Multi-Stage Compressor Pneumatic Shut-Off Valve
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Solution Overview
Problem
Existing pressure control systems with multi-stage compressors face challenges in adjusting compression capacity and compressed volume flow to match operating modes efficiently and reliably, particularly in vehicle air spring systems, where energy consumption and compression performance need optimization.
Innovation Solution
A pneumatically controlled check valve is used to limit or completely switch off the first compression stage, allowing only pre-compressed air from an upstream stage to be compressed further by the second stage, thereby adjusting compression capacity and reducing energy consumption based on control pressure, without additional electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the first compression stage operates continuously to provide precompressed pressure medium, then the compression capacity is maintained, but energy consumption increases unnecessarily in closed operating mode
Solution Approach 1:
The first compression stage is designed to be dynamically switchable between active and inactive states. A shut-off valve controlled by a piston responds to pressure differences between the first compression chamber and intermediate volume, automatically adjusting the operation of the first compression stage based on system requirements. This dynamic adjustment allows the system to optimize energy consumption by disabling the first compression stage when precompressed medium is already available in the intermediate volume.
2Use of energy by moving object
If the first compression stage is switched off to reduce energy consumption, then energy efficiency improves, but the compression performance and volume flow delivery may be insufficient
Solution Approach 1:
The system employs a feedback mechanism where the pressure difference between the first compression chamber and the intermediate volume controls the shut-off valve. When the intermediate volume has sufficient precompressed medium, the pressure feedback closes the shut-off valve, switching off the first compression stage. When the intermediate volume pressure drops, the feedback opens the shut-off valve, reactivating the first compression stage. This ensures the system automatically adjusts compression capacity to match actual demand, maintaining productivity while optimizing energy use.
3Use of energy by moving object
If precompressed pressure medium from the intermediate volume is used in closed operating mode, then energy consumption is reduced, but the control system complexity increases
Solution Approach 1:
The control system utilizes the existing pressure differential between the first compression chamber and the intermediate volume as a self-regulating mechanism. The shut-off valve's piston automatically responds to these pressure differences without requiring external sensors, controllers, or additional power sources. The system essentially controls itself using the physical state of the compressed medium, thereby reducing energy consumption while avoiding the complexity of electronic control systems.
4Volume of stationary object
If the first compression stage operates at full capacity, then the intermediate volume is quickly filled with precompressed medium, but the compression work is excessive when only small amounts are needed
Solution Approach 1:
The system applies partial action by allowing the first compression stage to operate only when and to the extent needed. The shut-off valve modulates the operation based on the actual pressure requirements in the intermediate volume, preventing excessive compression work. Instead of continuously operating at full capacity, the first compression stage performs partial compression cycles only when the intermediate volume requires additional precompressed medium, thereby eliminating energy waste while maintaining adequate filling.
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 method allows for simple and automatic adjustment of compression capacity, reducing energy consumption and optimizing compression performance, especially in closed operating modes, while maintaining high final volume flow and pressure delivery to consumers.
Implementation Method 1
a compression output of a first compression stage of a multi-stage compressor, in particular in a closed operating mode of a pressure control system, is reduced or limited by a pneumatically controlled check valve depending on a control pressure prevailing on a control line
Implementation Method 2
The multi-stage compressor compresses the pressure medium introduced into an intake chamber from the atmosphere over two or more compression stages and transfers the multi-stage compressed pressure medium to the compression springs
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The invention relates to a method for operating a pressure control system (1), in particular for vehicles (200), comprising a multi-stage compressor (4). A pressure medium (L3) compressed multiple times is provided from the multi-stage compressor (4) in order to fill a pressure medium reservoir (20) or is provided from pressure medium chambers (3.i; i=1,...4) of the pressure control system (1). For this purpose, - a pre-compressed pressure medium (L2) is provided from a first compression stage (5) and is compressed additionally at least via a second compression stage (6), and/or - an already compressed charging pressure medium (A) is introduced into an intermediate volume (13) between the first compression stage (5) and the second compression stage (6) of the multi-stage compressor (4), and the charging pressure medium (A) is compressed again at least by the second compression stage (6). The charging pressure medium (A) at the same time passes via a control line (26.2) to a control input (26.1) of a shut-off valve (26) cooperating with the first compression stage (6), such that a charging pressure (pA) of the charging pressure medium (A) defines a control pressure (pS) of the shut-off valve (26). A pressure limit (pG) dependent on the control pressure (pS) and/or a volumetric flow limit (QG) of the pre-compressed pressure medium (L2) conveyed from the first compression stage (5) into the intermediate volume (13) is reached via the shut-off valve (26) in order to automatically adapt the compression power of the first compression stage (5) by means of the charging pressure medium (A) in the control line (26.2).