Air Compressor Controller Dynamic Pressure Adjustment
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Solution Overview
Problem
Existing air compressors face challenges in maintaining optimal pressure and motor output to balance efficiency, noise reduction, and component longevity, with existing control methods lacking sufficient followability to changing air consumption rates.
Innovation Solution
An air compressor system with a controller that dynamically adjusts the ON and OFF pressure values and motor output based on continuous drive and stop times, using pressure detectors to calculate change rates and execute setting changes, ensuring sensitive responses to pressure changes and optimizing operation modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressure in the tank part is kept slightly high, then it is difficult for the compressed air to be deficient, but the drive time of the motor increases and power consumption increases
Solution Approach 1:
The patent applies dynamics by making the motor output and pressure settings adjustable and changeable over time. The controller dynamically adjusts the motor output based on operation mode and changes pressure settings stepwise based on continuous drive/stop time, transforming static fixed settings into dynamic adaptive settings that optimize both reliability and energy consumption at different operational stages.
2Use of energy by moving object
If the pressure in the tank part is kept slightly low, then noise is reduced and power consumption is reduced, but the compressed air for driving a tool is likely to be deficient
Solution Approach 1:
The patent applies preliminary action by proactively increasing motor output and pressure settings before compressed air deficiency occurs. The controller monitors continuous drive time and preemptively adjusts settings stepwise to ensure sufficient compressed air supply is maintained, preventing tool operation interruption before it happens.
3Reliability
If the output of the motor and pressure in the tank part are increased stepwise every predetermined time, then it is difficult for the compressed air to be deficient, but the followability is insufficient and settings may be excessively increased
Solution Approach 1:
The patent applies feedback by continuously monitoring operation mode and compressed air consumption patterns, then using this information to intelligently adjust the execution cycle and change amount of setting modifications. The controller adapts the stepwise increase parameters based on actual system response, ensuring settings are adjusted appropriately without excessive increases or delays.
4Use of energy by moving object
If the motor is stopped for a predetermined time or longer, then noise and power consumption are reduced, but the followability is insufficient and settings may be excessively reduced
Solution Approach 1:
The patent applies feedback by monitoring motor stop duration and compressed air consumption patterns to intelligently determine when and how much to reduce settings. The controller uses this feedback information to adapt the execution cycle and change amount of setting reductions, preventing excessive reduction that would compromise compressed air supply reliability while still achieving noise and energy reduction benefits.
Data Source
AI summary
An air compressor includes: a motor actuating a mechanism to generate compressed air; a tank part in which the compressed air is stored; a pressure detector detecting a pressure value in the tank part; and a controller driving the motor when the pressure value is equal to or smaller than an ON pressure value and to stop drive of the motor when the pressure value is equal to or greater than an OFF pressure value. The controller executes processing for detecting a continuous drive time or a continuous stop time of the motor and changing at least one of the ON pressure value, the OFF pressure value and an output of the motor, and the controller detects a change amount of the pressure value, and to determine an execution cycle of the processing or a change amount of a value in the processing, based on the detected change amount.