, laser, inductive, or capacitive and detects the moving parts of the pneumatic pump, such as its shaft.The sensor detects the reciprocating motion of the shaft, which translates into strokes or cycles that can be counted and stored in an electronic control system. This system receives the data either via cable or wirelessly. Piston or diaphragm rupture sensors (13A, 13B) can be magnetic, optical, laser, inductive, or capacitive and detect the presence of any type of fluid in the pneumatic pump's air chamber. Once fluid is present, the sensor detects it and sends a signal to the electronic control system, which then closes the main air valve to stop the pump. The information from the sensor can also be used to generate a visual or audible signal indicating a malfunction.The control system, comprised of a pump, sensors, and electronics, features user identification, tank level control, pump cycle count control, and diaphragm / piston rupture detection. It enables product dosing and tank filling and emptying operations. The electronic system measures volume, which is displayed locally on the unit via the display (21). If one or more communication modules (27, 37) are present, all information is transmitted to the rest of the system. The user can set different alert thresholds in the control system. When these thresholds are exceeded by the product inside the container, visual and / or audible alerts are generated for the user and / or the rest of the system, notifying them of critical or particularly important volumes for the process. In addition to real-time stock monitoring, the control system provides overflow protection.Based on the functionality described above, the level is determined, and in combination with one or more actuators, the system can (based on user-entered parameters) control the flow of product into and / or out of the container to prevent overflow and / or complete emptying. This operating mode, in combination with one or more sensors, actuators, and / or flow meters, allows the equipment to transfer specific masses / volumes, either into the monitored container or to extract them from it to another container or containers. The quantities to be transferred are entered by the user (either directly or by selecting from a series of predefined quantities). This mode can be combined with level control and overflow protection modes for enhanced process safety. In addition to all of the above, the control system allows for pump monitoring.In this mode (which can be combined with any of the others described), the equipment monitors (in conjunction with one or more sensors) the basic operating parameters of one or more product pumps. Based on user-entered parameters, it allows the system to determine the correct operating status of these pumps, as well as inform the user of any maintenance requirements (preventive or corrective) and stop the pump if abnormal operation is detected that poses a risk of pump and / or process failure. Finally, the control system allows for flow rate monitoring. That is, the equipment monitors (in conjunction with one or more sensors or flow meters) the flow rate of product entering or leaving the container. This mode can also be combined with any of the others described previously.DESCRIPTION OF THE DRAWINGS To complement the description provided and to aid in a better understanding of the invention's features, a set of drawings is included as an integral part of this description. These drawings, for illustrative purposes only and not intended to be limiting, depict the following: Figure 1.- A schematic representation of the operation of a pneumatic motor with a pivoting directional valve in a double-diaphragm pump with an air-saving system (3). Figure 2.- A schematic representation of the operation of a pneumatic motor with a pivoting directional valve, a rapid air filling system (2), and the dual functionality of the limit switches. Figure 3.- A schematic representation of the operation of a pneumatic motor with a pivoting directional valve, a rapid air filling system (2), and an air-saving system (3). Figure 4.Figure 5 shows a diagram of the constituent parts of the air sensor. Figure 6 shows a diagram of the constituent parts of the rapid air filling system. Figure 7 shows a diagram of the constituent parts of the air saving system. Figure 8 shows a cross-section of a diaphragm pump equipped with the cycle sensor (11) and the diaphragm leak sensors (13A, 13B). Figure 9 shows a diagram of the remote exhaust system. Figure 10 shows a diagram of the information flow between the components of the control system.PREFERRED EMBODIMENT OF THE INVENTION The pneumatic motor with pivoting directional valve with low pressure starting system incorporating a rapid air filling system (2) and / or an air saving system (3) applied to a double diaphragm pneumatic pump, is composed of the following elements according to the required functionality: Air motor with pivoting directional valve and low pressure starting system (1) Rapid air filling system (2) Air saving system (3) Limit switch sensors (4A,4B) Main air inlet (8) Cycle sensor (11) Diaphragm rupture sensors (13) Air exhaust system (10) The operation of the air motor begins when said motor is supplied with a compressed air pipe.Compressed air reaches the pivoting directional valve (1) through the main air inlet (8), which distributes the compressed air alternately to one or the other air chamber (5A, 5B) and delivers the pilot compressed air pressure to the non-return valve (4.2) of the pneumatic sensors (4A, 4B). The change in air inlet from one air chamber (5A, 5B) to the other occurs through the pneumatic signal received from the limit switches (4A, 4B), via the pilot line (4.5) of the pneumatic sensors (4A, 4B), alternately, when the slide valve (4.4) of the pneumatic sensors (4A, 4B) opens the non-return valve (4.2) of the pneumatic sensors (4A, 4B), releasing the pilot pressure. The air entering the air chamber (5A) pushes the membrane (6A) until it reaches the end of its travel, where the membrane (6B), which is displaced by the central shaft (12) attached to the membrane (6A), impacts with the slide (4).4) The pneumatic sensor (4B) sends a pneumatic signal to the pivoting directional valve (1), opening the non-return valve (4.2) of the pneumatic sensor (4B). This valve changes position, allowing air to enter the other air chamber (5B), which initiates the reverse stroke of the diaphragm (6B). The compressed air arriving through the main inlet duct (8) reaches the rapid air filling system (2), which, due to pressure equilibrium, is in its open position and allows unrestricted air flow to the air chamber (5B). When the diaphragm (6A) reaches the end of its stroke, driven by the central shaft (12) attached to the diaphragm (6B), it strikes the slide (4.4) of the air sensor (4A), which in turn impacts the non-return valve (4.2) of the pneumatic sensor (4A). This causes the air pressure from the air motor inlet to flow through the pilot duct (4).5) from the pneumatic sensor (4A) to the pivoting directional valve (1), causing it to change position. At that instant, the rapid air filling system (2) changes position, closing the air inlet to the air chamber (5B) and allowing unrestricted air to enter the air chamber (5A) again, as shown in Figure 3. During this process, just as the diaphragm (6A) is about to reach the end of its stroke, the air saving system (3) closes the air inlet to the air chamber (5B), causing the diaphragm (6B) to reach its extreme position by inertia and without additional air consumption. Once the change of direction has occurred, the air contained in the air chamber (5B) is evacuated through the exhaust system (10) into the environment.This pneumatic double-diaphragm pump with a pneumatic motor, pivoting actuator valve, air-saving system (3), and rapid air filling system (2) may include a cycle sensor (11) that detects the movement of the connecting shaft (12) between the two diaphragms. This sensor sends a signal to an external operating control system that can count the number of cycles per minute of the pneumatic pump. For cycle detection, a protrusion is machined into the central shaft (12) connecting the diaphragms, which is detected by the cycle sensor (11). Diaphragm rupture sensors (13) may also be installed. These sensors detect if fluid enters the air chamber (5A, 5B) as a result of a rupture in one of the diaphragms (6A, 6B).If the diaphragm rupture sensors (13A, 13B) detect fluid, it means that the diaphragm (6A, 6B) has ruptured. Therefore, they send an electrical signal, either via cable or wirelessly, to the pneumatic pump's management and control system. This system can then control the main air supply valve (14), causing the pump to stop and preventing the entire pumped fluid from spilling onto the ground. This system can be installed as a precaution or for safety if the pumped fluid is aggressive, corrosive, or could potentially harm the environment. It is crucial to stop the double-diaphragm pneumatic pump when a diaphragm (6A, 6B) ruptures. Otherwise, the pumped fluid would enter the air chamber (5A, 5B) and eventually reach the pump's exhaust system (10), spilling the entire pumped fluid into the surrounding environment.To prevent this fluid from reaching areas that could cause damage, a remote exhaust system can also be installed. This system connects directly to the pump and uses a pipe or hose to carry the exhaust air (or fluid in case of a membrane rupture) to a safe area, as shown in the diagram in Figure 8.

Claims

AMENDED CLAIMS received by the International Bureau on September 2, 2025 Amended Claims (Clean Copy) 1. Pneumatic motor with pivoting directional valve and low-pressure starting device, incorporating a rapid air filling system module (2) and / or an air saving system module (3) or both simultaneously, characterized by: o The rapid air filling system module (2) comprising: ■ a slide valve (2.1), with two air inlets to the air quick filling system module (2.2) that alternately close the air inlets (2.3) to the air chamber (5A,5B) of the pump; ■ A pneumatic sensor (4) with the sole function of sending the pneumatic pilot signal to the pneumatic motor (1), via the pilot conduit (5), to effect the stroke change; a housing or sleeve (4.1) including a non-return valve (4.2), which maintains the pilot pressure until it is released by the action of the stem (4.3) when the diaphragm or piston (6A, 6B) moves said stem (4.3) against the non-return valve (4.2); wherein the rapid air filling system module (2) eliminates the dead spot at the moment of starting the filling of the air chamber by means of a conduit independent of the pneumatic sensor. The air saving system module (3) comprising: ■ a housing or sleeve (3.4) that houses the timing shaft (3.1) and the air inlets (3.2) and air outlets (3.3) with the side covers (3.5) and (3.6), wherein the side covers (3.5) and (3.6) limit the stroke of the timing shaft (3.1) and through them the end of the timing shaft comes into contact with the pistons or diaphragms (6A,6B) of the pneumatic pump when its stroke is completed; wherein the air saving system module (3) interrupts the air inlet to the air chambers (5A,5B) alternately at the final instant of filling the air chambers.

2. Pneumatic motor with pivoting directional valve with low pressure starting system, characterized according to claim 1 in that the pneumatic motor with pivoting directional valve with low pressure starting system incorporates only the air rapid filling system module (2).

3. Pneumatic motor with pivoting directional valve with low pressure starting system, characterized according to claim 1 in that the pneumatic motor with pivoting directional valve with low pressure starting system incorporates only the air saving system module (3).

4. Pneumatic motor with pivoting directional valve with low pressure starting system, characterized according to claim 1 in that the simultaneous integration of both modules (2) and (3) allows rapid filling of the air chambers combined with the interruption of the air flow at the end of the stroke by inertia.

5. Pneumatic motor with pivoting directional valve with low pressure starting system, characterized according to claim 1 in that the air quick filling system module (2) and / or the air saving system module (3) can be included in the body of the pneumatic motor with pivoting directional valve and low pressure starting device (1) or, each in an independent module and located outside the pump body.

6. Pneumatic motor with pivoting directional valve with low pressure starting system, characterized according to the first, second and third claims in that it has a remote exhaust system that allows the noise attenuation elements to be placed outside the pump body or the room where the pump is located.

7. Pneumatic motor with pivoting directional valve with low pressure starting system, characterized according to the first, second and third claims in that the rapid air filling system module (2) and the air saving system module (3) can be electronically actuated.

8. Pneumatic motor with pivoting directional valve with low-pressure starting system, characterized according to the first, second, and third claims in that it drives a diaphragm pump comprising: a cycle sensor (11) located in the pump body and detecting the movement of the shaft connecting the diaphragms (12); diaphragm rupture sensors (13) located in the lower part of the air chambers (5); or a control system comprising: ■ one or more printed circuit boards (PCBs) (40,41) containing a microprocessor (24,34) for storing software instructions and memories (25,35) for operating and configuration data; ■ communications interfaces (27,37), wired or wireless; ■ a display (21) for visualization of the status; ■ a keypad (23,33) for commands and user identification; ■ LED indicators (22, 32) for status and level; ■ electrical connectors (28,38) for expansion; ■ power supplies (29,39); ■ input / output connectors (26,36); ■ wireless antennas (18,30); ■ USB connectors (20,31); ■ a selector with safety key (19) for emergency mode; ■ cycle (15) and leakage (17) sensors; ■ physical actuators (14); ■ a communications bus.

9. Pneumatic motor with pivoting directional valve with low pressure starting system, characterized according to claim eight in that the cycle sensor and the diaphragm rupture sensors communicate in a wired or wireless manner with a diaphragm pump control system.

10. Pneumatic motor with pivoting directional valve with low pressure starting system, characterized according to claim eight in that the pneumatic diaphragm pump has a remote exhaust system that includes a duct and an acoustic reduction or noise reduction element at the end of the duct, which can be placed outside the room where the pneumatic pump is installed.

11. Pneumatic motor with pivoting directional valve with low pressure starting system, characterized according to the first, second and third claims in that it incorporates a drive fluid other than compressed air but which serves equally well for the drive of pneumatic devices such as double diaphragm pneumatic pumps or piston pumps.

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