Pneumatic Inflator Automatic Pressure Control

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Solution Overview

Problem

The existing dunnage bag inflation process is inefficient and hazardous, requiring operators to manually depress a compressor hose trigger for extended periods, leading to reduced productivity and increased risk of cargo shifting and bag rupture due to the need for constant monitoring of pressure.

Innovation Solution

A pneumatic inflator that automatically inflates inflatable articles, such as dunnage bags, to a desired pressure, allowing the operator to select the pressure and enabling automatic shut-off, thus reducing manual labor and risk of injury.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual trigger operation is used for inflation, then the operator can control the inflation process, but productivity is reduced due to the need for constant manual intervention

Engineering Contradiction:

Improvemanual controlVSAvoidinflation speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system uses a pressure sensor to automatically detect when the dunnage bag has reached the desired pressure and triggers the compressor to stop inflation automatically, eliminating the need for continuous manual monitoring and trigger operation by the operator

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The pressure sensor provides real-time feedback on the internal pressure of the dunnage bag to the control system, which automatically adjusts the inflation process and stops when the target pressure is reached, creating a closed-loop control system that improves both productivity and precision

Inventive Principle:

Principle #23Feedback

2Measurement precision

If the operator stands near the dunnage bag to monitor inflation, then pressure control is possible, but safety is compromised due to risk of cargo shifting

Engineering Contradiction:

Improvepressure monitoringVSAvoidcargo shifting risk

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The system replaces the mechanical approach of visual monitoring by the operator with a pressure sensor-based detection system that automatically measures internal pressure and sends signals to the control unit, eliminating the need for the operator to be physically present near the dunnage bag during inflation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The pressure sensor acts as an intermediary between the dunnage bag and the control system, allowing remote monitoring and control of the inflation process without requiring direct physical proximity, thus protecting the operator from potential cargo shifting hazards

Inventive Principle:

Principle #24Intermediary (Mediator)

3Speed

If continuous air flow is used for inflation, then speed is increased, but the risk of overinflation and bag rupture increases

Engineering Contradiction:

Improveinflation rateVSAvoidbag integrity

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The pressure sensor continuously monitors the internal pressure of the dunnage bag and provides feedback to the control unit, which automatically stops the air flow when the desired pressure is reached, preventing overinflation and maintaining bag integrity while allowing rapid inflation

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system uses periodic pressure checking and automatic trigger actuation to control the inflation process, allowing high-speed inflation through repeated short bursts of air flow rather than continuous flow, which maintains bag integrity while achieving fast inflation

Inventive Principle:

Principle #19Periodic action

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 pneumatic inflator increases productivity by allowing operators to perform other tasks during inflation and reduces the risk of cargo shifting and bag rupture by ensuring precise pressure control without constant manual intervention.

Implementation Method 1

A pressure sensor configured to detect when an internal air pressure of the inflatable article has reached a desired air pressure and send a signal to the control unit

Methodology Applied

Scientific EffectPressure sensing:

Implementation Method 2

The control unit is actuated to actuate the control valve to stop the air flow from the compressed air source into the inflation hose when the pressure sensor sends the signal

Methodology Applied

Scientific EffectPneumatic control:

Data Source

PatentUS10618450B2Pneumatic inflator for automatically inflating inflatable articles to a desired pressure

Publication Date: 2020.04.14 SIGNODE IND GROUP LLC

AI summary

Various embodiments of the present disclosure provide a pneumatic inflator for automatically inflating inflatable articles, such as dunnage bags, to a desired pressure. Generally, once activated, the pneumatic inflator of the present disclosure inflates an inflatable article via a compressed air source until the air pressure inside the inflatable article reaches an operator-selected desired pressure. Thereafter, the pneumatic inflator automatically stops inflating the inflatable article. In various embodiments, the pneumatic inflator also includes a manual shut-off that, when activated while the pneumatic inflator is inflating the inflatable article, causes the pneumatic inflator to stop inflating the inflatable article. The pneumatic inflator of the present disclosure thus enables automatic inflation of inflatable articles to particular, operated-selected desired pressures with limited operator input.