Pilot Relay Fine Duct for Fast Pressure Settling
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Solution Overview
Problem
Conventional pilot relays face challenges in quickly settling output air pressure without increasing the bleed rate, leading to increased steady-state air consumption and larger pilot relay sizes.
Innovation Solution
The pilot relay design incorporates a poppet valve assembly with a fine connecting duct that connects to either a space containing a spring member connected to atmosphere or a discharge air chamber, reducing the force applied by supply air pressure and minimizing pressure reduction, thereby reducing the dead band and increasing the speed of output air pressure settling without increasing the bleed rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the bleed rate is increased to quickly settle output air pressure, then the settling speed is improved, but the steady-state air consumption increases
Solution Approach 1:
The patent segments the air discharge function into two distinct paths: a fine connecting duct for rapid pressure equalization during transient settling, and a main discharge air chamber for steady-state pressure control. This segmentation allows the system to achieve fast settling without requiring a continuously high bleed rate, as the fine duct provides quick relief while the main chamber maintains stable operation.
Solution Approach 2:
The patent introduces an intermediary fine connecting duct that mediates between the output air pressure chamber and the discharge air chamber. This intermediary pathway enables rapid pressure equalization during transient conditions without requiring the main discharge path to operate at high flow rates continuously, thereby reducing steady-state air consumption while maintaining fast settling capability.
2Loss of substance
If the pilot relay size is increased to reduce steady-state air consumption, then air consumption is reduced, but the device size increases
Solution Approach 1:
The patent segments the discharge function into two spatially distinct chambers: a compact fine connecting duct integrated into the poppet valve assembly for rapid pressure response, and a separate discharge air chamber for steady-state pressure management. This segmentation allows each component to be optimized independently, reducing the overall device volume while maintaining low steady-state air consumption.
Solution Approach 2:
The patent implements a nested structure where the fine connecting duct is integrated within the poppet valve assembly, which itself is housed within the larger pilot relay body. The discharge air chamber is positioned to receive exhaust from both the fine duct and main valve. This nesting arrangement minimizes the overall device volume by efficiently utilizing internal space while maintaining the dual-function discharge system.
3Speed
If the force applied by supply air pressure is reduced, then the dead band is reduced and settling speed is improved, but the pressure control stability may be affected
Solution Approach 1:
The patent segments the pressure control function into two distinct modes handled by different pathways: the fine connecting duct handles transient pressure equalization with minimal force application, while the main discharge air chamber handles steady-state pressure stabilization. This segmentation allows the system to achieve fast settling during transitions without compromising stability during normal operation.
Solution Approach 2:
The patent ensures continuous pressure control by maintaining the discharge air chamber as an active stabilization mechanism throughout operation. While the fine connecting duct provides intermittent rapid equalization during settling, the discharge air chamber continuously maintains stable pressure conditions, ensuring that reducing the supply air pressure force during settling does not compromise overall pressure control stability.
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 allows for faster settling of output air pressure while maintaining a reduced bleed rate, which in turn decreases the steady-state air consumption rate, and can be applied to both single-action and double-action pilot relays.
Implementation Method 1
a spring member for biasing the poppet valve in the direction wherein the supply air valve closes the connecting hole
Implementation Method 2
a fine connecting duct for connecting the connecting duct to the output air pressure chamber... reducing the force applied by supply air pressure and minimizing pressure reduction
Data Source
AI summary
A poppet valve assembly is structured divided into a seat portion and a seat retaining portion. A spring is contained within an interior space between the seat portion and the seat retaining portion, where a poppet valve is held between the seat portion and the seat retaining portion in a state biased by the spring. The poppet valve is provided with a through hole for connecting a chamber that contains the spring and a discharge air duct of a spool, and a fine connecting duct for connecting the through hole and an output air pressure chamber. The chamber that contains the spring is separated from a supply air pressure chamber by an O-ring.