Diaphragm Pump Pressure Regulator for Hydraulic Volume Control
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Solution Overview
Problem
Existing diaphragm pumps face challenges in maintaining sufficient hydraulic fluid volume, especially under pressure feed conditions, leading to reduced pump performance and the need for bias springs to purge air from the hydraulic chamber.
Innovation Solution
A diaphragm pump system with a pressure regulator assembly that maintains hydraulic fluid pressure above the pumped fluid inlet feed pressure, using a combination of back pressure regulators and remote pressure control valves to ensure proper fluid volume and air purging without the need for bias springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring bias pressure system is used to purge air from the hydraulic chamber, then air purging is achieved, but the system complexity increases and the diaphragm may not achieve full stroke under pressure feed conditions
Solution Approach 1:
The patent removes the spring bias pressure system from the hydraulic chamber, extracting the air purging function to a separate phase separation chamber. This eliminates the complexity of springs and bias pressure mechanisms while maintaining air purging capability through gravitational separation in the external chamber.
Solution Approach 2:
The patent introduces a phase separation chamber as an intermediary component between the hydraulic fluid supply and the diaphragm chamber. This intermediary chamber separates air and hydraulic fluid phases, allowing air to be purged without requiring spring bias pressure in the main hydraulic system.
2Device complexity
If replenishment fluid is drawn from an atmospheric pressure sump, then the system is simple, but the volume of oil that can enter each stroke is insufficient for large pumps under pressure feed conditions
Solution Approach 1:
The patent uses a hydraulic fluid supply system that maintains positive pressure (greater than atmospheric pressure) to force hydraulic fluid into the phase separation chamber and subsequently into the diaphragm chamber. This hydraulic pressure ensures sufficient fluid volume is delivered during each stroke cycle, overcoming the limitations of atmospheric pressure sump systems.
Solution Approach 2:
The system pre-pressurizes the hydraulic fluid in the supply system before it enters the phase separation chamber. This preliminary pressurization ensures that when the diaphragm creates negative pressure during its stroke, sufficient pre-pressurized fluid is already available to be drawn in, ensuring full stroke operation even for large pumps.
3Device complexity
If the hydraulic fluid pressure is not maintained above the pumped fluid inlet feed pressure, then the system operates simply, but the diaphragm cannot achieve full stroke and pump performance is diminished
Solution Approach 1:
The patent implements a pressure feedback mechanism where the hydraulic fluid supply system monitors and maintains pressure above the pumped fluid inlet feed pressure. This feedback control ensures that the diaphragm chamber always has sufficient hydraulic fluid pressure to achieve full stroke, optimizing pump performance without overly complex pressure control.
Solution Approach 2:
The system dynamically adjusts the hydraulic fluid supply pressure to respond to changing operating conditions, ensuring that pressure remains above the pumped fluid inlet feed pressure. This dynamic pressure maintenance allows the diaphragm to achieve full stroke across varying load conditions, maximizing pump 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 system effectively maintains the correct hydraulic fluid volume during the entire suction stroke, even under pressure feed conditions, enhancing pump performance and eliminating the need for bias springs to purge air from the hydraulic chamber.
Implementation Method 1
A spring applies a force to the diaphragm that opposes the pressure
Implementation Method 2
provides a hydraulic fluid pressure above a pumped fluid inlet feed pressure
Implementation Method 3
A driven plunger slides in a reciprocating motion and forcing hydraulic fluid against the diaphragm
Data Source
AI summary
A diaphragm pump system includes a diaphragm pump and a pressure regulator. The diaphragm pump has a housing having a pumping chamber containing fluid to be pumped, and a transfer chamber adapted to contain hydraulic fluid. A diaphragm is supported by the housing and at least partially defines a pumping chamber side and a transfer chamber side. A driven plunger slides in a reciprocating motion and forcing hydraulic fluid against the diaphragm. A first valve allows hydraulic fluid into the transfer chamber and a second valve allows hydraulic fluid to be removed from the transfer chamber. A hydraulic fluid reservoir is in fluid communication with the transfer chamber. The pressure regulator includes valving that provides a hydraulic fluid pressure above a pumped fluid inlet feed pressure to maintain a proper amount of hydraulic oil in the transfer chamber.