Vacuum System Dynamic Control via Needle Valve
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Solution Overview
Problem
Vacuum systems for material handling face challenges in reducing air consumption, especially when handling leaking objects, and existing solutions do not adequately consider the varying vacuum levels required across different lifting stages, leading to inefficient energy use and short solenoid valve lifespan due to overheating.
Innovation Solution
A dynamically controlled vacuum system that adjusts the vacuum level based on the lifting process stages using a pressure sensor and vacuum system controller, coupled with a needle valve that minimizes air leakage, allowing for precise adjustment of vacuum levels during the entire lifting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the vacuum system uses a solenoid valve to dynamically control vacuum levels during lifting stages, then the air consumption is reduced, but the solenoid valve lifespan decreases due to overheating
Solution Approach 1:
The patent replaces the solenoid valve (electromechanical component) with a needle valve (purely mechanical component) for controlling compressed air flow to the vacuum generator. This substitution eliminates the overheating issue inherent in solenoid valves while maintaining dynamic control capability through manual or automated adjustment of the needle valve position, thereby extending valve lifespan without sacrificing energy efficiency.
Solution Approach 2:
The patent implements dynamic adjustment of vacuum levels by changing the flow parameters of compressed air through the needle valve during different lifting stages. By modulating the air flow rate and pressure parameters according to actual lifting needs, the system reduces overall air consumption while avoiding the thermal stress that would degrade a solenoid valve.
2Reliability
If the vacuum system over-dimensions vacuum capacity for leaking objects, then the required vacuum level is maintained, but the air consumption increases
Solution Approach 1:
The patent applies dynamic control of vacuum levels by adjusting the needle valve position during different stages of the lifting process. Instead of maintaining a constant high vacuum level, the system dynamically adapts the vacuum capacity to match the actual requirements at each stage, reducing air consumption for leaking objects while ensuring the vacuum level remains sufficient for reliable lifting.
Solution Approach 2:
The patent avoids excessive vacuum generation by providing only the necessary vacuum capacity required at each lifting stage. By using partial action (adjusting needle valve opening) rather than full vacuum generation continuously, the system reduces air consumption while maintaining adequate vacuum levels for handling leaking objects.
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 approach reduces compressed air consumption and extends the lifespan of valves by optimizing vacuum levels according to the lifting stages, enhancing energy efficiency and operational reliability.
Implementation Method 1
a vacuum generator arrangement driven by a compressed air flow, wherein the vacuum generator arrangement via a vacuum chamber being part of the vacuum system is arranged to be brought in flow connection with the vacuum lifter, in order to supply vacuum to the vacuum lifter in result of the compressed air flow
Implementation Method 2
A pressure sensor for monitoring a system-pressure is arranged inside the vacuum chamber
Data Source
Figure 1
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AI summary
A vacuum system (10) and method (100) used for creating a dynamically controlled vacuum system (10) for lifting processes (Wc) are disclosed. The compressed air used for an ejector (3) is varied by calculating the required vacuum levels (V-) during the lifting process (Wc). The required vacuum levels are calculated based on measured acceleration of the object being lifted at each monitored point during the complete lifting process.