Engine-Driven Air Compressor Clutch Control for Fuel and Noise Reduction

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Solution Overview

Problem

Conventional engine-driven power systems that include air compressors consume large amounts of fuel, require frequent maintenance, and produce environmental noise and exhaust, especially when operating at idle with a high load from the air compressor.

Innovation Solution

A system and method for controlling an engine-driven air compressor that senses air pressure and adjusts the compressor's operation to reduce the load on the engine, including using a clutch to disengage the compressor when pressure levels are low, and employing a bleed down valve to reduce pressure and power consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the air compressor is continuously driven by the engine, then the compressor can maintain ready-to-operate status, but fuel consumption increases and maintenance frequency increases

Engineering Contradiction:

Improvecompressor readinessVSAvoidfuel consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The system dynamically adjusts the clutch engagement state based on real-time air pressure sensor feedback. When tank pressure reaches the upper threshold, the clutch disengages to stop compressor operation. When pressure drops to the lower threshold, the clutch re-engages to resume compression. This dynamic on-off control eliminates continuous operation while maintaining system readiness.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The control system incorporates pressure sensors that continuously monitor tank pressure and provide feedback to the clutch control mechanism. This closed-loop feedback enables automatic engagement/disengagement decisions based on predetermined pressure thresholds, optimizing the balance between compressor readiness and fuel consumption.

Inventive Principle:

Principle #23Feedback

2Speed

If the air compressor operates at idle with high load, then the compressor can respond quickly to demand, but environmental noise and exhaust increase

Engineering Contradiction:

Improveresponse speedVSAvoidnoise and exhaust

Core Design Contradiction:

SpeedVSObject-generated harmful factors

Solution Approach 1:

The system implements periodic operation cycles with distinct on and off phases. During off-phase, the clutch disengages completely, allowing the engine to idle without compressor load, eliminating noise and exhaust during these periods. During on-phase, the compressor operates at full load efficiently. This periodic action replaces continuous idle operation with alternating active and rest periods.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system allows the engine to operate at partial load (idle without compressor) rather than maintaining constant full-load operation. By disengaging the clutch during low-demand periods, the engine runs at minimal power output, reducing noise and exhaust while still being capable of rapid full-power response when air demand arises.

Inventive Principle:

Principle #16Partial or excessive action

3Use of energy by moving object

If the clutch frequently engages and disengages the compressor, then fuel consumption decreases, but mechanical wear and maintenance needs increase

Engineering Contradiction:

Improvefuel consumptionVSAvoidclutch durability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The system uses predetermined pressure thresholds (upper and lower limits) to control clutch engagement timing. By adjusting these threshold parameters, the system optimizes the balance between fuel savings and clutch cycle frequency. The differential pressure range between thresholds determines the duration of each off-period, allowing tuning to reduce excessive clutch cycling while maintaining fuel efficiency.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution reduces fuel consumption, minimizes maintenance needs, and decreases environmental noise and exhaust by allowing the engine to idle only when necessary and optimizing the air compressor's operation based on demand.

Implementation Method 1

a pressure sensor configured to measure a pressure level that exceeds a first pressure level at an outlet of the air compressor

Methodology Applied

Scientific EffectPressure sensing: Pressure Gradient

Implementation Method 2

an inlet valve of the air compressor configured to close in response to the pressure level in order to prevent air from being introduced into the air compressor

Methodology Applied

Scientific EffectPressure control: Pressure Gradient

Implementation Method 3

a clutch configured to disengage from an engine in response to the second pressure level, the clutch configured to transfer power from the engine to the air compressor

Methodology Applied

Scientific EffectMechanical power transmission: Mechanical Force

Data Source

PatentUS12331746B2Methods and systems for air compressor and engine driven control

Publication Date: 2025.06.17 ILLINOIS TOOL WORKS INC

AI summary

Power systems and methods of controlling an engine driven air compressor include an air compressor driven by an engine via a clutch. A first pressure sensor configured to sense a pressure level at an outlet of the air compressor. An inlet valve configured to close in response to the first pressure sensor sensing a pressure level above a first pressure level. In addition, a second pressure sensor to sense a pressure level below a second pressure level at a housing of the air compressor, wherein the clutch is configured to disengage in response to the second pressure level, wherein the first pressure level is higher than the second pressure level.