Back-Worn Air Compressor With Dual-Stage Pressure Control
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Solution Overview
Problem
Traditional air compressors are large, stationary, and require external power sources, limiting their portability and causing inefficiencies, safety hazards, and worker fatigue, especially in remote or confined work environments.
Innovation Solution
A wearable, battery-powered air compressor device with a dual-stage compression mechanism, ergonomic harness, and automatic pressure control, featuring a lithium-ion battery pack and low-noise motor, providing a portable and reliable compressed air source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional air compressors are used, then reliable compressed air supply is achieved, but portability and mobility are severely limited
Solution Approach 1:
The traditional stationary air compressor system is segmented into a portable wearable unit and separate pneumatic tools. The compressor, air tank, and power source are divided into a wearable backpack configuration, allowing the compressed air generation capability to be separated from fixed locations and transported to where work is needed.
Solution Approach 2:
The patent replaces the mechanical/electrical connection to stationary compressors with a self-contained portable system. Instead of relying on fixed mechanical infrastructure, the system uses a portable motor-driven compressor with an integrated air tank and battery power source, substituting the stationary mechanical system with a mobile version.
2Productivity
If traditional stationary compressors are used, then consistent air pressure is maintained, but worker mobility and productivity are reduced
Solution Approach 1:
The system transitions from a static stationary compressor to a dynamic portable unit that moves with the worker. The wearable design allows the compressor to be repositioned freely, adapting to different work locations and angles, thereby enhancing worker mobility while maintaining operational capability.
Solution Approach 2:
The patent incorporates a pressure regulator with feedback control to maintain consistent air pressure despite the portable nature of the system. The regulator monitors tank pressure and controls compressor operation to deliver stable output pressure to pneumatic tools, ensuring ease of operation comparable to stationary systems.
3Weight of moving object
If battery-powered portable compressors are used, then mobility is improved, but power consistency and runtime are limited
Solution Approach 1:
The system uses a high-capacity battery that provides more energy than the minimum required for basic operation. This excessive action approach ensures sufficient runtime for complete work tasks without interruption, accounting for variable load conditions and ensuring the battery can handle peak power demands of the compressor motor.
Solution Approach 2:
The patent employs a dual-voltage battery system capable of operating at different power levels. The system can switch between high-power mode for rapid compression and lower-power mode for maintenance operation, optimizing battery energy consumption based on actual compressor needs and extending operational runtime.
4Ease of operation
If wearable design is implemented, then worker comfort is enhanced, but device weight distribution becomes challenging
Solution Approach 1:
The wearable harness system incorporates counterbalancing elements and ergonomic design features that distribute the weight of the compressor and air tank across multiple body contact points. The shoulder straps, waist belt, and back support structure work together to counteract the weight, reducing strain on any single area and enhancing user comfort during extended wear.
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
Enhances mobility and user comfort by eliminating the need for stationary equipment, reducing fatigue, and improving workplace safety and efficiency by ensuring a consistent air supply without external power.
Implementation Method 1
The compressor assembly is further powered by a removable lithium-ion battery pack featuring a charge status indicator and charging port
Implementation Method 2
A dual-stage compressor mechanism with an intercooler, low-noise motor, and automatic pressure control ensures reliable airflow
Implementation Method 3
A dual-stage compressor mechanism with an intercooler, low-noise motor, and automatic pressure control ensures reliable airflow
Data Source
AI summary
A back-worn air compressor device is provided. The device is designed to provide a portable, battery-powered source of pressurized air for pneumatic tools without reliance on stationary compressors or external power supplies. The device is comprised of a body-worn frame that supports at least one air tank and compressor assembly, with an adjustable harness system that evenly distributes weight to reduce fatigue. A dual-stage compressor mechanism with an intercooler, low-noise motor, and automatic pressure control ensures reliable airflow. The compressor assembly is further powered by a removable lithium-ion battery pack featuring a charge status indicator and charging port.