Two-Stage Air Control Valve for Vacuum Transfer Systems
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Solution Overview
Problem
Existing air control valves in vacuum transfer systems are inefficient in terms of energy consumption and operational precision, often requiring frequent on/off operations, leading to reduced lifespan and potential malfunctions, and rely solely on electric signals for control, which lacks precision in responding to vacuum pressure levels.
Innovation Solution
A two-stage control air control valve system that utilizes both electric and pneumatic signals to control the supply of compressed air, featuring a main body with a stopper and separate control parts operated by electronic and pneumatic control valves, allowing for precise control based on vacuum pressure levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the air control valve is operated by frequent on/off operations of the electronic control valve, then the control of compressed air supply is achieved, but the expected life span of elements is reduced and excessive electricity is consumed
Solution Approach 1:
The control function is segmented into two independent control valves (first electronic control valve and second electronic control valve) that operate separately. The first valve controls the supply of compressed air to the piston chamber, while the second valve controls the exhaust of compressed air from the piston chamber. This segmentation allows for more precise control and reduces the need for frequent complete on/off cycles, thereby extending element lifespan.
Solution Approach 2:
A piston chamber is introduced as an intermediary mechanism between the electronic control valves and the main valve body. The piston chamber accumulates compressed air and uses pneumatic pressure to actuate the valve, providing smooth transitions and reducing mechanical shock from frequent on/off operations, thus improving reliability.
2Productivity
If the electronic control valve is used to operate the air control valve, then the control response is achieved, but the operational precision is reduced when determining compressed air supply based on vacuum pressure levels
Solution Approach 1:
The system incorporates feedback from the vacuum pressure level to control the compressed air supply. The electronic control valves monitor the vacuum pressure in the working chamber and adjust the compressed air supply to the piston chamber accordingly. This feedback mechanism ensures that compressed air is supplied only when the vacuum pressure reaches the required level, improving operational precision.
Solution Approach 2:
The system uses pneumatic pressure from the piston chamber to actuate the valve mechanism. The compressed air accumulated in the piston chamber creates pneumatic force that opens or closes the valve, providing precise control based on the actual vacuum pressure conditions rather than relying solely on electrical signals.
3Device complexity
If the air control valve is configured to be operated by on/off operation of the electronic control valve, then the valve construction is simple, but the energy efficiency is reduced when the turned on state must be continued to avoid malfunction
Solution Approach 1:
The system uses periodic on/off control of the electronic control valves to maintain the required vacuum pressure. Instead of continuous operation, the valves are activated periodically to supply compressed air when needed, and deactivated when the vacuum pressure is sufficient. This periodic action reduces energy consumption while maintaining system functionality.
Solution Approach 2:
The piston chamber maintains continuous pneumatic pressure to keep the valve in the desired state once activated. This eliminates the need for continuous electrical power to maintain the valve position, as the pneumatic pressure provides continuous useful action, reducing energy waste from continuous electrical operation.
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 two-stage control system enhances operational stability, energy efficiency, and precision in controlling compressed air supply, reducing energy waste and improving system reliability.
Implementation Method 1
a first control part including a hollow first piston moving between the inlet and the stopper, thereby opening or closing the path
Implementation Method 2
a second control part including a hollow second piston moving between the stopper and the outlet, thereby opening or closing the outlet
Implementation Method 3
an electronic control valve mounted to an external surface of the housing; a first control part including a hollow first piston moving between the inlet and the stopper
Implementation Method 4
a second control part including: a hollow second piston moving between the stopper and the outlet, thereby opening or closing the outlet; and a second fluid line extending through a pneumatic control valve
Data Source
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AI summary
The present invention applies to a vacuum transfer system, and relates to an air control valve for controlling the supply of compressed air in a vacuum transfer system. More specially, the air control valve of the present invention is configured to execute a two-stage control. The two-stage control is realized by a piston operation method, in which, although the control is performed by compressed air supplied thereto, a first control unit is operated by an electronic control method, and a second control unit is operated by a pneumatic control method. In particular, the second control unit is operated by vacuum pressure supplied from the vacuum transfer system. The air control valve of this invention can realize improved operational stability, improved energy efficiency and improved operational precision.