Pilot-Controlled Pressure Regulator for Airjet Weaving
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Solution Overview
Problem
Airjet weaving machines face challenges in maintaining consistent output pressure for weft thread insertion due to variations in feed pressure, which can lead to unreliable weft thread placement and efficiency issues.
Innovation Solution
A pilot-controlled pressure regulator with a diaphragm actuator loaded by pilot pressure and an enlarging device, allowing output pressure regulation independent of airflow and feed pressure variations, ensuring consistent output pressure through a motor-controlled second pressure regulator and open-loop control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pressure regulator is used to maintain output pressure, then the system responds to pressure changes, but the output pressure varies with feed pressure fluctuations and airflow changes
Solution Approach 1:
The patent introduces a pilot pressure regulator as an intermediary device that controls the main pressure regulator valve. The pilot regulator operates at a lower pressure level and uses a force amplification mechanism (lever or bellows) to control the main valve, thereby isolating the main regulation system from direct feed pressure variations and achieving more stable output pressure control.
Solution Approach 2:
The patent changes the operating parameter of the pressure regulation system by using a two-stage approach: the pilot regulator sets a reference pressure, and the main regulator uses this reference to control the output. This parameter transformation allows the system to maintain consistent output pressure regardless of feed pressure fluctuations, as the main valve is controlled by the pilot pressure rather than directly by feed pressure variations.
2Volume of moving object
If the pressure regulator is made compact, then the device size is reduced, but the force required to control high output pressure becomes insufficient
Solution Approach 1:
The pilot pressure regulator acts as a force amplifier by using a lever mechanism or bellows that converts small pilot pressure forces into large forces capable of controlling the main high-pressure valve. This intermediary force amplification allows a compact actuator to control high output pressures that would otherwise require much larger and more complex actuators.
Solution Approach 2:
The patent transitions from direct high-pressure force control to indirect low-pressure pilot control, effectively changing the dimensional scale of the controlling pressure. By using a pilot pressure dimension (lower pressure) to control the main dimension (higher pressure), the system achieves force amplification without increasing actuator size, as the pilot pressure operates in a different pressure dimension that requires smaller forces.
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 solution provides a compact, efficient pressure regulation system that maintains consistent output pressure, independent of airflow and feed pressure fluctuations, enabling reliable weft thread insertion and adaptable to varying weaving conditions.
Implementation Method 1
a pilot controlled pressure regulator having an actuator and a valve element arranged for reciprocal movement by the actuator, wherein the actuator is loaded by a load of a pilot pressure
Implementation Method 2
a force enlarging device for enlarging the load exerted by the set pilot pressure on the actuator and for regulating the output pressure to values higher than the values of the set pilot pressure
Data Source
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AI summary
Air supply system having a pilot controlled pressure regulator (2) with an actuator (19) and a valve element (18) wherein the actuator (19) is loaded by a load of a pilot pressure exerted against the load of an output pressure and wherein a setting device (67) for setting the pilot pressure and a force enlarging device (45) for enlarging the load are provided. Air supply system wherein a pilot controlled pressure regulator (2) is provided.