Compact Nitrogen Generator with Compressor Failure Monitor

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing nitrogen generation systems for laser cutting are inefficient and costly due to large components, space requirements, and the need for expensive oil detection systems to prevent compressor failures, which can lead to significant downtime and damage.

Innovation Solution

A self-contained, plug-and-play nitrogen generation system that operates using compressed air at high psi, incorporating a compressor failure monitor to detect potential oil carryover through pressure and temperature changes, and utilizing modular high-pressure storage and a compact design to minimize footprint and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a traditional nitrogen generation system is used, then nitrogen production capability is sufficient, but the system occupies large floor space and has high installation cost

Engineering Contradiction:

Improvefloor spaceVSAvoidnitrogen production capability

Core Design Contradiction:

Area of stationary objectVSProductivity

Solution Approach 1:

The patent changes the operating pressure parameter from conventional low pressure to high pressure (4350 psi), enabling compact storage vessel design. This parameter change allows the system to achieve sufficient nitrogen production capability in a much smaller floor space, resolving the contradiction between space occupancy and productivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent transitions from horizontal floor space occupation to vertical space utilization by implementing a vertically oriented high-pressure storage vessel. This dimensional change allows the system to maintain adequate nitrogen storage capacity while minimizing the footprint on the factory floor

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If a real-time hydrocarbon detector is installed to protect against compressor failure, then system reliability is improved, but the cost increases significantly

Engineering Contradiction:

Improveprotection against compressor failureVSAvoidcost

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the expensive real-time hydrocarbon detector with a simple, low-cost pressure sensor that monitors for sudden pressure changes indicating oil influx. This substitution maintains adequate protection against compressor failure while dramatically reducing system cost and complexity

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent substitutes a complex electronic detection system (hydrocarbon detector) with a simple mechanical sensing approach (pressure monitoring). This substitution achieves the same protective function with minimal cost and complexity, resolving the contradiction between reliability and device complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Volume of stationary object

If high pressure operation (4350 psi) is used, then storage vessel size is reduced, but the system requires more robust components

Engineering Contradiction:

Improvestorage vessel sizeVSAvoidcomponent robustness

Core Design Contradiction:

Volume of stationary objectVSStrength

Solution Approach 1:

The patent changes the operating pressure parameter to high pressure (4350 psi), which dramatically reduces the storage vessel size for a given nitrogen capacity. The system compensates for the increased strength requirements by using standardized high-pressure components and conservative design factors, achieving an acceptable balance between compactness and component durability

Inventive Principle:

Principle #35Parameter changes

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 system provides a compact, cost-effective nitrogen source with reduced space requirements and lower operational costs, while effectively monitoring compressor failures to prevent damage and downtime, achieving efficient nitrogen production suitable for industrial applications like laser cutting.

Implementation Method 1

a nitrogen generator configured to receive compressed air from a compressor through the compressed air input

Methodology Applied

Scientific EffectPressure swing adsorption: Pressure Swing Adsorption

Implementation Method 2

A pressure drop and/or a temperature increase indicates a compressor failure

Methodology Applied

Scientific EffectPressure monitoring: Pressure Drop

Implementation Method 3

the compressor failure monitor monitors a pressure and/or a temperature of the compressed air upstream of the nitrogen generator

Methodology Applied

Scientific EffectTemperature monitoring: Heating

Data Source

PatentUS11872523B2Self-contained nitrogen generator

Publication Date: 2024.01.16 MSS LASERS

AI summary

An apparatus and method for nitrogen production from compressed air. The apparatus is a portable compact unit including a compressed air input, a nitrogen generator configured to receive compressed air from a compressor through the compressed air input, a nitrogen storage vessel configured to store pressurized nitrogen, and a compressor failure monitor disposed between the compressed air input and the nitrogen generator. The compressor failure monitor can be in combination with an air dryer device, wherein the compressor failure monitor is configured to monitor a change in air pressure and/or air temperature at or from the air dryer, which can indicate compressor issues.