Pneumatic Condensate Pump with Pilot Valve Mechanism
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Solution Overview
Problem
Existing devices for transporting condensate using steam or compressed air face high production costs and rapid wear due to spring-assisted float mechanisms, which are size-dependent and require frequent replacement, limiting their operational cycle and efficiency.
Innovation Solution
A pilot switching mechanism with a universal design for all device sizes, featuring a chamber with a pilot valve, bellows, supporting valve, and lever system, which synchronizes valve operations based on condensate levels within the vessel, eliminating the need for individual mechanisms and reducing wear and tear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a spring assisted float mechanism is used to automate valve operation, then the liquid transportation process becomes automatic, but the mechanism experiences rapid wear and short exploitation cycle
Solution Approach 1:
The patent replaces the spring-assisted mechanical float mechanism with a pneumatic control system. A pilot valve regulated by float position controls main inlet and outlet valves through pneumatic pressure, eliminating the spring mechanism that caused rapid wear and short exploitation cycle while maintaining automation.
Solution Approach 2:
The patent introduces a pilot valve as an intermediary element between the float position indicator and the main valves. The pilot valve uses pneumatic pressure as a mediator to transmit the switching signal from the float position to the main valves, avoiding direct mechanical contact and wear.
2Reliability
If a large size float is used to prevent steam condensation, then device malfunction is avoided, but production price increases
Solution Approach 1:
The patent divides the float into two separate functional parts: a small pilot float that triggers valve switching at specific liquid levels, and a separate pneumatic system that prevents steam condensation. This segmentation allows the pilot float to be small and inexpensive while the pneumatic system handles the condensation prevention function.
Solution Approach 2:
The patent introduces pneumatic pressure as an intermediary to prevent steam condensation without requiring a large float. The pneumatic system actively manages the vapor phase, allowing a small pilot float to suffice for control purposes, thereby reducing production costs while maintaining reliability.
3Ease of operation
If individual switching mechanisms are designed for every device size, then operation is optimized, but production cost increases
Solution Approach 1:
The patent designs a universal pilot valve mechanism that can be used across different device sizes. The pneumatic control system and pilot valve architecture remain the same regardless of scale, allowing standardized manufacturing while maintaining optimized operation through proper sizing of associated components like main valves and vessels.
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 pilot mechanism ensures smooth and automatic operation, prolongs the device's operational cycle, reduces production costs, and minimizes wear, while maintaining a wide range of discharge rates by allowing for easy adjustments in valve sizes.
Implementation Method 1
When the pilot valve opens, steam enters the bellows, which expands, and through the lever actuates the main inlet valve to open position and the main outlet valve to closed position
Implementation Method 2
The float is hinged at its bottom and rises when the level of condensate in the vessel increases and falls when the level of condensate decreases
Implementation Method 3
transportation of condense by steam
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a device for transportation of condense by steam. According to the invention inside the vessel (1) a pilot mechanism (2) with two volume float (3) is installed. The upper volume (4) of the float ensures positive buoyancy. The change of the level of the condense inside the vessel moves the float in vertical direction that switches the pilot mechanism to allow or stop the steam income. The pilot mechanism provides or stops providing steam income to the main valves' mechanism (5), that simultaneously opens the main inlet valve and closes the main outlet valve for discharging, or closes the main inlet valve (6) and opens the main outlet valve (7) for filling, depending on the position of the float. The vessel is fed with condense through inlet check valve (8). Condense is discharged through outlet check valve (9). The proposed device ensures smooth and automatic transport of condense.