Battery-Powered Compressor Pressure Control for Longer Run-Time
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Solution Overview
Problem
Conventional air compressors powered by AC motors are not suitable for environments without an electrical supply, and DC motor-based compressors with battery packs 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 regulates compressor operation based on pressure levels, optimizing energy use and extending battery run-time by selectively activating the compressor only when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a battery pack is used to power the compressor, then the compressor can be used in environments without AC power, but the energy demand is high and battery run-time is limited
Solution Approach 1:
The compressor operates in periodic cycles, running only when the air tank pressure drops below a predetermined threshold and stopping when the pressure reaches the threshold. This periodic operation pattern allows the compressor to accumulate sufficient compressed air in the tank during off-peak moments, thereby reducing the average energy demand on the battery pack and extending operational run-time between charges.
2Productivity
If a pressure tank is included to store compressed air, then the compressor can meet temporary demand, but surplus compressed air is wasted
Solution Approach 1:
The system incorporates a pressure sensor that continuously monitors the air tank pressure and provides feedback to the controller. The controller uses this feedback to intelligently control the compressor's operation, starting only when pressure drops below the threshold and stopping when the threshold is reached. This feedback mechanism ensures the compressor operates precisely when needed, eliminating energy wastage from compressing air that would remain unused in the tank.
3Quantity of substance
If the compressor runs continuously to pressurize air, then sufficient air is available for pneumatic devices, but energy is wasted on surplus air
Solution Approach 1:
The system uses partial action by operating the compressor only for the minimum necessary duration to reach the required air pressure threshold, rather than running continuously. The predetermined pressure threshold is set to provide just enough compressed air for typical pneumatic device operation, avoiding the excessive action of over-compressing air that would result in energy wastage while ensuring sufficient air availability when needed.
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 efficient airflow in environments without AC power, reducing energy consumption and extending battery life, allowing for a larger number of nail drives with a single charge, such as powering up to 1220 nails with a single battery charge.
Implementation Method 1
an electrical system with a battery pack docking station
Implementation Method 2
a pump capable of reaching 135 psi in under 135 seconds
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.