Air Compressor Pneumatic Air Release Valve Energy Saving
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Solution Overview
Problem
Existing air compressors with solenoid-controlled air release valves consume excessive energy due to the necessary electromagnetic force required to control pressure, leading to increased power consumption and longer restart times in no-load and automatic stop modes.
Innovation Solution
An air compressor system utilizing an air-pressure-operated air release valve and a solenoid-operated three-way valve, which reduces the electromagnetic force needed and subsequently the power consumption by selectively communicating between the air release system and the intake throttle valve, allowing for more efficient pressure control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solenoid-operated air release valve is used to control pressure in the separator, then the air release function is achieved, but the electromagnetic force and power consumption increase excessively
Solution Approach 1:
The patent introduces an air-pressure-operated air release valve as an intermediary mechanism. Instead of using a large solenoid to directly control the air release valve, compressed air pressure is used as the primary actuating force. The solenoid only needs to control a smaller three-way valve to regulate this air pressure, thereby reducing electromagnetic force requirements and power consumption while maintaining reliable pressure control in the separator.
Solution Approach 2:
The patent employs pneumatic actuation for the air release valve. A three-way valve controls the supply of compressed air to the air release valve's actuating chamber, using pneumatic pressure to open or close the air release valve. This replaces the need for a large electromagnetic actuator, significantly reducing power consumption while achieving the same pressure control function in the separator.
2Ease of operation
If the separator pressure is not reduced sufficiently after compressor stop, then the restart function is limited, but the time limit for restart increases
Solution Approach 1:
The patent implements preliminary pressure reduction action before compressor restart. When the compressor stops, the air release valve is activated to release compressed air from the separator in advance. This preliminary action reduces the separator pressure sufficiently before restart is attempted, eliminating the need for extended waiting periods and enabling faster restart operations.
Solution Approach 2:
The patent uses a pressure sensor to monitor separator pressure and provides feedback to the control unit. Based on this feedback, the control unit determines when the pressure has been reduced sufficiently and when restart is permitted. This feedback mechanism ensures that the restart function is only enabled when pressure conditions are appropriate, preventing premature restart attempts while minimizing the restart time limit.
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
This configuration achieves energy savings by reducing the necessary electromagnetic force and power consumption compared to systems using solenoid-operated air release valves, while also shortening the time required for compressor restarts.
Implementation Method 1
an air-pressure-operated air release valve provided in an air release system connected to a primary side of a check valve in the compressed air system
Implementation Method 2
at least one solenoid-operated three-way valve, selects one of the primary side of a check valve in the compressed air system and a primary side of the intake throttle valve to make the selected primary side communicate with an operation chamber
Implementation Method 3
a compressor body compressing air with injecting a liquid into a compression chamber
Implementation Method 4
a separator provided on a delivery side of the compressor body, the separator separating, from the compressed air delivered from the compressor body, the liquid contained in the compressed air
Data Source
AI summary
To provide an air compressor capable of achieving energy saving. The air compressor is provided with a compressor body compressing air with injecting oil into a compression chamber; an air-pressure-operated intake throttle valve provided on an intake side of the compressor body; a separator provided on a delivery side of the compressor body and separating, from the compressed air delivered from the compressor body, a liquid contained in the compressed air; a compressed air system supplying the compressed air separated by the separator to a supply destination; an air release system connected to a primary side of a check valve in the compressed air system; an air-pressure-operated air release valve provided in the air release system; and an air-pressure operation circuit having a solenoid-operated three-way valve.