Patent Application
20160178084
The invention relates to a pressure regulator.
Manually setting the outlet pressure of a pressure regulator is an inefficient, clumsy and empirical process that requires a feedback system in which an operator visually monitors an outlet pressure gauge and adjusts and tweaks the regulator pressure drop until a final outlet pressure is eventually achieved. This approach is time consuming, inaccurate, and allows for an operator to overshoot or undershoot a desired outlet pressure during the process. Such error can cause operational difficulties, as well as preventing operation at the outlet pressure desired. A strong need exists for a new control system for manually setting the outlet pressure of pressure regulators.
An embodiment of the present invention is directed to an air compressor that eliminates the regulator pressure gauge and allows the regulator to manually be set to a predetermined pressure.
In an embodiment, a pressure regulator can have a scale indicating a number of outlet pressures which can be set as a selected outlet pressure of a gas exiting the pressure regulator. A regulator knob can be adapted to be rotated manually to a selected outlet pressure chosen from the number of outlet pressures. A regulator spring can be used that at least in part controls a valve that regulates a flow of the gas. The regulator knob can be adapted to change a spring compression of the regulator spring when the regulator knob is manually rotated to set the selected outlet pressure of the gas.
In an embodiment, rotation of the regulator knob to the selected outlet pressure, as well as setting a selected outlet pressure, can be free of a feedback control mechanism. The selected outlet pressure can be set by the regulator knob to a value selected on the scale and the pressure regulator can be configured to produce an outlet pressure free of reference to an outlet pressure gauge.
The scale can be of a variety of configurations. For example, the scale can be configured to be generally coaxial with the circumference of the regulator knob. In an embodiment, the scale can be configured to be generally coaxial with the circumference of the regulator knob and can indicate a plurality of outlet pressures which can be selected and which have one or more of the plurality of outlet pressures in a range of from 25 psig to 250 psig, or higher.
The regulator knob can also have of a variety of designs. In one embodiment, the regulator knob can have single-turn coarse grooves which slideably engage single-turn coarse threads which project from a portion of a regulator body, such as a control cylinder. Optionally, the regulator knob can have an indicium which can be aligned with a portion of the scale to set the selected outlet pressure. In an embodiment, the indicium can be an arrow, such as a set point arrow, which can be pointed to a pressure indicated by the scale to set a selected outlet pressure.
The rotation of the regulator knob and the indication of its position can have a variety of mechanisms, in an embodiment the regulator knob can be ratcheted when rotated to cause an alignment of a portion of the regulator knob to a portion of the scale to set the selected outlet pressure.
In an embodiment, a pressure control system can have the pressure regulator which can have a regulator knob which can be rotated to control an outlet pressure of a gas exiting the pressure regulator. The pressure control system can also have the scale configured proximate to the regulator knob and indicating a plurality of outlet pressure values one of which can be selected as an outlet set pressure; an indicium mounted on and moved by the regulator knob, the indicium proximate to an outlet pressure value that is selected as an outlet set pressure. In an embodiment, the outlet set pressure can be selected by rotating the regulator knob to control the outlet pressure of the gas exiting the regulator at a desired outlet set pressure.
In an embodiment, the pressure control system can have a control cylinder can have a single-turn course thread projecting from a portion of a regulator body. The single-turn course thread can be configured to slideably engage the regulator knob. The pressure control system can use a regulator knob which is a single-turn regulator knob.
The pressure control system can control the outlet pressure to within 15 percent, or 10 percent, or closer, of an outlet set pressure when the regulator knob remains in a fixed position corresponding to a selected outlet pressure. In an embodiment, the pressure control system can be configured to indicate an outlet pressure midpoint when the regulator knob is rotated to a point that is located at about one-half of its rotational range.
A compressor can have the pressure-setting regulator and/or the pressure control system which uses the pressure-setting regulator. In an embodiment, a compressor for producing a compressed gas can have the pressure regulator, a scale indicating a plurality of outlet pressures which can be set as a selected outlet pressure of a gas exiting the regulator and a regulator knob adapted to be manually rotated to set the selected outlet pressure from the plurality of outlet pressures of the scale. A regulator spring can at least in part control a valve that regulates a flow of the gas of the pressure-setting regulator. The regulator knob can be adapted to change a spring compression of the regulator spring when the regulator knob is manually rotated to set the selected outlet pressure of the gas. In an embodiment, the scale can be configured proximate to the regulator knob.
In an embodiment, a positive control method of pressure regulation can use the pressure-setting regulator. A method of controlling the regulator outlet pressure can have the steps of: providing a regulator having a single-turn regulator knob which has an indicium adapted to indicated a portion of the scale; providing the scale configured proximate to the single-turn regulator knob and having a plurality of outlet pressures; rotating the single-turn regulator knob such that the indicium indicates an outlet pressure which is an outlet pressure set point; and in which the rotating of the single-turn regulator knob changes the pressure exerted by a regulator spring which changes the differential pressure of the regulator to change the outlet pressure. In an embodiment, the method of controlling regulator outlet pressure can control the controlling the outlet pressure within 20 percent of the outlet pressure set point.
In an embodiment, the pressure-setting regulator can be set to an outlet pressure by rotating the regulator knob such that the indicium, such as the set point arrow, is proximate to a selected outlet pressure. In an embodiment, the regulator knob can be calibrated to position the indicium, such as an arrow or other mark, such that it is configured at the mid-range of the single-turn regulator knob rotational range. In another embodiment, the pressure-setting regulator can be calibrated to achieve a minimum variance in the outlet pressure when the indicium is at a position within 45 degrees of the rotational mid-point of the regulator knob.
The present invention in its several aspects and embodiments solves the problems discussed above and significantly advances the technology of pressure regulators. The present invention can become more fully understood from the detailed description and the accompanying drawings, wherein:
Herein, like reference numbers in one figure refer to like reference numbers in another figure.
The invention relates to the many and varied embodiments of a positive control regulator, pressure regulation system and to methods for regulating outlet gas pressure from a compressor. The pressure regulation system can be used with a compressor assembly which can compress air, or a gas, or gas mixtures. The compressor can compress one or more gases, inert gases, or mixed gas compositions.
The definition of “air” herein is intended to be very broad. The term “air” includes breathable air, ambient air, treated air, conditioned air, clean room air, cooled air, heated air, non-flammable oxygen containing gas, filtered air, purified air, contaminated air, air with particulates solids or water, air from bone dry (i.e. 0.00 humidity) air to air which is supersaturated with water, as well as any other type of air present in an environment in which a gas (e.g. air) compressor can be used. It is intended that cooling gases which are not air are encompassed by this disclosure. For non-limiting example, a cooling gas can be nitrogen, can comprise a gas mixture, can comprise nitrogen, can comprise oxygen (in a safe concentration), can comprise carbon dioxide, can comprise one inert gas or a plurality of inert gases, or comprise a mixture of gases.
In an example embodiment, the compressor assembly 20 can have a pressure-setting regulator 400 configured at least in part within a housing 21. The compressor assembly includes a tank pressure gauge 325, a regulator knob 410 and a tool connect member 10 located on a face of the housing 21. An ON/OFF switch 11 can be located on a front portion of the housing 21. The regulator knob 410 is the control which controls the pressure-setting regulator 400 that is set within a desired air outlet pressure guide. The regulator knob 410 that is rotatable to a position that corresponds to the desired air output pressure to the tool. The desired air outlet pressure guide, which can be a scale 500, is located on a dashboard 300 on the face of the housing 21 to be readable by an operator. The outlet pressure guide can optionally be in the form of a label. Alternatively, the outlet pressure guide can be integrally molded with the manifold, or etched thereon. Thereby, the regulator outlet pressure gauge 122 of the prior art shown in
As shown, for example in
In an embodiment, the compressor assembly 20 can have a weight between 15 lbs and 100 lbs. In an embodiment, a portable embodiment of the compressor assembly 20 can have of weight between 10 lbs and 50 lbs, such as 10 lbs to 30 lbs, or 15 lbs to 40 lbs.
In an embodiment, the housing 21 can have a front housing 161 and a rear housing 170 and a plurality of intake ports 182. The compressor assembly can be cooled by air flow provided by a fan 200 the plurality of intake ports 182.
Power can be supplied to a motor 33 of the compressor assembly through a power cord 5 extending through the housing 21. In an embodiment, the compressor assembly 20 can comprise one or more of a cord holder member, such as a first cord wrap 6 and a second cord wrap 7.
In an embodiment, the power switch 11 can be used to change the operating state of the compressor assembly 20 at least from an “on” to an “off” state, and vice versa. In the “on” state, the compressor can be in a compressing state (also herein as a “pumping state”) in which it is compressing air, or a gas, or a plurality of gases, or a gas mixture.
In an embodiment, other operating modes can be engaged by the power switch 11 or a compressor control system, e.g. a standby mode, or a power save mode. In an embodiment, the dashboard 300 can provide an operator-accessible location for connections, gauges and valves which can be connected to a manifold 303 (
A plurality of intake ports 182 can be formed in the housing 21 proximate to the fan 200 and a plurality of exhaust ports 31 (not shown) can be formed in the housing 21 proximate to the pump. The total cross-sectional open area of the intake ports 182. In an embodiment, the cooling gas employed to cool the compressor assembly 20 and its components can be air, which optionally can be taken in from the environment in which the compressor assembly 20 is placed. The cooling gas can be exhausted from the compressor assembly 20 through a plurality of exhaust ports (not shown).
Numeric values and ranges herein, unless otherwise stated, also are intended to have associated with them a tolerance and to account for variances of design and manufacturing, and/or operational and performance fluctuations. Thus, a number disclosed herein is intended to disclose values “about” that number. For example, a value X is also intended to be understood as “about X”. Likewise, a range of Y-Z, is also intended to be understood as within a range of from “about Y-about Z”. Unless otherwise stated, significant digits disclosed for a number are not intended to make the number an exact limiting value. Variance and tolerance, as well as operational or performance fluctuations, are an expected aspect of mechanical design and the numbers disclosed herein are intended to be construed to allow for such factors (in non-limiting e.g., ±10 percent of a given value). This disclosure is to be broadly construed. Likewise, the claims are to be broadly construed in their recitations of numbers and ranges.
The compressed gas tank 150 can operate at a pressure in a range of at least from ambient pressure, e.g. 14.7 psig to 3000 psig (“psig” is the unit lbf/in̂2 gauge), or greater. In an embodiment, the compressed gas tank 150 can operate at 200 psig. In an embodiment, the compressed gas tank 150 can operate at 150 psig.
In an embodiment, the pressure-setting regulator 400 can use a pressure regulating valve. In an embodiment, excess air pressure can be vented to atmosphere through a pressure relief valve 199, such as a spring loaded safety valve. In an embodiment, the pump assembly 25 and the compressed gas tank 150 can be connected to a frame 111 (
In an embodiment, the compressor has a pressure regulated on/off switch which can stop the pump assembly 25 when a specified compressed gas tank pressure is obtained. Activation of the pump assembly 25 can occur at a pressure in a wide range of set operating pressure, e.g. 25 percent to 99.5 percent of specified compressed gas tank operating pressure. The specified compressed gas tank operating pressure can be in a range from 25 psig to 3000 psig. In an embodiment, the specified compressed gas tank 150 pressure can be 50 psig, 75 psig, 100 psig, 150 psig, 200 psig, 250 psig, 300 psig, 500 psig, 1000 psig, 2000 psig, 3000 psig, or greater than or less than, or a value in between these example numbers.
Depending upon the compressed gas output specifications, such as output flow ranges and outlet pressure ranges, of the compressor assembly 20, the motor 33 can operate at a motor speed between 1,000 rpm and 30,000 rpm. In an embodiment, the motor 33 can operate at a speed in a range of between 7,500 rpm and 12,000 rpm. In further embodiments, the motor 33 can operate at e.g. 11,252 rpm, or 11,000 rpm; or 10,000 rpm; or 9,000 rpm; or 7,500 rpm; or 6,000 rpm; or 5,000 rpm.
In an embodiment, the motor can be a non-synchronous universal motor rated, for example, at ½ horsepower, at ¾ horsepower, at 1 horsepower, at 2 horsepower, at 5 horseposer or greater. In an embodiment, the motor can be a synchronous motor. The compressor assembly 20 can accommodate a variety of types of motor 33. The pressure-setting regulator 400 can be used in large-scale industrial equipment and compressors, as well as in portable equipment and compressors.
The pump assembly 25 can have the components which are attached to the motor and/or which serve to compress a gas; which in a non-limiting example can comprise the fan 200, the motor 33, and a pump 59, with a pump arm 91.
The pump assembly 25 can have the pump 59, such as a “gas pump” or an “air pump” that includes a piston 63, a pump cylinder 60, in which a piston 63 reciprocates and a connecting rod 69. The pump further includes a pulley 66, a drive belt 65 and driving mechanism driven by motor 33. The connecting rod 69 can connect to the piston 63 which can move inside of the pump cylinder 60. The motor can be a high speed universal motor, or other type of motor. The piston 63 can compress a gas in the pump cylinder 60 pumping the compressed gas through the valve plate assembly 62 into the cylinder head 61 and then out through a compressed gas outlet port 782 through an outlet line 145 and into the compressed gas tank 150.
The pulley 66 and a sprocket 49, can in part drive the drive belt 65, and can be sized to achieve reduced pump speeds, which can correspond to reciprocation rates and/or a piston speed at which the piston 63 is reciprocated.
In an embodiment shown in
The pitch thread angle, whether the fine pitch thread angle 414, or the coarse pitch thread angle 415 can achieve a desired angle of rotation in which the knob is rotated to achieve a set outlet pressure 550, or to achieve any number of turns or partial turns of a knob to achieve a set outlet pressure 550.
The regulator spring 430 imparts pressure from the regulator knob 410 to the piston 432. In the example embodiment of
The pressure-setting regulator 400 regulates the flow of a compressed gas and creates a pressure drop between the compressed gas pressure in the compressed gas tank 150 and/or the manifold 303 and/or the regulator inlet 509, such as inlet pressure 501, and a regulator outlet 549 having the outlet pressure 550.
Optionally, the scale 500 can be set for a single-turn configuration in which a single, or partial, rotation of the regulator knob 410 can be applied to allow a user to select any outlet pressure on the scale 500.
The thread angle and/or number of threads per inch can be set to accommodate a desired range of pressures to achieve a single-turn functionality for a desired range of pressures and/or scale 500.
In single-turn and multi-turn applications, the regulator knob 410 can be reversibly turned, for example in one direction to increase gas flow and in the reverse direction to decrease gas flow.
The dashboard 300 of the example of
In the embodiment of
In
The scale 500 shown in
In an embodiment, the pressure-setting regulator 400 can be calibrated for exacting performance in achieving and maintaining a set outlet pressure 550. A calibrated pressure gauge can be attached to a test manifold having an attached uncalibrated pressure-setting regulator. The uncalibrated pressure-setting regulator 400 can be set to a mid-range outlet pressure, such as 100 psig in a non-limiting example. In a calibration step, when the uncalibrated pressure-setting regulator 400 is set to a mid-range outlet pressure, an indicium, such as a label bearing a set point arrow 420, can be placed on the knob driver top 428 (
In an embodiment, the mid-range outlet pressure can occur at a one-half of the rotational range of the regulator knob, and the scale can be configured to have the mid-range outlet pressure value positioned at the point of one-half of the rotation al range of the regulator knob. This allows the indicium to be configured on the regulator knob such that at the point in which the one-half of the rotational range of the regulator knob the indicium is aligned with, or is proximate to, the mid-range outlet pressure value of the scale, for example an arrowhead 422 pointing to the mid-range outlet pressure value of the scale.
Optionally, the high-end set point of outlet pressure 550 of the scale 500 can be a maximum output pressure possible from the compressor. In another embodiment, the high-end set point of outlet pressure of the scale 500 can be limited to less than the maximum outlet pressure from the compressor. The limit on the outlet pressure 550 can be achieved by the design of the control knob threads or the knob thread grooves. Alternately, the compressor can be mechanically limited to the high-end set point of outlet pressure 550 of the scale 500.
The rotation of the regulator knob 410 is reversible and the regulator knob 410 can be turned in either the increasing flow direction 590, or the decreasing flow direction 595 (
In an example the regulator knob 410 can be rotated from a set pressure, such as 150 psig, by rotating the regulator knob 410 in the decreasing flow direction 595 to the first position in which the pressure-setting regulator 400 is in an “no flow” position in which the set point value is zero, the outlet gas stream 560 is zero.
In an embodiment, the pressure-setting regulator 400 can be self-relieving and can respond to maintain a constant set outlet pressure when the set pressure is changed from a higher set outlet pressure to a lower set outlet pressure. In another example, the pressure-setting regulator 400 can be non-relieving. However, in the non-relieving embodiment the outlet pressure will reset from a higher outlet pressure to a lower outlet pressure after turning the regulator knob to set the lower outlet pressure and once the residual higher pressure gas is released from the valve channel 439 by use of a tool or other means. In either the relieving or non-relieving embodiments, the pressure-setting regulator valve configuration will respond to maintain a constant outlet pressure as compressed gas is used.
In the embodiment of
When the regulator knob 410 is rotated in the decreasing flow direction 595, the pressure of an outlet gas stream which is flowing is also reduced. When the regulator knob 410 is rotated in decreasing flow direction 595, poppet 437 is moved toward poppet seat 438 and the flow rate from compressed gas stream 510 through the valve channel 439 is decreased, and the flow rate which becomes outlet gas stream 560 is also decreased. When the regulator knob 410 is rotated in decreasing flow direction 595, for example in the counterclockwise direction, the poppet 437 is moved toward poppet seat 438 which increases the pressure drop across the valve 490, decreases the flow rate and decreases the outlet pressure 550 during flow.
From any set outlet pressure, the pressure-setting regulator 400 can be rotated in the decreasing flow direction 595 to a “no flow” position (as shown in
The scope of this disclosure is to be broadly construed. It is intended that this disclosure disclose equivalents, means, systems and methods to achieve the devices, designs, operations, control systems, controls, activities, mechanical actions, fluid dynamics and results disclosed herein. For each mechanical element or mechanism disclosed, it is intended that this disclosure also encompasses within the scope of its disclosure and teaches equivalents, means, systems and methods for practicing the many aspects, mechanisms and devices disclosed herein. Additionally, this disclosure regards a pressure regulator and its many aspects, features and elements. Such an apparatus can be dynamic in its use and operation. This disclosure is intended to encompass the equivalents, means, systems and methods of the use of the compressor assembly and its many aspects consistent with the description and spirit of the apparatus, means, methods, functions and operations disclosed herein. The claims of this application are likewise to be broadly construed.
The description of the inventions herein in their many embodiments is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention and the disclosure herein. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
It will be appreciated that various modifications and changes can be made to the above described embodiments of the compressor assembly as disclosed herein without departing from the spirit and the scope of the following claims.
This patent application is a nonprovisional application of copending U.S. provisional application 62/093,702, and incorporates by reference in its entirety copending U.S. provisional patent application 62/093,702 entitled “Pressure-Setting Regulator” filed Dec. 18, 2014. This patent application also incorporates by reference in its entirety U.S. Pat. No. 8,899,378 entitled “Compressor Intake Muffler And Filter” issued Dec. 2, 2014.
| Number | Date | Country | |
|---|---|---|---|
| 62093702 | Dec 2014 | US |
