Two-Valve Pulsator for Reducing Liquid Suction in Milking Systems

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Solution Overview

Problem

Conventional milking systems are unable to reduce the ratio of time providing vacuum relative to fresh air to the pulsation chamber while maintaining a milk to rest ratio of 50:50 or greater, leading to issues like liquid being sucked into the pulsator and hoses due to liner failures.

Innovation Solution

An electronic controller is used to manage two-valve pulsator mechanisms, allowing for a duration of fresh air supply to exceed vacuum supply, enabling a sharp transition between air and vacuum pressures and reducing liquid suction by using separate valves for vacuum and air control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional pulsator design with seals at both ends of valve plunger is used, then proper sealing and control of air/vacuum is achieved, but liquid can be rapidly sucked up the hoses into the pulsator and vacuum pump when liner fails

Engineering Contradiction:

Improvesealing performanceVSAvoidliquid suction into pulsator

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes one seal from the valve plunger (leaving only the upstream seal) and introduces a separate downstream seal positioned downstream of the valve plunger. This separation allows the downstream seal to block liquid suction paths while the upstream seal maintains vacuum/air control, resolving the contradiction between sealing performance and liquid suction prevention.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an intermediary downstream seal that acts as a barrier between the pulsation chamber and the vacuum pump. This downstream seal prevents liquid from reaching the pulsator while allowing the upstream seal to maintain proper vacuum control, thus mediating between sealing requirements and liquid suction prevention.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If vacuum supply duration is increased to maintain milk to rest ratio of 50:50, then milking efficiency is improved, but liquid suction into the system increases during liner failures

Engineering Contradiction:

Improvemilking efficiencyVSAvoidliquid suction into hoses

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

By removing one seal and adding a downstream seal, the system can maintain long vacuum durations for milking efficiency while the downstream seal prevents liquid from being suctioned into the pulsator during liner failures, thus resolving the contradiction between productivity and liquid suction prevention.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If single seal design is used to minimize air/vacuum leakage, then sealing efficiency is improved, but liquid can enter the pulsation chamber more easily during liner failures

Engineering Contradiction:

Improveair/vacuum sealingVSAvoidliquid entry into pulsation chamber

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sealing function is segmented into two separate seals: an upstream seal for air/vacuum control and a downstream seal for liquid prevention. This segmentation allows each seal to specialize in its specific function, resolving the contradiction between air/vacuum sealing and liquid entry prevention.

Inventive Principle:

Principle #1Segmentation

4Reliability

If two independent solenoids with single seal each are used, then air/vacuum control is improved, but the system cannot close off vacuum supply while maintaining liner open position

Engineering Contradiction:

Improveair/vacuum control precisionVSAvoidvacuum supply control flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The downstream seal acts as an intermediary that enables the system to close off the vacuum supply while maintaining the liner in an open position. The downstream seal blocks the vacuum path independently, providing the flexibility needed to control vacuum supply duration without affecting liner position control.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 design reduces liquid suction into the vacuum system during liner failures and allows for positive air pressure to push back accumulated liquid, enhancing milking efficiency and reducing power consumption and valve heat.

Implementation Method 1

The solenoid valve plunger in each of the two independent solenoids moves up and down in the center of the solenoid and has a seal at only one end to minimize air or vacuum leakage when in the closed position.

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Implementation Method 2

Typical milking systems apply periodic alternating pressure to the pulsation chamber (teat cup) of a milking apparatus. This results in the removal and the flow of milk from the udder to which the teat cup is applied.

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS10993410B2Pulsation system

Publication Date: 2021.05.04 GEHM LANNY

AI summary

A valve device that transitions between the pressure and vacuum phases for the purpose of milking animals. The improvement provides a pulsation output with a vacuum supply duration less than that of atmospheric air pressure supply duration.