Vacuum System Controller Pressure Adaptation

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Solution Overview

Problem

Existing vacuum systems for material handling require skilled operators to manually set pressure threshold values, which are not adaptable to fluctuations in vacuum pressure over time, leading to inefficient energy saving and potential loss of energy-saving functionality during working cycles.

Innovation Solution

A method and controller for automatic pressure level determination and adaptation, using a pressure sensor and vacuum system controller to calculate and adjust system-pressure levels dynamically, ensuring energy-saving operation by setting maximum and minimum pressure levels based on real-time system-pressure fluctuations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual pressure threshold setting is used, then the system can operate with simple control logic, but the system requires skilled operators and cannot adapt to pressure fluctuations

Engineering Contradiction:

Improveadaptability to pressure fluctuationsVSAvoidcontrol system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system automatically determines and adapts pressure thresholds using a pressure sensor and controller that monitor system pressure in real-time and adjust thresholds without operator intervention, enabling the system to serve itself and adapt to fluctuations

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The pressure sensor provides continuous feedback to the controller about system pressure levels, which then automatically adjusts the pressure thresholds based on this feedback, creating a closed-loop control system that adapts to pressure fluctuations

Inventive Principle:

Principle #23Feedback

2Use of energy by moving object

If energy saving function is implemented with fixed pressure thresholds, then energy consumption is reduced, but the energy-saving functionality is lost during pressure fluctuations

Engineering Contradiction:

Improveenergy consumptionVSAvoidreliability of energy-saving function

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The pressure thresholds are made dynamic rather than fixed, automatically adjusting to system pressure fluctuations while maintaining the energy-saving function, ensuring reliability under varying operating conditions

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the pressure threshold parameters dynamically based on real-time pressure sensor data, allowing the energy-saving function to remain reliable even when system pressure fluctuates during operation

Inventive Principle:

Principle #35Parameter changes

3Reliability

If skilled operators manually set thresholds considering pressure fluctuations, then the system can maintain energy-saving functionality, but the operation becomes complex and requires extensive expertise

Engineering Contradiction:

Improveenergy-saving functionalityVSAvoidease of setup and operation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system performs automatic threshold determination and adaptation without requiring operator expertise or manual configuration, making the system easy to operate while maintaining reliable energy-saving functionality

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual operator judgment and expertise are replaced with an automated electronic control system that uses pressure sensor data and control algorithms to determine optimal thresholds, eliminating the need for skilled operators

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 user-friendly operation, adapts to varying demands, and maintains energy-saving functionality by automatically determining optimal pressure levels for each working cycle, reducing the need for manual intervention and improving system efficiency.

Implementation Method 1

a vacuum generator arrangement driven by a compressed air flow

Methodology Applied

Scientific EffectCompressed air flow:

Implementation Method 2

the vacuum generator arrangement...is arranged to be brought in flow connection with the vacuum gripper tools, in order to supply vacuum to the vacuum gripper

Methodology Applied

Scientific EffectVacuum generation:

Implementation Method 3

A pressure sensor for monitoring a system-pressure p -t) is arranged inside the vacuum chamber

Methodology Applied

Scientific EffectPressure sensing:

Data Source

PatentEP3252317B1Controlling a vacuum system comprising a vacuum generator arrangement

Publication Date: 2020.01.29 PIAB

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AI summary

The invention relates to energy saving in vacuum systems by means of a method and a controller enabling to consider the fluctuation in system-pressure of a system by determining a maximum system-pressure S2H and a minimum system-pressure S2h for each working cycle WC based on a determined target system-pressure pn and a pre-set system-pressure p0 for the current working cycle WCn (n = 1, 2, 3, ...). The method is especially adapted to fluctuations in system-pressure level of a vacuum system comprising a vacuum gripper tool.