Method to optimize regulated pressure to a cyclical air application
An air flow control assembly moves a pressurized air stream to a cyclical application, such as a molding machine, with air pressure at the cyclical application returned to the air flow control assembly to modulate the rate at which the air stream is delivered to the cyclical application.
1. A dome loaded air pressure regulator assembly for controlling the movement of pressurized supply air from one or more compressors to an operating device at a regulated lower pressure, comprising:
a valve body with an inlet opening connected to an inlet air conduit for receiving pressurized inlet air from said one or more compressors and an outlet opening for discharging air at a lower pressure to the operating device;
an air passage extending through the valve body from the inlet opening to the outlet opening for passing air through the valve body, and a valve seat surrounding the air passage;
a valve assembly including a disc valve movable toward and away from the valve seat for regulating the flow of air through the air passage;
a spring at one end of the disc valve for biasing the disc valve toward a closed position with the valve seat;
a diaphragm at the other end of the disc valve for biasing the disc valve toward an open position, the diaphragm including a reference or setpoint pressure application surface on the outer side of the diaphragm for receiving reference or setpoint pressurized air for opposing the force of the spring and for opening the valve, and a process pressure application surface on the inner side of the diaphragm for receiving process signal pressure air for opposing the force of the reference or setpoint pressurized air received by the reference or setpoint pressure application surface for closing the valve;
an air delivery conduit extending from the outlet opening of the valve body to the operating device;
a return port in the valve body extending from outside the valve body to the inner pressure application surface of the diaphragm for connection externally to the operating device; and
a process signal air pressure line extending from the operating device or from an air tank connected to the operating device back to the return port of the valve body for applying process signal pressure air from the operating device or from the air tank connected to the operating device to the process pressure application surface of the diaphragm for opposing the force of the pressurized air applied to the reference or setpoint pressure application surface of the diaphragm.
2. The dome loaded air pressure regulator assembly of claim 1 , and further including an external blow tank with an air inlet for receiving elevated pressure air from said one or more compressors and an air outlet for delivering air from the blow tank to the air regulator.
3. The dome loaded air pressure regulator assembly of claim 1 , wherein the air delivery conduit includes an internal blow tank for accumulating pressurized air from the air pressure regulator and delivering the air to the operating device.
4. The dome loaded air pressure regulator assembly of claim 3 , and further including a pilot regulating valve connected between the inlet air conduit and the reference or setpoint pressure application surface of the diaphragm for applying the reference or setpoint pressure air to the reference or setpoint pressure application surface.
5. The dome loaded air pressure regulator assembly of claim 3 , and further including an external pressure source connected to the valve body for applying the reference or setpoint pressure air to the reference or setpoint pressure application surface of the diaphragm.
6. The dome loaded air pressure regulator assembly of claim 3 , and further including two or more supply and exhaust valves to modulate, mechanically or electrically, the reference or setpoint pressure air applied to the reference or setpoint pressure application surface of the diaphragm.
7. The dome loaded air pressure regulator of claim 1 , further comprising an electrically controlled device with a local or remote pressure measuring device that send a signal to a controller connected to the electrically controlled device.
8. The dome loaded air pressure regulator assembly of claim 1 , wherein the process signal air pressure line extends from the air tank back to the return port.
9. The dome loaded air pressure regulator assembly of claim 1 , wherein the process signal air pressure line extends from the operating device back to the return port.
10. The dome loaded air pressure regulator assembly of claim 1 , wherein the return port of the valve body is located just below the process pressure application surface of the diaphragm and in between the outlet opening and the process pressure application surface of the diaphragm.
11. A dome loaded air pressure regulator assembly for controlling the movement of pressurized supply air from one or more compressors to an operating device at a regulated lower pressure, comprising:
a valve body with an inlet opening connected to an inlet air conduit for receiving pressurized inlet air from said one or more compressors and an outlet opening for discharging the pressurized inlet air at a lower pressure to the operating device;
an air passage extending through the valve body from the inlet opening to the outlet opening for passing air through the valve body, the air passage having a valve seat therein;
a valve assembly, the valve assembly including a disc valve movable toward and away from the valve seat for regulating a flow of air through the air passage;
a spring at one end of the disc valve for biasing the disc valve toward a closed position with the valve seat;
a diaphragm at the other end of the disc valve for biasing the disc valve toward an open position, the diaphragm including a reference or setpoint pressure application surface for receiving pressurized air for opposing the force of the spring and for opening the valve, and a process pressure application surface for receiving process signal air pressure for opposing the force of the pressurized air received by the reference or setpoint pressure application surface for closing the valve;
an air delivery conduit extending from the outlet opening of the valve body to the operating device;
a return port in the valve body extending from outside the valve body to the process pressure application surface of the diaphragm; and
a process signal air pressure line having a first end disposed at a location at or sufficiently near the operating device to receive a portion of pressurized air received in the operating device, the process signal air pressure line having a second end connected to the return port of the valve body for providing the portion of the pressurized air to the process pressure application surface of the diaphragm for opposing the force of the pressurized air received by the reference or setpoint pressure application surface of the diaphragm.