Proportional Solenoid Inlet Control for Stable Compressor Pressure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air compressor systems, particularly oil-injected rotary screw compressors, face efficiency limitations due to deadband and cycling frequency issues in load/unload and mechanical modulation inlet control strategies.
Innovation Solution
A system utilizing a proportional solenoid valve to control the flow of air into the compressor, with a controller generating electronic control signals responsive to sensed air pressure, allowing for precise modulation of the compressor inlet valve to maintain target pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If load/unload inlet control methods using two-position solenoid valves are used, then the compressor can be controlled to operate in discrete load and unload states, but a deadband of approximately 30 psi exists between cut-in and cut-out pressure settings, causing inefficiency and increased cycling frequency
Solution Approach 1:
The patent applies dynamics by transitioning from a static two-position solenoid valve system to a dynamic proportional solenoid valve system that can modulate the inlet valve position continuously. The proportional solenoid valve responds proportionally to the control signal, enabling smooth transitions between fully open and fully closed states, thereby eliminating the deadband and reducing cycling frequency while maintaining ease of operation through electronic control.
Solution Approach 2:
The patent changes the control parameter from discrete on/off signals to proportional electronic control signals that vary the solenoid valve position continuously. This parameter change allows the inlet control pressure to be modulated smoothly, eliminating the 30 psi deadband and enabling the compressor to operate efficiently across a continuous range of pressures rather than cycling between discrete states.
2Productivity
If mechanical modulation techniques are used for inlet control, then continuous modulation of compressor inlet capacity is achieved, but the system complexity increases with additional components such as regulator valves and multiple pressure settings mechanisms
Solution Approach 1:
The patent replaces the mechanical modulation system with an electronic control system. Instead of using mechanical regulator valves, springs, and multiple pressure setting mechanisms, the invention uses an electronic controller that sends proportional signals to a proportional solenoid valve. This substitution maintains continuous modulation capability while significantly reducing mechanical complexity and the number of moving parts.
Solution Approach 2:
The proportional solenoid valve serves multiple functions: it provides continuous modulation of inlet capacity, eliminates the need for separate regulator valves and pressure setting mechanisms, and enables both proportional control and binary on/off operation through electronic signaling. This multi-functionality reduces overall system complexity while maintaining productivity.
3Stability of the object's composition
If external air storage is used to reduce deadband and cycling frequency, then pressure can be maintained more smoothly, but the system requires additional components and increased space for air tanks
Solution Approach 1:
The patent replaces the mechanical air storage solution (external air tanks) with an electronic control system. The proportional solenoid valve, controlled by electronic signals from the controller, actively manages pressure stability by modulating the inlet valve position in response to pressure changes, eliminating the need for large external air storage components while maintaining pressure stability.
4Loss of energy
If a proportional solenoid valve with electronic control is used, then deadband is reduced and power consumption is minimized, but the device complexity increases with electronic components and sensors
Solution Approach 1:
The patent implements feedback by using a pressure sensor to continuously monitor the system pressure and feed this information back to the electronic controller. The controller compares the sensed pressure with the desired setpoint and adjusts the proportional solenoid valve position accordingly. This closed-loop feedback system minimizes power consumption by keeping the compressor running smoothly at partial load rather than cycling on and off, and it reduces deadband by providing continuous pressure regulation.
Solution Approach 2:
The electronic control system with proportional solenoid valve and pressure sensor creates a self-regulating system that automatically maintains optimal pressure without external intervention. The system monitors its own performance through the pressure sensor and adjusts the inlet valve position autonomously, eliminating the need for external air storage or manual pressure adjustment mechanisms.
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 deadband, minimizes power consumption, and simplifies the process of setting target pressures, leading to more efficient and responsive air compressor operation.
Implementation Method 1
A system utilizing a proportional solenoid valve to control the flow of air into the compressor
Implementation Method 2
with a controller generating electronic control signals proportionally responsive to sensed air pressure
Data Source
AI summary
A system and method for controlling flow of air into an air compressor of an air compressor system includes a proportional solenoid valve configured to control flow of supply air into the air compressor in proportional response to sensed air pressure generated by the air compressor system.