Integrated Pilot Valve Layout for Intermittent Air Supply
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Solution Overview
Problem
Conventional intermittent air generating devices have complex circuit configurations due to the presence of two pilot valves, leading to increased production costs and part count.
Innovation Solution
A switching unit is integrated downstream of the supply source, combining the functions of the pilot valve and on-off valve into a single component, simplifying the circuit configuration and reducing the number of parts and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a pilot type control valve and a pilot type on-off valve are used in the intermittent air generating device, then the compressed air can be intermittently supplied to the air nozzle, but the circuit configuration becomes complex and the number of parts increases
Solution Approach 1:
The patent combines the pilot type control valve and the pilot type on-off valve into a single integrated valve unit. The control valve portion includes a valve body with a control chamber that receives pilot pressure, while the on-off valve portion includes a valve element that opens/closes the air supply passage. This merging eliminates the need for separate pilot valves and complex interconnections, directly resolving the technical contradiction by maintaining intermittent air supply functionality while simplifying the circuit configuration and reducing part count
2Productivity
If a pilot type control valve and a pilot type on-off valve are used in the intermittent air generating device, then the compressed air can be intermittently supplied to the air nozzle, but the production cost increases
Solution Approach 1:
The integrated valve unit combines multiple valve functions into a single manufacturable component. The valve body houses both the control chamber with pilot pressure inlet and the air supply passage with valve element. This consolidation reduces the number of separate parts that need to be manufactured, assembled, and inventoried, directly lowering production costs while maintaining the intermittent air supply capability
3Device complexity
If compressed air is supplied directly to the air device without separate pilot air supply, then the device complexity is reduced, but pressure drop may affect operation stability
Solution Approach 1:
The patent uses pilot air as an intermediary substance to control the valve element movement. The pilot air supply is connected to the control chamber, and when pilot air is supplied, it creates pressure that moves the valve element to open the air supply passage. This intermediary control mechanism ensures stable operation by decoupling the control function from the main compressed air flow, preventing pressure drop issues while maintaining simple integrated structure
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 integrated switching unit enables stable intermittent operation without pressure drop issues, while simplifying the circuit and reducing costs compared to conventional devices.
Implementation Method 1
a valve element disposed so as to be movable along the interior of the body, and the valve element is moved inside the body by the pilot air supplied to the third port
Data Source
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AI summary
A control valve (14) configuring an intermittent air-generating device (10) is made from a five-port valve, the inlet port (24) of which is connected to a fluid supply source (12) and the outlet port (26) is connected to an air-spraying device (18). As a result of pilot air being supplied to a pilot input port (32), a valve element (46) moves and as a result of the inlet port (24) and the outlet port (26) being put in an ON state in which the two are in communication with each other, compressed air is sprayed from the air-spraying device (18). Meanwhile, as a result of the pilot air being discharged from the pilot input port (32) by way of a discharge port (62), the valve element (46) moves in the opposite direction and the inlet port (24) and the outlet port (26) are put in an OFF state in which the state of communication between the two is blocked. Said ON state and OFF state alternate intermittently.