Air Transfer Bag Deflator Using Vacuum Reservoir
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Solution Overview
Problem
Existing air transfer systems for vertical loading of empty boxes are inefficient due to high compressed air consumption by Venturi pumps and slow deflation of airbags, which can lead to article collisions and jams, especially in applications requiring multiple cases or boxes.
Innovation Solution
An air transfer system utilizing a vacuum reservoir and a fast-acting diaphragm valve, powered by an electrically driven vacuum pump, to rapidly deflate airbags, allowing for continuous air removal and maintaining a vacuum for quick and synchronized deflation of airbags.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a Venturi pump is used to deflate airbags, then airbags can be deflated, but compressed air consumption is high (5-10 compressor horsepower)
Solution Approach 1:
The system pre-creates a vacuum environment in the reservoir before deflation is needed. The vacuum pump operates during idle periods to establish and maintain vacuum pressure in the reservoir, so when deflation is required, the airbags can be rapidly deflated using this pre-prepared vacuum without requiring high-power compressed air at that moment.
Solution Approach 2:
A vacuum reservoir is introduced as an intermediary component between the vacuum pump and the airbags. The reservoir stores vacuum pressure and acts as a buffer, allowing the system to decouple the continuous operation of the vacuum pump from the intermittent need for rapid deflation, thereby reducing peak compressed air consumption.
2Speed
If a Venturi pump is used to deflate airbags, then deflation can occur, but deflation speed is insufficient for fast applications
Solution Approach 1:
The vacuum reservoir is pre-charged with vacuum pressure before deflation is needed. This preliminary action allows the system to achieve rapid deflation speeds when the valve opens, without requiring a high-power Venturi pump to create the vacuum at that moment. The pre-stored vacuum energy enables fast deflation while consuming less compressed air overall.
3Productivity
If multiple airbags are used in applications requiring multiple cases or boxes, then loading capacity increases, but deflation speed problems are exacerbated
Solution Approach 1:
The system segments the vacuum delivery to each individual airbag through separate valves. Each airbag can be deflated independently and simultaneously through its own valve connected to the common vacuum reservoir. This segmentation allows multiple airbags to deflate in parallel, maintaining high deflation speed even when multiple cases or boxes are being loaded simultaneously.
Solution Approach 2:
The vacuum reservoir serves as a common intermediary that can supply vacuum pressure to multiple airbags simultaneously. Instead of requiring separate vacuum sources for each airbag, the single reservoir can service multiple airbags through individual valves, enabling parallel deflation operations that maintain high speed while supporting increased loading capacity.
4Reliability
If airbags are not fully deflated, then articles may collide and cause jams, but complete deflation requires more energy
Solution Approach 1:
The system uses a valve that responds to the pressure differential between the airbag interior and the vacuum reservoir. As the airbag deflates, the valve remains open as long as there is a pressure difference, automatically closing when the airbag pressure equals the vacuum pressure. This feedback mechanism ensures complete deflation without requiring excessive vacuum pump capacity, as the valve self-regulates based on the actual deflation state.
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 system significantly reduces the capacity and footprint of air transfer systems, achieving faster deflation of airbags (in approximately 160 ms with 9 airbags) while consuming less power compared to traditional Venturi pump systems, preventing article collisions and improving operational efficiency.
Implementation Method 1
an electrically driven vacuum pump to maintain a vacuum on a reservoir
Implementation Method 2
a fast-acting diaphragm valve... permitting rapid deflation of the airbags into the vacuum reservoir
Data Source
AI summary
A case packing apparatus for loading articles into a case that includes two or more airbags adapted to be positioned above the case; a vacuum reservoir positioned in fluid communication with the airbags; and a supply of compressed gas positioned in fluid communication with the airbags.