Battery-Powered Air Compressor Pressure Control for Longer Run-Time
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Solution Overview
Problem
Conventional air compressors powered by AC motors are limited in their use to areas without AC power, and those replaced with DC motors for battery operation face high energy demands, leading to inefficient energy use and surplus compressed air storage.
Innovation Solution
A portable air compressor assembly with a DC motor powered by a battery pack, featuring a pressure switch assembly and controller circuit that optimizes energy use by regulating pressure and extending battery run-time, allowing efficient operation of air-powered tools in environments without AC power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a DC motor is used instead of AC motor for battery operation, then the compressor can be used in places without AC power, but the energy demand becomes too high for practical battery operation
Solution Approach 1:
The controller dynamically adjusts the motor operating parameters based on real-time feedback from pressure sensors and battery voltage monitoring. The system varies motor power delivery to match actual compressor needs, preventing excessive energy consumption while maintaining portability.
Solution Approach 2:
The system incorporates pressure sensors that provide continuous feedback to the controller, which adjusts motor operation accordingly. This closed-loop control ensures the motor only consumes energy when and where needed, reducing overall energy demand while maintaining the ability to operate without AC power.
2Productivity
If a pressure tank is included to store compressed air for meeting temporary demand, then the compressor can handle burst demands, but the energy expenditure increases due to pressurizing surplus air
Solution Approach 1:
The invention extracts and eliminates the traditional pressure tank from the system. Instead of storing compressed air in a tank, the system uses a capacitor to store electrical energy, which is then discharged to meet temporary air demand requirements. This removes the source of energy waste associated with pressurizing and storing surplus air.
Solution Approach 2:
The system replaces the mechanical pressure tank storage method with an electrical energy storage approach using a capacitor. The capacitor stores electrical energy that can be quickly discharged to power the motor during burst demand periods, eliminating the need for mechanical compression and storage of surplus air.
3Quantity of substance
If the compressor operates continuously to pressurize air in a tank, then sufficient air is available for pneumatic devices, but the battery life is reduced due to high energy consumption
Solution Approach 1:
The controller operates the motor in periodic intervals rather than continuously, activating it only when pressure drops below a threshold and deactivating it when the threshold is met. This intermittent operation significantly reduces energy consumption and extends battery run-time while still providing sufficient compressed air for pneumatic devices.
Solution Approach 2:
The system changes the operating parameters of the motor based on real-time pressure and battery conditions. The controller adjusts motor power, speed, and runtime dynamically to optimize the balance between compressed air production and energy consumption, thereby extending battery life while maintaining adequate air supply.
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 solution enables efficient operation of air-powered tools by regulating compressor activity based on pressure needs, extending battery life and allowing for a larger number of nail drives with a single charge, while maintaining suitable airflow for tools like finish nailers and brad nailers.
Implementation Method 1
a battery pack, and a controller circuit. The air compressor assembly may be configured to operate in environments without an AC power source by utilizing power from the battery pack
Implementation Method 2
The air compressor assembly includes a compressor mounted to a compressed air storage tank, a DC motor driving the compressor
Implementation Method 3
a piston assembly, or compressor pump, which compresses the fluid and forces it into the fluid pressure tank for temporary storage
Data Source
AI summary
A cordless compressor has an air storage tank, a pump, a motor for driving the pump, and a controller circuit electrically connected to the motor. A pressure switch assembly is connected to the controller circuit. The pressure switch assembly has first and second pressure switches for sensing pressure within the air storage tank. The controller circuit controls de-activation of the motor depending upon status of the first and second pressure switches.