Compressed Air Throttle Valve Reference Position Control
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Solution Overview
Problem
The existing compressed air throttle apparatuses in powder spraycoating equipment face challenges in achieving precise control over airflow due to manufacturing tolerances and difficulties in attaining a completely closed position, leading to inaccuracies in fine adjustments of compressed air flow.
Innovation Solution
The apparatus incorporates a controlled electric motor with a valve and a system of contacting elements that allow for precise adjustment of the throttle valve, ensuring reproducible and measurable airflow by defining a reference position for complete closure and incremental opening, using a displaceable valve needle and a non-circular passage to prevent rotation, and a resilient bar for secure alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the valve element is adjusted to complete closure position, then the reference position for airflow control is established, but manufacturing tolerances and motor shaft angular position errors prevent accurate attainment of this position
Solution Approach 1:
The patent establishes a preliminary reference position (complete closure) that serves as the starting point for all subsequent airflow measurements. The control system performs preliminary steps from this reference position to reach desired airflow settings, ensuring that all measurements are relative to a known baseline rather than attempting to directly position the valve at absolute closure each time.
Solution Approach 2:
The patent employs feedback mechanisms where the control system monitors the actual airflow and compares it with the desired airflow. Based on this feedback, the system automatically adjusts the valve position to compensate for manufacturing tolerances and motor positioning errors, ensuring accurate airflow control without requiring perfect mechanical precision.
2Length of moving object
If a high thread pitch is used to allow sufficient overlap between stops, then the axial displacement per motor step increases, but fine adjustment capability is lost
Solution Approach 1:
The patent divides the airflow control range into multiple segments or steps. Instead of relying on a single high-pitch thread that provides large discrete jumps, the system uses multiple smaller steps with a lower thread pitch, allowing for finer incremental adjustments while still achieving the full range of motion through cumulative steps.
3Reliability
If the valve is positioned at complete closure, then a reference position is defined, but it is exceedingly difficult to achieve and maintain this position due to tolerances and motor positioning errors
Solution Approach 1:
The system performs a preliminary operation to establish the reference position automatically. The control system commands the motor to move to the complete closure position, detects when the stops contact each other, and then back-offs by a predetermined number of steps to establish the reference position. This preliminary setup is done once and stored, eliminating the need to repeatedly achieve this difficult position.
Solution Approach 2:
The system uses its own motor and control mechanisms to automatically establish and maintain the reference position without requiring external intervention or precise manual positioning. The motor-driven valve system self-calibrates by using its built-in stops and control algorithms to define the reference point.
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 enables accurate and fine-tuned control of compressed air flow, ensuring better coating quality and efficiency in powder spraycoating equipment by allowing precise adjustments and minimizing errors in airflow settings.
Implementation Method 1
a bent resilient bar 32 stressed between a rear end face 36 of the motor housing 30 and a front end face 37 of a flange 38 of the valve case 34
Data Source
AI summary
A compressed air throttle apparatus has at least one throttle valve adjusted by an electric motor, and an electric circuit fitted with contacting elements to alternatively interrupt and close the electric circuit in relation to the throttle valve settings. This throttle apparatus preferably is applicable to a compressed air path of powder spraycoating equipment.