Piston Compressor Variable Capacity Control via Electromagnetic Valve
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Solution Overview
Problem
Existing piston compressors face challenges in achieving precise and rapid adjustment of delivery rate, particularly in large compressors, due to slow actuation mechanisms and limited control over the activation of additional chambers, leading to inefficiencies in pressure regulation.
Innovation Solution
The design incorporates a self-acting ring valve with a lifting gripper actuated by an electromagnetic actuator, which automatically adjusts the overflow opening based on pressure ratios and maintains the open state through the lifting gripper, allowing rapid response to load changes within a compression cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a self-acting ring valve with lifting gripper and electromagnetic actuator is used, then the response speed and precision of delivery rate adjustment is improved, but the device complexity increases
Solution Approach 1:
The patent replaces traditional slow mechanical or pneumatic actuation systems with an electromagnetic actuator that directly controls the lifting gripper. This substitution enables rapid response (within one compression cycle) and precise control of the switching valve, achieving fast delivery rate adjustment without the delays inherent in mechanical linkages or pneumatic systems.
Solution Approach 2:
The ring valve is designed as self-acting, utilizing the pressure difference between the compression chamber and expansion chamber to automatically open and close the overflow opening. The lifting gripper assists this self-acting mechanism by holding the valve open when needed, combining automatic pressure-driven operation with selective electromagnetic control to achieve both simplicity and precision.
2Ease of operation
If pneumatic or hydraulic actuation is used to control the switching valve, then the valve can be actuated, but the adjustment speed is slow compared to compressor speed and precise control is limited
Solution Approach 1:
The patent replaces pneumatic or hydraulic actuation with an electromagnetic actuator that directly drives the lifting gripper. This substitution eliminates the compressibility effects and friction in pneumatic/hydraulic systems, enabling precise control of the valve opening timing and duration, thereby achieving accurate delivery rate control that responds within one compression cycle.
Solution Approach 2:
The switching valve is designed to open automatically when compression chamber pressure exceeds expansion chamber pressure, requiring no external actuation for opening. The electromagnetic actuator only needs to provide a holding force to keep the valve open during the expansion stroke, simplifying the control requirement and enabling precise timing control through the lifting gripper mechanism.
3Adaptability or versatility
If a variable-volume expansion chamber is used to control capacity, then the displacement volume can be adjusted, but the control activation is slow and occurs in discrete steps only
Solution Approach 1:
The patent implements dynamic capacity control by enabling the switching valve to open and close within one compression cycle, allowing real-time adjustment of the expansion chamber volume connection. This dynamic control contrasts with static or slowly-actuating variable-volume expansion chambers, providing continuous adaptability rather than discrete step changes in displacement volume.
Solution Approach 2:
The electromagnetic actuator replaces the slow mechanical or manual adjustment mechanisms of traditional variable-volume expansion chambers. This substitution enables rapid switching of the overflow opening within a single compression cycle, achieving continuous and fast capacity control rather than slow, discrete volume changes.
4Device complexity
If the switching valve opens automatically based on pressure ratio, then simple control is achieved, but the valve opening time and gas delivery amount are highly dependent on compressibility and friction effects
Solution Approach 1:
The patent introduces an electromagnetic actuator with lifting gripper to supplement the simple pressure-ratio-based automatic opening mechanism. This substitution eliminates the dependence on compressibility and friction effects by providing direct electromagnetic control of the valve holding force, enabling precise control of valve opening time and duration while maintaining the simplicity of automatic pressure-driven opening.
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
Enables precise and fast control of delivery rate adjustments, reducing throttling losses and mechanical stress, especially in large compressors, by utilizing a self-acting ring valve with an electromagnetic actuator for swift valve operation.
Implementation Method 1
an electromagnetic actuator for actuating the lifting gripper
Implementation Method 2
automatically opens and closes the overflow opening depending on a pressure ratio between a pressure in the switching chamber and a pressure in the compression chamber
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
To provide a piston compressor (1) with an additional chamber (11) connected to the compression chamber (5) via an overflow opening (12), an additional valve (13) for opening and closing the overflow opening (12), and an additional valve control unit (14) for controlling the additional valve (13), which enables precise and rapid capacity control even at large stroke volumes, the invention provides that the additional valve (13) is designed as a self-acting ring valve that automatically opens and closes the overflow opening (12) depending on a pressure ratio between a pressure in the additional chamber (11) and a pressure in the compression chamber (5), wherein the additional valve (13) opens automatically when the pressure in the additional chamber (11) is greater than the pressure in the compression chamber (5), and that a lifting gripper (15) is provided which can be actuated by an electrically controlled actuator (17).to keep the switching valve (13) in an open state regardless of the pressure ratio and to ensure that the electromagnetic actuator (17) can be actuated by the switching valve control unit (14).