Pneumatic Waste Compressor Partial Control System
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Solution Overview
Problem
Existing pneumatic waste compressors consume excessive energy as the piston often reaches its bottom position before the resistance from compressed waste can counteract the 8-bar pressure, leading to inefficient compression cycles and high energy usage.
Innovation Solution
A partial control system that stops air supply to the compressor when the piston is in its bottom position, using a non-return valve and a closing valve activated by the piston's position to limit pressure to a maximum of 8 bars, reducing energy consumption and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the compressor maintains constant pressure of 8 bars throughout the compression cycle, then the waste is adequately compressed, but the energy consumption increases significantly when the piston reaches bottom position before full compression is needed
Solution Approach 1:
The patent applies dynamics by making the air supply control adaptive rather than static. The closing valve dynamically adjusts the air supply based on real-time piston position and waste compression state, transitioning from a constant pressure system to a variable pressure system that optimizes energy consumption while maintaining compression effectiveness.
Solution Approach 2:
The patent implements feedback control through the closing valve that responds to piston position signals. When the piston approaches bottom position, the system receives feedback and automatically closes the air supply, creating a closed-loop control system that prevents energy waste while ensuring adequate compression.
2Object-affected harmful factors
If the compressor operates continuously to maintain 8 bar pressure, then compression is ensured, but the noise level and energy consumption increase unnecessarily
Solution Approach 1:
The patent applies periodic action by interrupting the air supply in a controlled manner. Instead of continuous operation, the compressor delivers air in periodic bursts that correspond to the actual compression needs, reducing noise during idle periods while maintaining productivity through efficient timed delivery cycles.
Solution Approach 2:
The patent implements skipping by rapidly closing the air supply valve when the piston approaches bottom position, effectively skipping the unnecessary continued compression phase. This allows the system to rush through the essential compression phase quickly and transition to the return phase, reducing overall cycle time and noise.
3Reliability
If a high-capacity compressor is used to ensure adequate compression, then compression effectiveness is maintained, but the device complexity and maintenance costs increase
Solution Approach 1:
The patent applies partial action by delivering air supply only during the necessary compression phase rather than continuously at full capacity. The closing valve restricts air supply to the precise moment when compression is needed, allowing a lower-capacity compressor to achieve the same effectiveness as a higher-capacity continuous compressor would provide.
Solution Approach 2:
The patent implements parameter changes by varying the air supply pressure and flow rate based on piston position. The system transitions from a fixed high-capacity operation to a variable parameter operation, adjusting air supply characteristics to match the instantaneous compression requirements, thereby reducing the needed compressor capacity.
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
This solution reduces energy consumption, allows for faster operation with a lower-capacity compressor, decreases maintenance costs, and extends the compressor's lifespan while minimizing noise.
Implementation Method 1
a non-return valve (17) which closes for compressed air to the cylinder (1)
Implementation Method 2
a closing valve (18) whose admission side is coupled to the pipe (11) in front of the non-return valve (17) by means of a pipe (19), and whose discharge side is coupled to the pipe (11) after the non-return valve (17) at the pipe (20)
Implementation Method 3
The compressor cylinder (1) can be activated in the direction from the top of the cylinder to the bottom by compressed air
Implementation Method 4
activated in the direction from the top of the cylinder to the bottom by compressed air and in the opposite direction by springs
Data Source
Figure 1
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Figure 3
AI summary
In a pneumatic compressor for the compression of waste, for example waste paper comprising a cylinder (1) with a piston (2), which via a piston rod (4) activates a compression plate (3), which is slidably mounted in a compression chamber (5) which has a top door (6) through which waste paper is thrown into the compressor, and a bottom door (7) through which a finished bale can be taken out, which compression takes place in a series of compression cycles, which each time is charged with a new portion of waste, until the waste can offer a counter pressure corresponding to the pressure which the piston (2) can exert at a pressure of 8 bars. In 80 - 90% of the compression cycles necessary for the compression of a bale, the piston (2) reaches its bottom position in the cylinder, and each time the pressure reaches a pressure of 8 bars in the cylinder (1). According to the invention a partial control system is incorporated a control system which comprises a closing valve (18), which closed for admission of compressed air to the cylinder (1), when the piston reaches it bottom position. Consequently, the pressure developed in the cylinder (1) will in 80-90% of the compression cycles be reduced considerably. There will thus be a corresponding reduction of the energy consumption and the noise level.