Electronically-Controlled Compressed Air System Pressure Management
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Solution Overview
Problem
Compressed air systems in machines suffer from inefficiencies due to continuous charging and leakage through inlet valves, leading to over-pressurization and unnecessary power burdens, with existing pneumatic control systems being unreliable and inefficient.
Innovation Solution
An electronically controlled compressed air system that includes a reservoir pressure sensor, an outlet valve, and an electronic actuator, regulated by an electronic control module (ECM) to dynamically adjust the inlet and outlet valves based on actual and target pressures, ensuring precise pressure management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a running blow down valve with fixed orifice is used to release compressed air from the reservoir, then the reservoir pressure can be reduced to prevent over-pressurization, but the pressure release is slow and compressed air leaks to the atmosphere during drilling operations
Solution Approach 1:
The patent replaces the fixed orifice blow down valve with an electronically controlled valve that dynamically adjusts its opening degree based on real-time reservoir pressure feedback. The ECM receives pressure sensor signals and commands the electronic actuator to modulate the outlet valve position, enabling adaptive pressure control that prevents both over-pressurization and unnecessary air loss during drilling operations.
Solution Approach 2:
The system implements a closed-loop feedback control mechanism where the reservoir pressure sensor continuously monitors actual pressure and transmits signals to the ECM. The ECM compares actual pressure with target pressure and adjusts the outlet valve position accordingly, creating a self-regulating system that maintains optimal pressure without wasting compressed air.
2Reliability
If the running blow down valve is kept open to prevent over-pressurization, then the reservoir pressure remains controlled, but compressed air that could be delivered to the drill rod leaks to the atmosphere
Solution Approach 1:
The electronically controlled outlet valve dynamically adjusts its opening degree based on real-time pressure feedback, allowing the system to maintain precise pressure control while minimizing compressed air loss. Unlike the always-open blow down valve, this system only opens the valve when and where needed to maintain target pressure, thereby preserving compressed air for productive use at the drill rod.
Solution Approach 2:
The closed-loop feedback system enables intelligent decision-making about when to release compressed air. The ECM receives continuous pressure information, compares it with target pressure, and only commands the outlet valve to open when actual pressure exceeds target pressure, ensuring that compressed air is retained for productive operations while maintaining safe pressure levels.
3Ease of operation
If pneumatic actuators are used to control the blow down valves, then the valves can be controlled remotely, but the control system becomes inefficient, unreliable, and unstable
Solution Approach 1:
The patent replaces the pneumatic actuator system with an electronically controlled valve system. The electronic actuator receives electrical commands from the ECM and converts them to mechanical valve position adjustments. This substitution eliminates the inefficiencies and reliability issues of pneumatic control while maintaining remote control capability through electronic signaling between the pressure sensor, ECM, and electronic actuator.
Data Source
AI summary
A compressed air system may comprise an air compressor configured to generate compressed air, a reservoir configured to store the compressed air, a reservoir pressure sensor configured to monitor an actual reservoir pressure of the compressed air stored in the reservoir, an outlet valve configured to regulate a flow of the compressed air out of the reservoir, and an outlet electronic actuator configured to adjust a position of the outlet valve. The compressed air system may further comprise an electronic control module (ECM) configured to transmit a command to the outlet electronic actuator to cause the outlet electronic actuator to open the outlet valve when the actual reservoir pressure is above a target reservoir pressure, and transmit a command to the electronic actuator to cause the electronic actuator to close the outlet valve when the actual reservoir pressure is below the target reservoir pressure.