Vacuum Source Control for Milking Systems
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Solution Overview
Problem
The existing milking system vacuum pump technology is inefficient due to over-dimensioning for regulatory requirements, leading to increased energy consumption, capital costs, and unnecessary wear and tear, as well as the need for redundant backup pumps that are costly and cumbersome to maintain.
Innovation Solution
A milking system with a control system that regulates vacuum pumps based on real-time vacuum requirements, allowing for the use of fewer and smaller pumps by selectively activating and deactivating them according to the operating modes of milking machines, and controlling their rotation speed to optimize energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum pumps are over-dimensioned to meet regulatory vacuum reserve requirements, then reliability is improved, but energy consumption increases and pump efficiency decreases
Solution Approach 1:
The patent applies dynamics by making the vacuum pump system adjustable and flexible. Multiple vacuum pumps can be dynamically activated or deactivated based on actual system needs, and pump rotation speeds can be varied to match operational requirements. This replaces the static over-dimensioned single-pump approach with a dynamic multi-pump configuration that adapts to varying vacuum demands, maintaining reliability while reducing energy consumption during low-demand periods.
Solution Approach 2:
The patent segments the vacuum pump system into multiple independent pumps rather than using a single over-dimensioned pump. This segmentation allows individual pumps to be sized appropriately for specific tasks and enables selective operation of only the necessary pumps at any given time. The system can activate one or more pumps based on actual vacuum requirements, avoiding the energy waste of running a single large pump at low capacity.
2Use of energy by moving object
If vacuum pumps operate at lower rotation speeds to match reduced airflow requirements, then energy consumption decreases, but pump overheating occurs and lubrication becomes insufficient
Solution Approach 1:
The system dynamically adjusts pump operation by selectively activating multiple pumps rather than running a single pump at low speed. When total vacuum requirement is high, multiple pumps operate simultaneously; when requirements are low, fewer pumps are activated. This maintains adequate rotation speeds and airflow through operating pumps, preventing overheating and ensuring proper lubrication while achieving overall energy savings through selective pump deactivation.
Solution Approach 2:
The control system acts as an intermediary that monitors vacuum requirements and intelligently determines which pumps to activate and at what speeds. It mediates between the conflicting requirements of energy efficiency and pump health by distributing the vacuum load across multiple pumps, ensuring each operating pump maintains adequate speed and airflow for proper lubrication and cooling.
3Reliability
If a back-up vacuum pump is maintained for reliability, then system reliability is improved, but capital cost and maintenance complexity increase
Solution Approach 1:
The patent applies universality by making all vacuum pumps multi-functional and interchangeable. Rather than having dedicated primary and backup pumps with different roles, all pumps in the system can perform any vacuum supply function. Any pump can be activated to replace another if needed, eliminating the need for a separate backup pump and reducing system complexity while maintaining reliability through redundancy of capability across multiple identical units.
Solution Approach 2:
The system merges the functions of primary and backup pumps into a unified pool of interchangeable vacuum pumps. Instead of maintaining separate primary and backup roles, all pumps are integrated into a single operational pool where any unit can fulfill any vacuum requirement. This consolidation eliminates redundant backup infrastructure and simplifies maintenance while preserving system reliability through the availability of multiple capable units.
4Use of energy by moving object
If multiple vacuum pumps are used to reduce energy consumption, then energy efficiency is improved, but system complexity and control requirements increase
Solution Approach 1:
The control system employs feedback by continuously monitoring actual vacuum requirements and adjusting pump activation and speed accordingly. Sensors monitor system vacuum levels and airflow demands, feeding this information back to the controller which then optimizes pump operation in real-time. This feedback mechanism automates the complex decision-making process of managing multiple pumps, simplifying control while achieving energy efficiency through intelligent, adaptive pump management.
Data Source
AI summary
The present invention relates to a vacuum source for providing vacuum to at least a first vacuum drain through conduits, comprising at least a first and a second vacuum pump. The vacuum source comprises a control system adapted to detect the consumed airflow, and to control the operation of each of the first and second vacuum pump based on the detected airflow.