Pilot Check Valve Flow Controller for Low-Cost Air Cylinder Exhaust
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Solution Overview
Problem
Conventional flow rate controllers for air cylinders are complex, requiring numerous components and costly production steps, particularly due to the need for precision parts like spools that necessitate grinding or polishing, making them difficult to manufacture at a low cost.
Innovation Solution
A simplified flow rate controller design featuring a housing with a first and second flow path, throttle valves, and a pilot check valve that switches based on pilot air pressure to control exhaust air passage, eliminating the need for complex switching valves and precision components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional flow rate controller uses a three-way valve for switching exhaust air flow, then the flow control function is achieved, but the device complexity increases and manufacturing cost rises due to precision components like spools requiring grinding or polishing
Solution Approach 1:
The patent extracts the complex three-way valve from the system and replaces it with simpler components: a two-way valve and a check valve. This separation of functions eliminates the need for precision spools requiring grinding or polishing, directly reducing manufacturing cost and complexity while maintaining the exhaust air flow control capability
Solution Approach 2:
The patent segments the flow switching function into two separate valves: a two-way valve for primary flow control and a check valve for directional control. This segmentation allows each valve to be simpler in design and easier to manufacture compared to a single complex three-way valve, resolving the contradiction between ease of manufacture and device complexity
2Manufacturing precision
If a conventional flow rate controller uses multiple component parts for throttling exhaust air, then the flow control precision is improved, but the ease of manufacture deteriorates due to numerous production steps required
Solution Approach 1:
The patent employs standard, off-the-shelf valve components (two-way valve and check valve) that can be readily purchased and assembled, rather than custom-machined precision parts. This approach maintains adequate flow control precision while dramatically improving ease of manufacture by eliminating numerous production steps
Solution Approach 2:
The patent merges the flow control and directional switching functions into a coordinated system of two simple valves working together, rather than using a single complex precision valve. This combination achieves the required control precision through functional integration while maintaining ease of manufacture through component simplicity
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 simplified configuration reduces manufacturing costs and complexity, allowing for easier production and efficient operation of air cylinders by controlling exhaust air flow without requiring intricate components.
Implementation Method 1
depending on a pressure of the pilot air, the pilot check valve switches between a state allowing passage of exhaust air discharged from the air cylinder, and a state preventing the passage of the exhaust air
Implementation Method 2
a first throttle valve disposed in the first flow path, a second throttle valve disposed in the second flow path, and a third throttle valve disposed in the pilot air flow path
Data Source
AI summary
In a flow rate controller and a drive device, a housing is provided therein with a first flow passage, a second flow passage adjacent to the first flow passage, a first throttle valve provided to the first flow passage, and a second throttle valve provided to the second flow passage. A pilot check valve is provided to the second flow passage and is connected in series to the second throttle valve. A pilot air flow passage communicates with a pilot port of the pilot check valve for supplying and discharging pilot air, and a third throttle valve is provided to the pilot air flow passage. In response to the pressure of the pilot air, the pilot check valve switches between a state in which the passage of exhaust air discharged from an air cylinder is permitted and a state in which passage of the exhaust air is prevented.