Compressor Intake Regulator with Integrated Relief Valve
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Solution Overview
Problem
Existing compressor intake regulators are complex and require multiple components, leading to potential faults and operational issues, especially at low temperatures, and separate relief devices are needed for pressure relief.
Innovation Solution
A simplified regulator design using a rod-shaped valve element with a valve disk and soft spring, which automatically adjusts to a slightly open state at standstill, integrating relief and check valve functions, eliminating the need for additional control devices and ensuring operational reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If additional control devices such as proportional controllers, electric valves, pneumatic valves, and control pistons are used, then the control function is improved, but the device complexity increases and reliability decreases
Solution Approach 1:
The patent combines the control valve and relief valve into a single integrated regulator assembly. The rod-shaped valve element serves dual purposes: controlling intake flow and providing pressure relief functionality, thereby reducing the number of separate components while maintaining both control and relief functions
Solution Approach 2:
The rod-shaped valve element is designed to perform multiple functions simultaneously: it acts as both the control valve element for regulating intake flow and as the relief valve element for pressure relief. This multi-functional design eliminates the need for separate control and relief devices
2Device complexity
If the valve element is preloaded in the closed position by a soft spring, then the structure is simplified, but the risk of freezing or blocking at low temperatures increases
Solution Approach 1:
The valve element is designed to remain in a slightly open state rather than fully closed when the compressor is at standstill. The soft spring preloads the valve in the closed position, but the valve disk remains slightly lifted from the valve seat, creating a small clearance that prevents complete sealing. This partial opening prevents freezing and blocking while maintaining simplicity
Solution Approach 2:
The soft spring is designed to maintain a slight gap between the valve disk and valve seat even in the closed position. This preliminary design feature prevents the valve from completely sealing, thereby preemptively avoiding freezing and blocking issues that would occur with a fully closed valve at low temperatures
3Reliability
If a separate relief device is used, then the pressure relief function is ensured, but the device complexity and space requirement increase
Solution Approach 1:
The relief valve is integrated into the regulator housing, sharing the same rod-shaped valve element and valve seat assembly. The relief bore is formed in the regulator housing, allowing the relief function to be accomplished within the existing regulator structure without adding separate relief device components
4Volume of moving object
If the regulator is designed with essential functional elements in a nested arrangement, then the space requirement is reduced, but the manufacturing complexity may increase
Solution Approach 1:
The relief valve components are nested within the regulator housing structure. The rod-shaped valve element is positioned within the regulator, and the relief bore is formed in the housing itself, creating a compact nested arrangement where the relief function is embedded within the existing regulator geometry
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 design enhances operational reliability by preventing freezing and blocking at low temperatures, simplifies the structure, and integrates multiple functions into a compact, fault-free system suitable for mass production.
Implementation Method 1
the rod-shaped valve element is preloaded in the closed position by means of a soft spring
Implementation Method 2
the pressure increasing in the intake area of the compressor acts as closing pressure on the valve disk of the rod-shaped valve element
Data Source
Figure 1
Figure 2
AI summary
The invention concerns a regulator (1, 1'), in particular an intake regulator for compressors, the regulator having a rod-shaped valve element (3) which can be moved longitudinally in a regulator housing (2) and brings about, in the open position, a communicating connection with a pressure space (5), for example of the compressor. In the closed position, this pressure space (5) is shut off. The regulator (1, 1') is configured in such a way that the rod-shaped valve element (3) has at one end a valve plate (4) which cooperates with a valve seat on the regulator housing (2), and that the rod-shaped valve element (3) is pre-loaded in the closed position by means of a flexible spring (6) in such a way that when the compressor is in the stationary state and relieved of pressure the valve plate (4) stays in the slightly lifted-up (open) state. In addition, the regulator (1, 1') has at the same time a non-return valve function which is formed by virtue of the fact that when the compressor is switched off, the pressure which rises in the intake region (5) of the compressor acts on the valve plate (4) of the rod-shaped valve element (3) as a closing pressure. In addition, the regulator (1, 1') has an integrated relief valve (8, 8') which is constructed and configured in such a manner that in order to relieve the pressure of the interior of the regulator (1, 1'), in the closed position of the valve element (3) of the regulator (1, 1'), a communicating connection is produced, via the flattened portion (9) and the circumferential groove (12), with a relief borehole (3) which is formed in the regulator housing (2) and which leads to the external surroundings.