Pressure-Sensor Clutch Control for Engine-Driven Air Compressors
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Solution Overview
Problem
Engine-driven air compressor systems consume large amounts of fuel, require frequent maintenance, and generate environmental noise and exhaust due to continuous operation, especially when idle with a high load, which affects engine performance and electrical power variability.
Innovation Solution
A control system that uses pressure sensors to manage the engagement and disengagement of the clutch between the engine and air compressor, adjusting the inlet valve and bleed down valve to reduce energy consumption by idling the engine when air pressure exceeds a threshold and re-engaging when pressure drops below it, allowing the system to operate efficiently and reduce fuel usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air compressor is continuously driven by a direct connection with the engine, then the air compressor can maintain consistent operation, but fuel consumption increases and environmental noise and exhaust are generated
Solution Approach 1:
The patent implements periodic action by using a clutch mechanism to intermittently connect and disconnect the air compressor from the engine based on air pressure demands. The system alternates between engagement (when compressed air is needed) and disengagement (when air pressure is sufficient), eliminating continuous operation and reducing fuel consumption while maintaining operational reliability when needed.
Solution Approach 2:
The patent extracts the air compressor from continuous engine operation by introducing a clutch mechanism that selectively disconnects the compressor during periods when compressed air is not required. This separation allows the engine to operate independently without the parasitic load of the compressor, reducing fuel consumption and environmental impact while preserving the ability to re-engage the compressor when needed.
2Reliability
If the air compressor operates at high load during idle conditions, then the compressor can maintain pressure, but engine performance deteriorates and power variability increases
Solution Approach 1:
The patent implements feedback control by continuously monitoring air pressure levels and using this information to control clutch engagement. When air pressure reaches the desired level, the system receives feedback and disengages the clutch, preventing the engine from operating under unnecessary high load. This feedback mechanism ensures pressure maintenance only when needed while optimizing engine performance during idle conditions.
Solution Approach 2:
The patent applies dynamics by making the clutch engagement state variable rather than fixed. The system dynamically adjusts the connection between engine and compressor based on real-time pressure demands, allowing the engine to transition between loaded and idle states. This dynamic control prevents sustained high-load operation during idle conditions while maintaining the ability to quickly re-engage when pressure is needed.
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 solution reduces fuel consumption and minimizes environmental impact by optimizing engine load based on air compressor demand, maintaining a consistent idle speed and reducing power consumption during no-flow conditions, thereby improving the efficiency and reliability of engine-driven power systems.
Implementation Method 1
A control system that uses pressure sensors to manage the engagement and disengagement of the clutch between the engine and air compressor
Implementation Method 2
A control system that uses pressure sensors to manage the engagement and disengagement of the clutch between the engine and air compressor
Implementation Method 3
adjusting the inlet valve and bleed down valve to reduce energy consumption by idling the engine when air pressure exceeds a threshold
Data Source
AI summary
Power systems and methods of controlling an engine driven air compressor include an air compressor driven by an engine via a clutch. A first pressure sensor configured to sense a pressure level at an outlet of the air compressor. An inlet valve configured to close in response to the first pressure sensor sensing a pressure level above a first pressure level. In addition, a second pressure sensor to sense a pressure level below a second pressure level at a housing of the air compressor, wherein the clutch is configured to disengage in response to the second pressure level, wherein the first pressure level is higher than the second pressure level.