Universal Pneumatic Valve Control for Precise Actuator Positioning
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Solution Overview
Problem
Existing pneumatic actuator systems require a large number of specific valve types and complex programming, leading to high engineering and programming times, as well as inefficient use of compressed air, resulting in significant energy costs.
Innovation Solution
The implementation of a universal valve system mounted directly onto the cylinder port, combined with a universal valve controller and a continuous piston position sensor, allows for precise control of compressed air flow, minimizing unnecessary air usage and reducing energy costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple specific valve types are used for different actuator functions, then the actuator can perform diverse functions, but the number of valve types and programming complexity increases significantly
Solution Approach 1:
The patent implements a universal valve with multiple positions that can perform various actuator functions (single stroke, double stroke, spring return, etc.) through a single valve design. The valve's multiple positions allow it to control compressed air flow in different configurations, eliminating the need for multiple specialized valve types while maintaining full functional versatility across all actuator operating modes.
Solution Approach 2:
The patent employs programmable logic that dynamically configures the universal valve's operation based on real-time actuator position feedback and desired motion patterns. The controlling logic adapts valve positioning and air flow distribution dynamically, allowing the same hardware configuration to serve multiple functions through software-controlled behavior changes.
2Reliability
If traditional pneumatic valve systems are used, then actuator control is achieved, but compressed air is wasted in air lines and through unnecessary exhaust
Solution Approach 1:
The patent incorporates piston position sensors that provide real-time feedback to the programmable logic controller. This feedback enables the system to monitor actual actuator position and adjust valve operations accordingly, allowing the controller to stop compressed air flow precisely when the actuator reaches its target position and prevent unnecessary exhaust by recapturing or redirecting air based on actual system state.
Solution Approach 2:
The universal valve system is designed to manage its own air flow distribution based on programmable logic that responds to position feedback. The system automatically optimizes air flow paths, directs exhaust air appropriately, and prevents waste without requiring external intervention, making the air management self-regulating through integrated sensing and control.
3Manufacturing precision
If compressed air continues to flow until pressure equalization, then complete actuator positioning is ensured, but energy is wasted compressing and exhausting unnecessary air
Solution Approach 1:
The programmable logic controller uses position feedback to anticipate when the actuator will reach its target position and pre-adjusts the valve configuration accordingly. By stopping compressed air flow slightly before pressure equalization is complete, the system ensures the actuator reaches the desired position while avoiding the energy waste of continuing to compress and exhaust air unnecessarily, as the position sensors provide early warning of approach to target.
Data Source
AI summary
A system initiates a start of at least one of a flow of a fluid into one section of an actuator or an exhaust of the fluid from another section of the actuator to move a piston from a current to a destination position. The system also initiates a stop of at least one of the flow of the fluid into the one section of the actuator or the exhaust of the fluid from the another section of the actuator no later than when the current position is at the destination position and before at least one of: a pressure of the fluid within the one section is the same as the pressure of the fluid in a fluid line providing the fluid; or pressure of the fluid within the another section is the same as the pressure of the fluid at an end of an exhaust line exhausting the fluid.