Diaphragm Vacuum Pump Self-Calibration for Dead Volume Reduction
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Solution Overview
Problem
Membrane vacuum pumps face challenges with limited compression ratios due to dead volumes and require high manufacturing precision, which cannot be adjusted if the membrane wears out, leading to suboptimal performance and increased costs.
Innovation Solution
A self-calibration method using a control device with a voice coil drive to detect and adjust the dead center of the piston, allowing for automatic calibration before operation, reducing manufacturing tolerances and improving final pressure and pumping efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the membrane is pressed tightly against the membrane head to eliminate dead volume, then the compression ratio is improved, but the membrane wear increases leading to premature failure
Solution Approach 1:
The patent applies preliminary action by performing an automatic calibration run before the pump is put into operation. During this calibration, the piston is operated with reduced force to move the membrane into the membrane head and determine the optimal dead center position. This preliminary positioning eliminates dead volume for optimal compression ratio while preventing excessive force that would cause premature membrane wear, thus resolving the contradiction between compression ratio and membrane service life.
2Manufacturing precision
If high manufacturing precision is used to eliminate dead volume, then the compression ratio is improved, but the manufacturing costs increase
Solution Approach 1:
The patent applies parameter changes by introducing an automatic calibration process that determines the optimal dead center position of the piston based on actual operational parameters rather than relying solely on precise manufacturing tolerances. The calibration run adjusts the piston position to achieve optimal membrane contact with the membrane head, eliminating dead volume and improving compression ratio without requiring higher manufacturing precision, thus reducing manufacturing costs.
3Productivity
If the piston stroke is increased to improve pumping speed, then the productivity is improved, but the dead center positioning becomes more critical affecting reliability
Solution Approach 1:
The patent applies feedback by using a device for detecting the dead center and position of the piston, with a control device that adjusts the dead center based on the detected signal. This feedback mechanism ensures accurate dead center positioning even with increased piston stroke for higher pumping speed, maintaining reliability while improving productivity.
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 self-calibration method enhances the membrane vacuum pump's performance by optimizing the dead center, reducing dead volumes, and minimizing wear, resulting in improved final pressure and pumping speed while reducing manufacturing costs and time.
Implementation Method 1
a piston (2) which can be driven linearly with a voice coil drive (7, 8) in a drive chamber (15)
Data Source
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AI summary
The invention relates to a method for calibrating a diaphragm vacuum pump and a diaphragm vacuum pump for conveying a medium, comprising a piston linearly driven by a voice coil drive in a drive chamber, a diaphragm oscillating between a conveying chamber and a drive chamber, separating the conveying chamber and the drive chamber, a diaphragm head forming the conveying chamber with the diaphragm, the piston being designed as a piston that sets the diaphragm in motion and is movable by a predetermined distance, and a device for detecting a dead point and/or position of the piston, wherein a control device adjusts the dead point depending on the detected signal of the device.