Compressed Air Tool Speed Control With Regulated Generator Voltage
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Solution Overview
Problem
Compressed air-driven tools in the metal-processing industry face challenges in maintaining consistent rotational speed under varying loads due to dependence on variable voltage generated by the motor shaft, leading to inefficiencies and potential hazards when the internal generator fails.
Innovation Solution
A compressed air-driven tool with a voltage regulator that generates a constant output voltage independently of the rotational speed, allowing for electromagnetic control of the air passage at the inlet valve to maintain selected rotational speeds, even under load, and ensures a safe drop to minimal rotational speed in case of generator failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rotational speed regulation is performed by centrifugal force regulators, then the supply of air is throttled in idle state and opened under loading, but the reliability and maintenance of constant rotational speed under changing work processes cannot be achieved
Solution Approach 1:
The patent replaces the mechanical centrifugal force regulator with an electronic control system comprising a generator, voltage regulator, microcontroller, and electromagnetic actuator. The generator converts rotational mechanical energy to electrical energy, the voltage regulator stabilizes the output voltage, and the microcontroller processes signals to control the electromagnetic actuator, thereby maintaining rotational speed through electronic rather than purely mechanical means.
Solution Approach 2:
The patent implements a feedback control system where the microcontroller continuously monitors operational parameters and adjusts the electromagnetic actuator accordingly. The system uses the electrical signals generated by the generator during rotation as feedback to regulate the air supply, creating a closed-loop control mechanism that maintains constant rotational speed despite varying load conditions.
2Reliability
If an electromagnetic adjustment element is fed with variable voltage from the generator, then the inlet valve is controlled directly dependent on output voltage, but the maintenance of rotational speed under variable load is not possible or insufficient
Solution Approach 1:
The patent introduces a voltage regulator as an intermediary component between the generator and the electromagnetic actuator. This voltage regulator stabilizes the variable voltage output from the generator into a constant voltage supply, ensuring that the electromagnetic actuator receives stable electrical energy regardless of rotational speed variations, thereby enabling reliable rotational speed maintenance under variable load conditions.
Solution Approach 2:
The patent changes the electrical parameter (voltage) from variable to constant through the voltage regulator. By transforming the variable voltage output of the generator into a stable voltage supply, the system ensures that the electromagnetic actuator operates with consistent energy input, allowing precise control of the inlet valve and maintenance of set rotational speed despite load variations.
3Adaptability or versatility
If no external current source is used and voltage is generated within the tool, then the adjustment element manages without external current source, but the generated energy is insufficient for reliable actuation of electromagnetic valve
Solution Approach 1:
The patent combines multiple functions into integrated components: the generator serves both as a power source and a rotational speed sensor, the voltage regulator integrates voltage stabilization with the control system, and the microcontroller coordinates air supply regulation and safety monitoring. This merging of functions creates a self-sufficient system that generates and manages its own energy while ensuring reliable actuation of the electromagnetic valve.
Solution Approach 2:
The patent transforms the electrical parameters through the voltage regulator, which converts the variable voltage and current output from the generator into stable voltage with sufficient current capacity. This parameter transformation ensures that despite the internal generation of power, the electromagnetic actuator receives adequate and stable electrical energy for reliable operation, resolving the insufficiency of self-generated power.
4Reliability
If rotational speed is regulated to maintain set value under load, then consistent tool performance is achieved, but the system complexity increases with voltage regulator and control electronics
Solution Approach 1:
The patent designs the generator to serve multiple functions: it generates electrical power for the control system, provides rotational speed information through its output frequency, and enables safety monitoring capabilities. The microcontroller similarly performs multiple tasks including air supply regulation, safety monitoring, and system coordination. This multi-functionality reduces the need for separate dedicated components, thereby limiting the increase in overall system complexity while achieving consistent performance.
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
Enables precise control of rotational speed regardless of load variations, ensuring consistent tool performance and safety by maintaining set rotational speeds and reducing hazards during generator failure.
Implementation Method 1
there is arranged on the shaft of the tool a generator which, in a manner dependent on the rotational speed of the shaft, generates a correspondingly variable output voltage
Implementation Method 2
An electromagnetic adjustment element is fed with the respective output voltage in order to control the inlet valve for compressed air at the tool in a manner directly dependent on the output voltage
Implementation Method 3
The rotational speed regulation for such tools is complex and has hitherto been performed by centrifugal force regulators which, in the idle state, throttle the supply of air and, under loading, open it up again
Data Source
AI summary
A compressed air-driven tool having an electromagnetically operated control element (27) for controlling a pneumatic control circuit in order to maintain a load-independent torque at a constant rotational speed. The tool includes a principal valve (5), which arranged in a drive housing (1) in a manner displaceable by the supplied compressed air against the force of a helical spring (13), and a generator (43), which is mounted on the shaft (49) of a turbine wheel (51). The rotational speed of the shaft (49) is measured with a speed sensor (75) and the supply of compressed air to the principal valve (5) is controlled in the event of a drop in rotational speed as a consequence of a load.