Diaphragm Pump Overload Protection via Breakaway Connection
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Solution Overview
Problem
Diaphragm pumps face issues with membrane damage and reduced delivery volume due to improper fluid management, leading to excessive stress and noise, especially when suction lines are dirty or blocked, and existing solutions like strong return springs cause cavitation and foam formation.
Innovation Solution
A closure element connected to the membrane core and retraction device that opens a return flow channel when a triggering force is exceeded, reducing fluid pressure and limiting membrane deflection, using a magnetic connection or predetermined breaking point for overload protection, and integrating the return flow channel within the pull rod and housing for compactness and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If strong return springs are used to prevent diaphragm deflection beyond discharge stroke position, then diaphragm protection is improved, but cavitation and foam formation occur causing noise and reduced delivery volume
Solution Approach 1:
The harmful function of the return spring is extracted and replaced by a dedicated overload protection device (breakaway connection between membrane core and pull rod). This separates the normal return function from the overload protection function, allowing the membrane to be pulled back without causing cavitation while still protecting against excessive deflection.
Solution Approach 2:
A breakaway connection serves as an intermediary element between the membrane core and pull rod. This intermediate component provides controlled failure under excessive load, protecting the membrane while avoiding the harmful effects of strong springs. The breakaway connection acts as a sacrificial element that fails safely rather than transmitting harmful forces.
2Reliability
If the suction line is blocked or contaminated, then fluid intake is reduced, but diaphragm deflection beyond discharge stroke position occurs causing excessive stress
Solution Approach 1:
The breakaway connection is pre-designed with a specific failure force threshold. Before any excessive stress can damage the membrane, the breakaway connection is already in place to detect and respond to overload conditions. This preliminary protective measure ensures that the membrane is protected before damage can occur.
Solution Approach 2:
The breakaway connection provides beforehand cushioning by being designed to fail at a predetermined force level. This creates a safety buffer that absorbs excessive forces before they can reach the membrane, protecting it from stress beyond its design limits while allowing normal operation.
3Device complexity
If membrane return device is made compact by integrating return flow channel within pull rod, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The return flow channel is merged with the pull rod structure, combining two previously separate components into one integrated element. This reduces the total number of parts and simplifies the overall device while maintaining the necessary functionality of both the return mechanism and fluid passage.
Solution Approach 2:
The pull rod is given multiple functions: it serves as both the mechanical return mechanism and as the housing for the return flow channel. This multi-functional design eliminates the need for separate return channels or additional hoses, reducing complexity while integrating fluid management directly into the mechanical component.
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
Prevents membrane damage, reduces noise and foam formation, and maintains consistent delivery pressure by limiting membrane deflection and fluid pressure, ensuring reliable operation under varying conditions without the need for additional hoses or lines.
Implementation Method 1
opens a return flow channel when a triggering force is exceeded, reducing fluid pressure
Implementation Method 2
using a magnetic connection or predetermined breaking point for overload protection
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a diaphragm pump (1) with a pumping chamber (3) and a working chamber (5), wherein the working chamber can be filled or is filled with a hydraulic fluid and is operatively connected to a pressure generating device in order to apply an oscillating pressure to the hydraulic fluid, further comprising a diaphragm (11) with at least one diaphragm layer (13) and a diaphragm core (15) that separates the pumping chamber (3) and the working chamber (5) from each other, wherein the diaphragm (11) can be brought into operative connection with a diaphragm return device (17) comprising a pull rod (19) that applies a return force to the diaphragm (11) in the direction of the suction stroke position.can be acted upon, and further comprising a reservoir (21) for receiving the hydraulic fluid, and wherein the working chamber (5) and the reservoir (21) are connected to each other by means of a return channel (25) closed by means of a closure element (23), and wherein the closure element (23) is in operative connection with the diaphragm core (15) and the diaphragm retraction device (17), so that the retraction force and a pressure force acting on the closure element (23) due to the fluid pressure in the working chamber (5) counteract the retraction force, and wherein the return channel (25) is opened when a predetermined release force is exceeded as the sum of the retraction force and the pressure force on the closure element (23).