Cordless Compressor Pressure Control for Battery Efficiency
Solution Overview
Problem
Existing air compressors powered by battery packs face challenges in efficiently providing airflow in environments without electrical supplies, often requiring high energy consumption and resulting in surplus compressed air that is not effectively utilized.
Innovation Solution
The air compressor assembly includes a compact design with a DC motor powered by a battery pack, featuring a pressure switch assembly and controller circuit to regulate air pressure efficiently, allowing for hand transport and extended battery run-time by optimizing compressor operation based on battery capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a battery pack is used to power the compressor, then the compressor can operate in environments without AC power, but the energy consumption increases and battery run-time is limited
Solution Approach 1:
The compressor operates in periodic cycles, running only when the air tank pressure drops below a predetermined threshold and stopping when the pressure reaches the threshold. This periodic operation pattern reduces overall energy consumption while maintaining adequate air supply for pneumatic tools, directly addressing the contradiction between portability and energy efficiency
2Productivity
If a pressure tank is included to store compressed air, then the compressor can meet temporary demand, but surplus compressed air is created that is not effectively utilized
Solution Approach 1:
The system incorporates a pressure sensor that continuously monitors the air tank pressure and provides feedback to the controller. The controller uses this feedback to intelligently control the compressor's operation, starting only when pressure drops below a threshold and stopping when the threshold is reached. This feedback mechanism ensures the compressor operates precisely when needed, eliminating energy wastage from surplus compressed air while maintaining adequate pressure for pneumatic tools
3Quantity of substance
If the compressor runs continuously to pressurize air, then sufficient air is available for pneumatic devices, but energy is wasted on air that is not utilized
Solution Approach 1:
The compressor operates periodically rather than continuously, running only when the air tank pressure drops below a predetermined threshold and stopping when the pressure reaches the threshold. This periodic operation pattern reduces overall energy consumption while maintaining adequate air supply for pneumatic tools
Solution Approach 2:
The system incorporates a pressure sensor that continuously monitors the air tank pressure and provides feedback to the controller. The controller uses this feedback to intelligently control the compressor's operation, starting only when pressure drops below a threshold and stopping when the threshold is reached. This feedback mechanism ensures the compressor operates precisely when needed, eliminating energy wastage from surplus compressed air
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 enables efficient airflow for small demand fasteners like finish nailers, extending battery run-time and allowing for a larger number of nails to be driven on a single charge, while minimizing energy wastage and ensuring operation in environments lacking electrical power.
Implementation Method 1
DC motor powered by a battery pack
Implementation Method 2
DC motor powered by a battery pack
Implementation Method 3
The compressor compresses air which is then stored in the air storage tank
Data Source
AI summary
A cordless compressor has an air storage tank, a pump, a motor for driving the pump, and a controller circuit electrically connected to the motor. A pressure switch assembly is connected to the controller circuit. The pressure switch assembly has first and second pressure switches for sensing pressure within the air storage tank. The controller circuit controls de-activation of the motor depending upon status of the first and second pressure switches.