Modular Pneumatic Pressure Control with Wiring-Free Valve Stacking
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Solution Overview
Problem
Existing pneumatic control systems require external wiring and dedicated communication devices for interconnecting proportional control functions, limiting their modularity and ease of use in applications such as closed-loop flow control.
Innovation Solution
A modular and stackable pneumatic system comprising a master module with integrated proportional electrovalves, sensors, and an electronic control unit, along with slave modules, that enables interconnection without external wiring or communication devices, using a digital communication bus for data exchange and allowing series or parallel operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple proportional control functions are integrated into one modular system, then system modularity and ease of use are improved, but device complexity increases
Solution Approach 1:
The system is divided into independent modular units (master module, slave modules) that can be individually manufactured, tested, and replaced. Each module contains specific proportional control functions that can be selectively combined, allowing complex control tasks to be achieved through simple module stacking without increasing overall system complexity.
Solution Approach 2:
The master module is designed with universal functionality to control multiple slave modules through a single digital communication bus. The standardized interface and communication protocol allow the same master module to perform different control functions by simply changing the connected slave modules, thereby improving adaptability without proportionally increasing device complexity.
2Ease of operation
If modules are interconnected without external wiring or communication devices, then ease of operation is improved, but reliability may worsen
Solution Approach 1:
The pneumatic connection and digital communication functions are merged into a single integrated interface. The digital communication bus is combined with the pneumatic signal paths, allowing data exchange and control signals to be transmitted through the same physical connection that carries pneumatic signals, thereby eliminating external wiring while maintaining reliable communication through redundant signaling paths.
3Device complexity
If a digital communication bus is used for data exchange between modules, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The digital communication bus interface is designed to perform self-alignment and self-configuration when modules are connected. The interface automatically detects the connected module type and configures the communication parameters without requiring manual setup or high-precision manual alignment, thereby reducing device complexity while maintaining acceptable manufacturing tolerances through intelligent compensation.
Data Source
Figure 1
Figure 1a
Figure 1b~5
AI summary
A pneumatic master module for pressure or flow proportional control comprises a master module valve body, a master proportional electrovalve, a relative pressure sensor for detecting the pressure of the regulated flow of pressurized air downstream the master proportional electrovalve, an electronic control unit adapted to drive the master proportional electrovalve and a slave proportional or on/off electrovalve of a respective slave module according to a pressure signal provided by the relative pressure sensor, the electronic control unit being further configured to implement a digital communication bus interface for data exchanging with other master modules. The relative pressure sensor and the electronic control unit are mounted on an electronic printed circuit board. A master male-type inlet electronic connector and a master female-type outlet connector are mounted on parallel opposite sides of the master electronic printed circuit board. [Fig. 4]