Air Compressor Pressure Control via Adjustable Clearance Volume
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air compressors risk over-inflating tires due to mechanical safety valves becoming stuck, leading to excessive pressure and potential blowouts, and require additional components that increase manufacturing costs.
Innovation Solution
An air compressor design featuring an electrically operated compressor unit with a piston that creates a space between the piston head and cylinder top when at top dead center, utilizing an auxiliary air chamber and adjusting bolt to control pressure without a mechanical safety valve, ensuring air pressure remains below a safety threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical safety valve is used to release air when pressure exceeds safety levels, then tire over-inflation can be prevented, but the safety valve may become stuck after prolonged use and fail to function properly
Solution Approach 1:
The patent removes the mechanical safety valve from the system entirely and replaces it with a pressure control mechanism using an adjusting bolt and auxiliary air chamber. This extraction eliminates the reliability issues associated with mechanical valves while maintaining pressure safety through a simpler adjustment mechanism.
Solution Approach 2:
The patent replaces the mechanical safety valve system with an adjustable pressure control system using a threaded bolt that modifies the compression ratio. This substitution transitions from a passive mechanical release mechanism to an active pressure control mechanism that prevents over-pressurization before it occurs.
2Reliability
If a mechanical safety valve is installed to prevent over-inflation, then tire safety is improved, but manufacturing cost increases due to additional components
Solution Approach 1:
By removing the safety valve component entirely and integrating pressure control into the existing compression mechanism through an adjusting bolt, the patent eliminates the need for separate safety valve procurement and installation, thereby reducing manufacturing costs while maintaining tire safety.
Solution Approach 2:
The adjusting bolt serves multiple functions: it controls the compression ratio, regulates output pressure, and prevents over-pressurization. This multi-functionality eliminates the need for dedicated safety valve components, reducing overall system complexity and manufacturing cost.
3Productivity
If the piston head contacts the top wall of the cylinder at top dead center to maximize compression, then compression efficiency is improved, but no space remains for pressure regulation mechanisms
Solution Approach 1:
The patent makes the clearance volume dynamic by using an adjusting bolt that can modify the position of the auxiliary air chamber. This allows the system to adjust the compression ratio dynamically, maintaining efficient compression while providing the necessary space for pressure regulation through the adjustable clearance volume.
Solution Approach 2:
The patent changes the physical parameter of clearance volume by incorporating an adjustable mechanism. The adjusting bolt modifies the volume of the auxiliary air chamber, thereby changing the compression ratio to achieve desired output pressure while maintaining efficient piston operation.
4Device complexity
If the clearance volume is fixed to simplify the structure, then device complexity is reduced, but the ability to regulate output pressure is lost
Solution Approach 1:
The patent transforms the fixed clearance volume into a dynamic, adjustable parameter through the use of a threaded adjusting bolt. This simple mechanical adjustment mechanism allows users to modify the auxiliary air chamber volume to regulate output pressure, maintaining structural simplicity while adding adaptability.
Solution Approach 2:
The adjusting bolt provides a user-friendly, self-service mechanism for pressure regulation. Users can directly adjust the clearance volume by turning the bolt to match their specific pressure requirements, eliminating the need for complex control systems or multiple components.
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 design prevents tire over-inflation by maintaining air pressure below safety levels without mechanical safety valves, enhancing operational security and reducing manufacturing costs.
Implementation Method 1
a motor drives a piston body to conduct reciprocating motion in a cylinder to produce compressed air
Implementation Method 2
an adjusting bolt being threadedly fitted into the tube to define an auxiliary air chamber communicating with an inner space of the cylinder via an auxiliary exit hole
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An air compressor is disclosed, which can keep the pressure of air supply less than a safety pressure without using a safety valve, so that a tire can be inflated without exceeding a safety pressure thereof. One feature of the air compressor is that: when the piston body, which conducts reciprocating motion in the cylinder, reaches top dead center, a space is existed between the head of the piston body and the top wall of the cylinder. Another feature of the air compressor is that: an adjusting bolt is used to adjust the volume of the auxiliary air chamber to change the maximum permissible output pressure of the air compressor to suit an object. As such, the air compressor does not require a mechanical safety valve to release air for limiting the pressure of air supply. The air compressor can protect a tire from over-inflation and save the manufacturing cost.