Pilot Relay Diaphragm Durability via Non-Adjacent Chamber Design
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Solution Overview
Problem
The existing pilot relay designs suffer from high hysteresis in input/output characteristics due to adjacent positioning of air pressure chambers, leading to diaphragm durability issues and poor manufacturability, with increased complexity and cost due to numerous chambers and diaphragms.
Innovation Solution
A pilot relay design with a non-adjacent input air pressure chamber configuration, utilizing a divided spool structure with separate discharge air ducts and reduced diaphragm placement to prevent violent pressure changes and facilitate easier assembly, featuring a housing with an input air pressure chamber, supply air pressure chambers, output air pressure chambers, discharge air chambers, and a bias chamber, with diaphragms interposed between these to enhance durability and manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If air pressure chambers are positioned adjacent to each other, then the device size is reduced, but hysteresis in input/output characteristics increases and diaphragm durability deteriorates
Solution Approach 1:
A partition wall is introduced as an intermediary structure between adjacent air pressure chambers. This partition wall includes a through-hole that controls pressure transmission between chambers, acting as a mediator that prevents violent pressure changes while maintaining compact chamber arrangement. The partition wall thus enables close positioning of chambers without directly exposing diaphragms to extreme pressure differentials.
Solution Approach 2:
The partition wall structure provides different local qualities: it is solid in most areas to separate chambers, but includes a specific through-hole region to allow controlled pressure communication. This localized differentiation enables the wall to simultaneously provide structural separation and pressure regulation functions, resolving the contradiction between compact arrangement and diaphragm protection.
2Adaptability or versatility
If multiple air pressure chambers and diaphragms are used, then the pilot relay functionality is improved, but the number of components and manufacturing complexity increase
Solution Approach 1:
Multiple air pressure chambers are merged into a single housing structure with shared walls and common mounting surfaces. The partition walls serve dual purposes as both chamber separators and mounting surfaces for diaphragms. This merging reduces the number of separate components while maintaining the required multi-chamber functionality for pilot relay operation.
Solution Approach 2:
The partition walls are designed to serve multiple functions simultaneously: separating adjacent air pressure chambers, providing mounting surfaces for diaphragms, and incorporating through-holes for pressure communication. This multi-functionality reduces the overall component count while maintaining the complex pilot relay functionality requiring multiple sealed chambers.
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 design improves diaphragm durability by eliminating violent pressure changes and simplifies assembly, reducing the number of chambers and components, resulting in a more reliable and cost-effective pilot relay with enhanced manufacturability and miniaturization potential.
Implementation Method 1
a diaphragm (409) that is displaced by input air pressure (Pn) directed into an input air pressure chamber (402)
Implementation Method 2
a first spring member (423) for biasing the first poppet valve (413) in a direction in which a first supply air valve (413b) closes a first connecting hole (411a)
Implementation Method 3
a second spring member (424) for biasing the second poppet valve (414) in a direction in which a second supply air valve (414b) closes a second connecting hole (412a)
Data Source
AI summary
A spool is provided with a first discharge air duct connecting the first opening to the first discharge air chamber, and a second discharge air duct connecting the second opening to the second discharge air chamber, where the first discharge air duct and the second discharge air duct are divided by a non-duct part. A first output air pressure chamber is adjacent to a first discharge air chamber with a first diaphragm interposed therebetween, the first discharge air chamber is adjacent to a bias chamber with a second diaphragm interposed therebetween, the bias chamber is adjacent to an input air pressure chamber with a third diaphragm interposed therebetween, the input air pressure chamber is adjacent to a second discharge air chamber with a fourth diaphragm interposed therebetween, and the second discharge air chamber is adjacent to a second output air pressure chamber with a fifth diaphragm interposed therebetween.