Modular Vacuum Pump Control for Stable Transfer and Air Saving
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Solution Overview
Problem
Existing vacuum control systems face limitations in efficient energy use, stable operation, and flexible sensor application due to fixed sensor configurations and lack of comprehensive compressed air management, especially in systems with multiple vacuum pumps.
Innovation Solution
A modular vacuum control unit with adjustable sensor units and electronic valves that manage compressed air supply based on pressure conditions, allowing flexible sensor configuration and efficient energy use, with integrated control for multiple vacuum pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple separate vacuum control units are used for multiple vacuum pumps, then each pump can be controlled individually, but installation and management become difficult and collective control is impossible
Solution Approach 1:
The patent combines multiple vacuum control units into a single integrated control unit that can manage multiple vacuum pumps simultaneously. The control unit includes multiple sensor units corresponding to each pump, allowing individual pressure detection while enabling centralized control and reduced installation complexity.
Solution Approach 2:
The integrated control unit is designed with multi-functional capabilities to control multiple vacuum pumps through a single device. It can detect pressure from multiple pumps, provide collective control functions, and adapt to different pump configurations, making the system universally applicable.
2Device complexity
If a fixed number of sensors are installed in the multi-sensing unit, then the structure is simplified, but variable application depending on work requirements cannot be applied
Solution Approach 1:
The control unit incorporates a dynamic sensor configuration where the number and activation of sensor units can be adjusted based on work requirements. Users can selectively activate or deactivate specific sensor units corresponding to different vacuum pumps, allowing the system to adapt to varying operational needs while maintaining a manageable structural framework.
3Reliability
If compressed air is continuously supplied to vacuum pumps, then vacuum level is maintained, but energy is wasted when vacuum level is already sufficient
Solution Approach 1:
The control unit incorporates feedback mechanisms through sensor units that continuously monitor vacuum pressure levels in each pump. Based on the detected pressure, the control unit intelligently regulates compressed air supply, reducing or stopping air supply when vacuum levels are sufficient, thereby minimizing energy waste while maintaining reliable vacuum conditions.
Solution Approach 2:
Instead of continuous compressed air supply, the system uses periodic or demand-based air supply controlled by the sensor feedback. The control unit activates air supply only when vacuum levels drop below required thresholds, creating an efficient on-demand operation pattern that reduces energy consumption while maintaining vacuum stability.
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
Enhances energy efficiency and operational stability by optimizing compressed air use and enabling adaptable sensor configurations, ensuring reliable object transfer across varying work conditions.
Implementation Method 1
one side sensor unit (17) sensing inner pressure (−kPa) of the corresponding vacuum pump (11)
Implementation Method 2
the other side terminal unit (18) connected to an electronic valve (19) that opens and closes a compressed air inlet of the vacuum pump (11)
Implementation Method 3
A vacuum transfer system refers to a system that exhausts an inner space of a suction pad by using a vacuum pump acting by compressed air to generate negative pressure therein
Data Source
AI summary
The present invention relates to a vacuum control unit that outputs an operation signal for transfer of an object depending on each internal pressure condition of a plurality of vacuum pumps in a vacuum transfer system. The control unit includes a module stack in which modules individually corresponding to each vacuum pump are assembled in a close contact manner and a control unit disposed at one side of the stack and being in signal connection with each module. Each module includes one side sensor unit configured to detect inner pressure of the vacuum pump and the other side terminal unit connected to an electronic valve configured to open and close a compressed air inlet of the vacuum pump.