Integrated Pilot Valve for Stable Intermittent Air Output
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Solution Overview
Problem
Conventional intermittent air generating devices have complex circuit configurations and high production costs due to the presence of two pilot valves, which complicates the design and increases costs.
Innovation Solution
A simplified configuration using a single switching unit with a movable valve element that switches communication between compressed air and pilot air ports, integrated with a pilot valve, allowing for stable intermittent operation without pressure drop effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pilot type control valve and a pilot type on-off valve are used separately, then the intermittent air generating device can achieve stable performance, but the circuit configuration becomes complex and production costs increase
Solution Approach 1:
The patent combines the pilot type control valve and the pilot type on-off valve into a single integrated valve unit. The control valve portion includes a control piston and control spring for regulating air supply, while the on-off valve portion includes a main valve element and main spring for intermittent air output. Both valve elements are housed within the same valve body with shared pilot ports and pressure chambers, eliminating the need for separate valve assemblies and reducing circuit complexity while maintaining stable intermittent air generation performance
2Adaptability or versatility
If two pilot valves are used in the intermittent air generating device, then the valve control function is complete, but the number of parts increases and production costs rise
Solution Approach 1:
The patent integrates two previously separate pilot valves into one unified valve assembly. The integrated design shares common components including the valve body, pilot ports, and housing structure, while maintaining distinct control and on-off valve elements with their respective springs and sealing mechanisms. This reduction in part count directly lowers manufacturing costs and assembly complexity while preserving complete valve control functionality
Solution Approach 2:
The integrated valve unit serves multiple functions within a single component structure. The control valve portion regulates air pressure and flow, while the on-off valve portion controls intermittent air output. Both functions operate simultaneously within the same valve body, allowing the single component to replace what previously required two separate pilot valves, thereby reducing production costs while maintaining full control capability
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 reduces the number of parts and production costs while maintaining stable performance by integrating the pilot valve and on-off valve into one component, enabling efficient and cost-effective intermittent air generation.
Implementation Method 1
the valve element is moved by the pilot air supplied to the third port to thereby cause the first port and the second port to communicate with each other
Data Source
AI summary
A control valve in an intermittent air-generating device has a five-port valve, the inlet port of which is connected to a fluid supply source and the outlet port is connected to an air-spraying device. As a result of pilot air being supplied to a pilot input port, a valve element moves, and as a result of the inlet port and the outlet port being put in an ON state in which the two are in communication with each other, compressed air is sprayed from the air-spraying device. Meanwhile, as a result of the pilot air being discharged from the pilot input port by way of a discharge port, the valve element moves in the opposite direction and the inlet port and the outlet port are put in an OFF state in which the state of communication between the two is blocked. The ON state and OFF state alternate intermittently.