Air Compressor Pressure Control for Reduced Motor Operation and Noise
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Solution Overview
Problem
Users face difficulties in properly determining and selecting mode settings for air compressors, often leading to inefficient compression, increased motor operation time, noise, and reduced durability due to high pressure settings, and insufficient compressed air supply when settings are too low.
Innovation Solution
An air compressor with a control unit that adjusts the motor start and stop pressure values and control current based on detected pressure levels and usage conditions, reducing high pressure loads and optimizing motor operation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the use mode is set to a higher pressure mode to ensure sufficient compressed air supply, then the compressed air availability is improved, but the motor operation time increases, noise increases, and durability decreases
Solution Approach 1:
The patent applies dynamics by making the pressure values (motor start pressure value and motor stop pressure value) variable rather than fixed. The control unit dynamically adjusts these pressure values based on the operational state and compressed air consumption rate, allowing the system to adapt between high and low pressure modes automatically, thereby reducing unnecessary motor operation time while ensuring sufficient compressed air supply when needed.
2Quantity of substance
If the use mode is set to a higher pressure mode, then the compressed air supply is improved, but the driving sound and noise increase
Solution Approach 1:
The control unit dynamically adjusts the motor start and stop pressure values based on actual compressed air consumption patterns. When consumption is low, lower pressure values are used, which reduces motor operation frequency and driving sound. When consumption is high, higher pressure values ensure sufficient compressed air supply. This dynamic adjustment eliminates the need for users to manually select noisy high-pressure modes.
3Quantity of substance
If the use mode is set to a higher pressure mode, then the compressed air supply is improved, but the durability of components decreases
Solution Approach 1:
The patent implements dynamic adjustment of pressure values to match actual compressed air consumption. The control unit monitors usage patterns and adjusts the motor start/stop pressure values accordingly, avoiding sustained high-pressure operation that causes component wear. This ensures durability by using high pressure only when necessary while maintaining sufficient compressed air supply capability.
4Adaptability or versatility
If multiple mode settings are provided for different work conditions, then the adaptability is improved, but the ease of operation decreases
Solution Approach 1:
The control unit automatically performs the function of mode selection by monitoring compressed air consumption patterns and dynamically adjusting pressure values accordingly. Users no longer need to manually determine or select from multiple mode settings (low pressure mode, normal pressure mode, high pressure mode, ultra-high pressure mode). The system serves itself by making intelligent adjustments based on actual usage, thereby maintaining adaptability while dramatically improving ease of operation.
5Quantity of substance
If the motor start pressure value and motor stop pressure value are kept high, then the compressed air supply is improved, but the energy consumption increases
Solution Approach 1:
The control unit dynamically adjusts the motor start and stop pressure values based on actual compressed air consumption rates. When consumption is low, lower pressure values are maintained, reducing the frequency of motor startup and energy consumption. When consumption increases, the system raises pressure values to ensure sufficient compressed air supply. This dynamic approach optimizes energy usage while maintaining adequate compressed air availability.
Data Source
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AI summary
An air compressor includes a tank unit that stores compressed air, a motor unit that generates compressed air to be stored in the tank unit, a pressure detection unit that detects a pressure value in the tank unit, and a control unit that drives the motor unit when a pressure value in the tank unit detected by the pressure detection unit is equal to or less than a motor start pressure value, and stops the motor unit when the pressure value in the tank unit detected by the pressure detection unit is equal to or greater than a motor stop pressure value. The control unit changes at least either of the motor start pressure value or the motor stop pressure value every time when a predetermined time passed.