Pilot-Valve Vacuum Distribution for High-Speed Sheet Feeders
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Solution Overview
Problem
High-speed sheet processing machines face challenges in maintaining production speed due to delays in gas and vacuum delivery to suction cups, leading to rapid wear of seals and diaphragms, which limits the machine's operational lifetime and efficiency.
Innovation Solution
A device for gas and/or vacuum distribution featuring a controllable pilot valve with a mobile piston that moves between open and closed positions without frictional seals, allowing precise control and reducing wear, enabling increased production speeds while maintaining a lightweight and cost-effective structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solenoid valves are used to provide alternatively vacuum and air at high speed, then production speed is improved, but seal wear increases rapidly reducing operational lifetime
Solution Approach 1:
The invention extracts the sealing function from the high-speed switching component. The solenoid valve only controls a small control line, while the main gas flow path uses a frictionless mobile element that doesn't require seals for the high-frequency switching, thereby separating the sealing requirement from the high-speed operation
Solution Approach 2:
The invention replaces the traditional mechanical seal-based valve with a frictionless mobile element system. Instead of using seals that wear out, the system uses a mobile element that opens and closes the main gas flow path without frictional contact, eliminating the wear mechanism while maintaining high-speed switching capability
2Reliability
If rotary valves are used to distribute gas and vacuum, then mechanical durability is improved, but production speed is limited due to constant gas travel delay
Solution Approach 1:
The invention implements preliminary action by controlling the solenoid valve in advance of the actual gas flow requirement. The control line is actuated beforehand to prepare the mobile element position, compensating for the gas travel time through the distribution path and ensuring vacuum or gas arrives at the suction cups at the precise moment needed for the working cycle
Solution Approach 2:
The invention segments the gas control system into a control line and a main gas flow path. The solenoid valve controls only the small-diameter control line, while the main gas flow path uses a frictionless mobile element. This segmentation allows the control system to respond quickly without being constrained by the larger main gas flow path dimensions
3Productivity
If machine speed is increased to improve productivity, then production speed is improved, but mechanical wear and seal failure risk increase
Solution Approach 1:
The invention replaces the seal-based mechanical system with a frictionless mobile element system. The mobile element opens and closes the main gas flow path without frictional contact, eliminating the wear mechanism that would otherwise accelerate with increased machine speed, thereby allowing high-speed operation without proportionally increased wear
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 extends the operational lifetime of the machine by minimizing seal wear and allowing for better control over gas and vacuum delivery, thereby increasing production speeds without the need for faster mechanical movements, resulting in a more efficient and durable system.
Implementation Method 1
a mobile piston axially movable in the housing by the action of a control gas or vacuum supplied in the second chamber through the at least one control gas opening
Implementation Method 2
a suction unit separates and transports the uppermost sheet of the stack during each working cycle of the sheet processing machine
Data Source
AI summary
The invention relates to a device for gas and/or vacuum distribution (1) for a sheet processing machine (100), the device includes: at least one controllable pilot valve (4; 40), a fixed body (5) including: at least one main gas inlet (7) to be connected to a gas or vacuum source, at least one main gas outlet (8) intended to be connected to at least one suction cup and/or to at least one nozzle, at least a first and a second control gas openings (10, 11), at least one of the openings being connected to the controllable pilot valve (4; 40), at least one housing (9) having a first chamber (9a) communicating with the main gas inlet (7) and outlet (8) and a second chamber (9b) communicating with the first and second control gas openings (10, 11), at least one mobile piston (6) axially movable in the housing (9) by the action of a control gas or vacuum supplied in the second chamber (9b) through the at least one control gas opening (10, 11) connected to the controllable pilot valve (4; 40), the mobile piston (6) being movable between: a closed position in which the mobile piston (6) blocks a gas path (16) between the main gas inlet (7) and outlet (8) in the first chamber (9a), and an open position in which the mobile piston (6) releases the gas path (16), first and second chambers (9a, 9b) isolated from each other by cooperation of shapes between the mobile piston (6) and the housing (9) without frictional seal between the mobile piston (6) and the housing (9). Also disclosed are a suction unit and a feeder including such a device for gas and/or vacuum distribution and a sheet processing machine comprising such feeder or such a device for gas and/or vacuum distribution.