Modular Pneumatic Limit Switch Box Without External Bores
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Solution Overview
Problem
Existing control units for pneumatic actuators of membrane valves require additional external bores for connecting channels, which can lead to weak points and limit flexibility in design and functionality.
Innovation Solution
A control unit with a modular design that includes integrated channels for connecting external and internal connections, allowing for compact, space-saving, and adaptable configurations without the need for additional external bores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional external bores are added for connecting channels, then flexibility in design and functionality is improved, but weak points and structural integrity deteriorate
Solution Approach 1:
The control unit is divided into a housing and a separate connecting piece that can be attached as needed. This segmentation allows the main housing to remain structurally intact without additional bores, while the connecting piece provides the necessary connection channels through a standardized interface, thus maintaining both structural integrity and design flexibility.
Solution Approach 2:
The connecting piece with its internal channels is nested within or attached to the housing structure. This nesting approach allows the connection channels to be housed within a dedicated component rather than requiring direct bores through the main housing, preserving the housing's structural integrity while providing the needed connectivity.
2Adaptability or versatility
If additional external bores are added for connecting channels, then functionality is extended, but device complexity increases
Solution Approach 1:
The connecting piece serves multiple functions: it provides connection channels, acts as a mounting interface for solenoid valves, and offers a standardized attachment mechanism to the housing. This multi-functionality extends the device's capabilities without proportionally increasing complexity, as a single component accomplishes multiple tasks.
Solution Approach 2:
The connecting piece acts as an intermediary component between the housing and the solenoid valves. It mediates the connection by providing standardized interfaces and internal channels, simplifying the overall system architecture compared to direct mounting arrangements that would require multiple bores and complex routing.
3Ease of manufacture
If modular design with integrated channels is used, then ease of production and customization is improved, but manufacturing precision requirements increase
Solution Approach 1:
By segmenting the control unit into a housing and a separate connecting piece with pre-integrated channels, the manufacturing process is simplified. Each component can be manufactured independently using optimized processes, and the connecting piece's channels are created once during its fabrication rather than requiring multiple precision bores in the housing.
Solution Approach 2:
The channels are pre-integrated into the connecting piece during its manufacturing process, before assembly with the housing. This preliminary action allows the channels to be created using appropriate manufacturing techniques for the connecting piece's geometry, avoiding the need for complex post-assembly modifications or precision drilling operations on the main housing.
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 modular design enables standardized control units to be customized to meet specific customer requirements, offering extended functionality while maintaining durability and ease of production.
Implementation Method 1
at least one solenoid valve is arranged in the housing component
Data Source
Figure 1
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AI summary
The invention relates to a control unit (28) for a pneumatic actuator of a diaphragm valve, wherein the control unit (28) comprises a housing component (13) having a supply port (18), at least one working port (19), and a vent port (20). At least one solenoid valve (17) is arranged in the housing component (13), each solenoid valve comprising a combination of the following ports: a working port, a vent port, and a supply port. The ports (18, 19, 20) of the housing component (13) are connected to the ports of at least one solenoid valve (17). The control unit (28) has a module comprising channels for connecting the ports (18, 19, 20).