Compressed Air Supply Device Regeneration Control
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Solution Overview
Problem
Compressed air supply devices in commercial vehicles face issues with air dryer saturation due to high humidity levels, leading to inefficient dehumidification and regeneration, especially in vehicles with high compressed air consumption, where conventional methods fail to maintain low humidity levels and prevent rapid saturation.
Innovation Solution
A method for regenerating the compressed air supply device involves supplying the first compressed air circuit to a predetermined target pressure and humidity level, with intermediate regeneration steps to maintain low humidity, ensuring the air dryer remains efficient and preventing saturation by dynamically adjusting parameters and using an electronic control device to manage the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air dryer is regenerated using conventional methods (once when service brake reaches maximum pressure), then the compressed air reservoir can be refilled, but the air dryer reaches saturation level quickly and cannot maintain low humidity
Solution Approach 1:
The patent implements periodic regeneration of the air dryer by monitoring humidity levels and triggering regeneration cycles at predetermined intervals or when saturation is detected, rather than relying on single conventional regeneration events. This ensures the air dryer maintains dehumidification capability throughout operation.
Solution Approach 2:
The system uses humidity sensors to monitor the air dryer's moisture content and provides feedback to the control unit, which automatically initiates regeneration when predetermined humidity thresholds are reached. This closed-loop control prevents saturation by responding to actual moisture levels in real-time.
2Reliability
If compressed air is used for regeneration, then the air dryer can be dried, but the pressure in the compressed air reservoir drops
Solution Approach 1:
The system performs regeneration operations at predetermined moments or when humidity thresholds are reached, rather than waiting for pressure depletion. This timing strategy ensures regeneration occurs proactively before pressure becomes critically low, maintaining both air dryer functionality and adequate reservoir pressure.
Solution Approach 2:
The control unit adjusts regeneration parameters such as duration, intensity, and timing based on monitored humidity levels and pressure conditions. This dynamic parameter adjustment optimizes the balance between drying effectiveness and pressure maintenance.
3Productivity
If moist air is guided through the air dryer during regeneration, then regeneration can occur, but the regeneration efficiency is limited due to high humidity
Solution Approach 1:
The system extracts and removes moisture from the compressed air stream before it passes through the air dryer during regeneration, using moisture separators or coalescing filters. This pre-drying step ensures that the air used for regeneration is as dry as possible, maximizing regeneration efficiency.
Solution Approach 2:
The patent employs composite drying mechanisms combining multiple drying technologies (e.g., refrigerated drying, desiccant materials, and moisture separation) to achieve thorough drying of regeneration air. This multi-stage approach ensures low humidity in the regeneration air stream.
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
This approach effectively maintains low humidity levels in the air dryer, preventing saturation and ensuring efficient operation by regularly regenerating the air dryer before it reaches saturation, thus ensuring reliable dehumidification and extended service life.
Implementation Method 1
an air dryer, which is generally fitted with an air dryer cartridge that removes moisture from the air flowing through it
Implementation Method 2
the flow of compressed air through the air dryer is reversed, such as by venting compressed air from supply tanks of one of the commercial vehicle's compressed air circuits through the air dryer to atmosphere. When flowing through the air dryer in the regeneration direction, the air flowing through removes moisture and any other foreign particles from the filter and the air dryer
Data Source
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AI summary
The invention relates to a method for regenerating a compressed air supply system (10) of a commercial vehicle, wherein the compressed air supply system comprises an air dryer and is suitable for supplying a first compressed air circuit and a second compressed air circuit with compressed air. A predetermined maximum pressure value (Pmax) is assigned to the first compressed air circuit. The method comprises the steps of: supplying the first compressed air circuit with compressed air until the first compressed air circuit has reached a predetermined target pressure value (Ps); subsequently supplying the second compressed air circuit with compressed air.Between the steps of supplying the first compressed air circuit and the second compressed air circuit, the following intermediate steps are performed: Regeneration of the air dryer with compressed air from the first compressed air circuit when the pressure (P) in the first compressed air circuit has reached the target pressure value (Ps) and a humidity value (F) of the air dryer is above a predetermined target humidity value (Fz); Termination of regeneration when the pressure (P) in the first compressed air circuit has dropped to a predetermined limit pressure value (Pg), or the humidity value (F) of the air dryer has reached or fallen below the target humidity value (Fz); Supply of compressed air to the first compressed air circuit until the first compressed air circuit has reached the predetermined target pressure value (Ps); Repeating the preceding intermediate steps if the humidity value (F) of the air dryer is greater than the target humidity value (Fz).