Modular Valve Assembly Energy Saving Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing module arrangements lack an efficient method to transition from an operating state to an energetically optimized state, particularly in reducing energy consumption and ensuring safety during faults.
Innovation Solution
The implementation of an energy-saving signal pattern and error signal pattern in a control device to manage pressure control means, allowing for reduction or shutdown of pressurization in valve module groups, and specific control of modules to achieve energy-saving or safety states, with the ability to differentiate between energy-saving and safety states based on priority.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the module arrangement operates in normal operating state with full pressurization, then all valve modules and connected components can function properly, but energy consumption is high
Solution Approach 1:
The system dynamically adjusts the pressurization state of valve module groups based on operational requirements. During idle periods or when certain valve groups are not needed, the pressurization is reduced or shut off completely, while maintaining full pressure in actively used groups. This dynamic state adjustment resolves the contradiction between maintaining functional reliability and reducing energy consumption.
Solution Approach 2:
The valve module arrangement is divided into multiple independently controllable valve module groups, each with its own pressure control means. This segmentation allows selective pressurization of only those groups currently in use, rather than pressurizing the entire system. Groups that are idle can be depressurized to save energy while maintaining pressure in active groups, thus resolving the energy consumption versus reliability contradiction.
2Object-affected harmful factors
If the system implements rapid shutdown for safety state, then hazard minimization is achieved, but energy consumption increases due to pressurization maintenance
Solution Approach 1:
The system pre-positions valve modules into safe states using stored energy (compressed air in accumulators) before a fault occurs. When a safety event is detected, the pre-positioned valves can rapidly shut off pressurization to affected groups without requiring additional energy input during the critical shutdown moment. This preliminary preparation resolves the contradiction between rapid hazard minimization and energy consumption during emergency shutdown.
3Adaptability or versatility
If all valve module groups are pressurized simultaneously, then system-wide functionality is ensured, but energy waste occurs in idle groups
Solution Approach 1:
The system segments the valve modules into multiple independently controllable groups with separate pressure control means. This allows the control device to selectively pressurize only those groups currently required for operation, while leaving other groups unpressurized. The segmentation enables the system to maintain adaptability for different operational configurations while eliminating energy waste in idle groups.
Solution Approach 2:
Different pressure states are applied to different spatial zones (valve module groups) based on their local operational requirements. Active groups receive full pressurization while idle groups remain unpressurized or at reduced pressure. This local differentiation of quality (pressure level) resolves the contradiction between maintaining system-wide adaptability and reducing energy loss in non-operational areas.
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 approach reduces energy consumption by lowering pressurization and enables quick safe shutdowns, minimizing hazards and maintaining advantageous functionality of the module arrangement.
Implementation Method 1
at least one valve module group is assigned a pressure control means which can be switched between a first and at least a second pressure level depending on a control signal from the control device in order to influence pressurization of the assigned valve module group
Data Source
Figure 1
AI summary
The arrangement (1) has modules (2) e.g. valve modules (3), joined together along a row direction (6). A control device (5) is communicated with a machine control (7) via a bus system (8) and provides control signals to the modules. The valve modules are combined in valve module groups (9-11). Pressure control units (23, 24) are switched between pressure levels based on the signals for influencing pressure application of the associated groups. An energy saving signal pattern to switch the control units from an operating position into an energy saving position is stored in the control device. An independent claim is also included for a method for operating a modular arrangement.