Abstract
An air-driven pump system comprising: a directional unit that defines a directional air chamber and comprises a directional piston, a first process air intake, and a second process air intake; two pump units each including a liquid chamber, an air chamber, and a piston; a shaft affixed to the pistons; an efficiency valve system comprising an efficiency piston, wherein the efficiency unit is configured to divide inlet air entering the air-driven piston pump into control air, first process air, and second process air, and wherein the efficiency piston is in communication with the control air, first process air, and second process air before the air is distributed to the directional unit; and a second shaft which is in communication with the efficiency piston. The efficiency valve system is to prevent overfilling of the air chambers.
Claims
1. An air-driven pump comprising: a source of pressurized air; a first pump unit including a first pump chamber, a first air chamber and a first end of stroke position; a second pump unit including a second pump chamber, a second air chamber and a second end of stroke position, an efficiency valve system pneumatically between the source of pressurized air and the first and second air chambers; a directional control valve pneumatically between the efficiency valve system and the first and second air chambers; a first air passage extending between the efficiency valve system and the directional control valve; a second air passage extending between the efficiency valve system and the directional control valve, the directional control valve shifting at the end of stroke positions to control air communication from the first and second air passages to the first and second air chambers, respectively, the efficiency valve system including a first valve position defining unrestricted air communication between the source of pressurized air and the first air passage and restricted air communication between the source of pressurized air and the second air passage and a second valve position defining unrestricted air communication between the source of pressurized air and the second air passage and restricted air communication between the source of pressurized air and the first air passage, the efficiency valve system shifting between the first and second valve positions before the directional control valve has shifted.
2. The air-driven pump of claim 1, the source of pressurized air being in continuous air communication with the directional control valve across the efficiency valve system through the first passage and in continuous air communication with the directional control valve across the efficiency valve system through the second air passage.
3. The air-driven pump of claim 1, the efficiency valve system further including efficiency valve system shifting elements extending into the first and second air chambers.
4. The air-driven pump of claim 1 further comprising: a pilot valve system pneumatically shifting the directional control valve at the first and second end of stroke positions, respectively.
5. The air-driven pump of claim 4, the pilot valve system including a pilot passage, the pilot passage being in continuous air communication with the directional control valve and the pilot passage being alternately in air communication with the source of pressurized air and atmosphere.
6. The air-driven pump of claim 4 further comprising: a valve cylinder including pilot valve ports therethrough, first efficiency valve ports therethrough and second efficiency valve ports therethrough; a valve piston including a pilot valve groove thereacross selectively in communication with the pilot valve ports, a first efficiency valve groove thereacross selectively in communication with the first efficiency valve ports, a second efficiency valve groove thereacross selectively in communication with the second efficiency valve ports, a first efficiency valve piston land selectively in communication with the first efficiency valve ports and a second efficiency valve piston land selectively in communication with the second efficiency valve ports, the pilot valve system including the pilot valve ports and the pilot valve groove, the efficiency valve system including the first and second efficiency valve grooves and the first and second efficiency valve lands.
7. An air-driven pump comprising: a source of pressurized air; a first pump unit including a first pump chamber, a first air chamber, a first divider between the first pump chamber and the first air chamber and a first end of stroke position of the first divider; a second pump unit including a second pump chamber, a second air chamber, a second divider between the second pump chamber and the second air chamber and a second end of stroke position of the second divider; an efficiency valve system pneumatically between the source of pressurized air and the first and second air chambers; a directional control valve pneumatically between the efficiency valve system and the first and second air chambers; a first air passage extending between the efficiency valve system and the directional control valve; a second air passage extending between the efficiency valve system and the directional control valve, the directional control valve shifting at the end of stroke positions to control air communication from the first and second air passages to the first and second air chambers, respectively, the efficiency valve system including a first valve position defining unrestricted air communication between the source of pressurized air and the first air passage and restricted air communication between the source of pressurized air and the second air passage and a second valve position defining unrestricted air communication between the source of pressurized air and the second air passage and restricted air communication between the source of pressurized air and the first air passage, the efficiency valve system shifting between the first and second valve positions before the directional control valve has shifted.
8. The air-driven pump of claim 7, the efficiency valve system further including efficiency valve system shifting elements extending into the first and second air chambers.
9. The air-driven pump of claim 7, the source of pressurized air being in continuous air communication with the directional control valve across the efficiency valve system through the first passage and in continuous air communication with the directional control valve across the efficiency valve system through the second air passage.
10. The air-driven pump of claim 7 further comprising: a pilot valve system pneumatically shifting the directional control valve at the first and second end of stroke positions, respectively.
11. The air-driven pump of claim 10, the pilot valve system including a pilot passage, the pilot passage being in continuous air communication with the directional control valve and the pilot passage being alternately in air communication with the source of pressurized air and atmosphere.
12. The air-driven pump of claim 10 further comprising: a valve cylinder including pilot valve ports therethrough, first efficiency valve ports therethrough and second efficiency valve ports therethrough; a valve piston including a pilot valve groove thereacross selectively in communication with the pilot valve ports, a first efficiency valve groove thereacross selectively in communication with the first efficiency valve ports, a second efficiency valve groove thereacross selectively in communication with the second efficiency valve ports, a first efficiency valve piston land selectively in communication with the first efficiency valve ports and a second efficiency valve piston land selectively in communication with the second efficiency valve ports, the pilot valve system including the pilot valve ports and the pilot valve groove, the efficiency valve system including the first and second efficiency valve grooves and the first and second efficiency valve lands.
13. An air-driven pump comprising: a source of pressurized air; a first pump unit including a first pump chamber and a first air chamber; a second pump unit including a second pump chamber and a second air chamber, an efficiency valve system including a first air passage pneumatically between the source of pressurized air and the first air chamber and a second air passage pneumatically between the source of pressurized air and the second air chamber; a directional control valve pneumatically between the first air passage and the first air chamber and pneumatically between the second air passage and the second air chamber, the directional control valve selectively controlling air communication from the first and second air passages to the first and second air chambers, respectively, the efficiency valve system selectively restricting air communication between the source of pressurized air and the first and second air passages, unrestricted air communication and restricted air communication between the source of pressurized air and the directional control valve being concurrently in communication through the first and second air passages.
14. The air-driven pump of claim 13, the source of pressurized air being in continuous air communication with the directional control valve through the first air passage and in continuous air communication with the directional control valve through the second air passage.
15. The air-driven pump of claim 13, the efficiency valve system including two efficiency valves, each efficiency valve having an efficiency valve in an efficiency valve cylinder and a shaft extending into one of the air chambers to selectively engage the pump.
16. The air-driven pump of claim 15, each efficiency valve having an unrestricted air communication position and a restricted air communication position.
17. The air-driven pump of claim 15, the pilot valve system including pilot passages through each of the efficiency valves.
18. The air-driven pump of claim 13 further comprising: a pilot valve system shifting the directional control valve at end of stroke positions of the pump to selectively control the directional control valve.
19. The air-driven pump of claim 18 further comprising: a valve cylinder including pilot valve ports therethrough, first efficiency valve ports therethrough and second efficiency valve ports therethrough; a valve piston including a pilot valve groove thereacross selectively in communication with the pilot valve ports, a first efficiency valve groove thereacross selectively in communication with the first efficiency valve ports, a second efficiency valve groove thereacross selectively in communication with the second efficiency valve ports, a first efficiency valve piston land selectively in communication with the first efficiency valve ports and a second efficiency valve piston land selectively in communication with the second efficiency valve ports, the pilot valve system including the pilot valve ports and the pilot valve groove, the efficiency valve system including the first and second efficiency valve grooves and the first and second efficiency valve lands.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
(1) The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying schematic drawings, in which:
(2) FIGS. 1-3 represent an air-driven expansible chamber pump system of the prior art.
(3) FIGS. 4, 4A, 5-6 represent an air-driven expansible chamber pump system of this invention with FIG. 4A representing a detail of the efficiency valve thereof.
(4) FIGS. 7-8, 8A-9 represent an air-driven expansible chamber pump system of this invention with FIG. 8A representing a detail of the left efficiency valve thereof.
(5) FIGS. 10, 10A-13 represent an air-driven expansible chamber pump system of this invention with FIG. 10A representing a detail of the left efficiency valve thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(6) Referring now to the drawings, wherein like reference numerals refer to like parts throughout, there is seen in FIGS. 4-13 several air-driven pump systems according to embodiments of the present invention. Each air-driven pump system comprises an efficiency valve that allows pneumatic equipment to significantly reduce the energy waste associated with overfilling or over pressurizing during operation, as compared to prior art designs.
(7) The pump systems described herein have a multitude of different uses and utilities. For example, the pump systems described herein and claimed below can be used to pump a wide variety of liquids. In addition to liquids, the pump systems can pump any gas capable of being pumped, including air. Any reference to a liquid pump system should be construed to mean a pump system capable of pumping a liquid and/or a gas.
(8) It should be noted that while the Examples described herein refer to several different elements as a piston, these elements could also be a diaphragm component in other embodiments of the present invention. A diaphragm component would typically comprise a central diaphragm with a piston element located on either or both sides which perform(s) the functions of the pistons described in the Examples below. Further, it should be noted that in a preferred embodiment, each of the pistons described herein comprise a perimeter seal such as an o-ring or a sleeve to prevent leakage, although any mechanism of preventing leaking known in the art could be used. Pressure transmitting devices such as pistons and diaphragms being generically identified herein as dividers.
Example 1
(9) The air-driven pump system described in Example 1 is shown in FIGS. 4-6. Starting with FIG. 4, inlet motive air enters the pneumatic pump. A small portion of the motive air is used as control air and is channeled to directional valve 210, thereby pressurizing chamber 212 to act on the small surface area of directional valve piston 211 inside directional valve 210. The balance of the inlet motive air enters efficiency valve 240 and is segmented into control air, left process air and right process air. Control air passes through efficiency valve piston 241 and exits efficiency valve 240 through pilot valve port 268 and is channeled through the pilot passage to pressurize chamber 213 in directional valve 210 acting on the large surface area of directional valve piston 211 inside directional valve 210, moving and holding directional valve piston 211 to the left inside directional valve 210. (Refer to the reference numbers in FIG. 4A). Left process air passes through efficiency valve groove 271 in efficiency valve piston 241 inside efficiency valve 240, unrestricted in its flow rate from efficiency valve port 272. Right process air passes around efficiency valve piston land 273 of efficiency valve piston 241 inside efficiency valve 240, maximally restricted in its flow rate from efficiency valve port 274. Both left and right process air are channeled to directional valve 210 from efficiency valve ports 272, 274. Directional valve piston 211 inside directional valve 210 blocks maximally restricted right process air and allows unrestricted left process air to pass through and exit directional valve 210 and be channeled to pump unit 230 where it expands and pressurizes air chamber 232 causing piston 231 to displace liquid from liquid chamber 233. At the same time, shaft 254 being connected to pistons 231 and 221 moves piston 221, inside pump unit 220, drawing liquid into liquid chamber 223 as once used process air is released from air chamber 222 out of pump unit 220 and channeled through directional valve 210 and directional valve piston 211 to atmosphere.
(10) In FIG. 5, toward the end of its stroke, piston 221 in pump unit 220 engages and moves shaft 264 which is connected to efficiency valve piston 241 inside of efficiency valve 240. The movement of efficiency valve piston 241 un-restricts the exiting right process air out of efficiency valve 240 through efficiency valve groove 275 and from efficiency valve port 274, and maximally restricts the left process air flow rate around efficiency valve piston land 276 out of efficiency valve port 272 of efficiency valve 240.
(11) In FIG. 6, efficiency valve piston 241 is moved to a position that allows channeled control air to be released to atmosphere from chamber 213 inside of directional valve 210. Control air pressure in chamber 212 of directional valve 210, acts on and moves directional valve piston 211 to the right inside of directional valve 210. During the movement of directional valve piston 211, maximally restricted left process air continues to flow at its maximally restricted flow rate through efficiency valve groove 271, by efficiency valve piston land 276, through efficiency valve port 272 and through directional valve 210 and directional valve piston 211 channeled to air chamber 232 of pump unit 230, reducing over filling or over pressurizing of air chamber 232. Directional valve piston 211 is held stationary to the right inside directional valve 210 by the control air pressure in chamber 212. As such, the pilot valve groove 266 in the efficiency valve piston 241 and the pilot valve ports 268, 270 through the cylinder of the efficiency valve 240 to the directional valve chamber 213 and to control air out, respectively, define the pilot valve system in this embodiment. Maximally restricted left process air exiting efficiency valve 240 is channeled to directional valve 210 and blocked by directional valve piston 211. Unrestricted right process air through efficiency valve groove 275 and from efficiency valve port 274 exiting efficiency valve 240 is channeled through directional valve 210 and directional valve piston 211 to pump unit 220, expanding into air chamber 222 as once used process air is channeled to atmosphere from air chamber 232 out of pump unit 230 and through directional valve 210 and directional valve piston 211. Pistons 221, 231 and shaft 254 reverse their directions. Unrestricted right process air acts on piston 221 in pump unit 220 to discharge liquid from liquid chamber 223 as piston 231 in pump unit 230 draws liquid into liquid chamber 233.
Example 2
(12) The air-driven pump system described in Example 2 is shown in FIGS. 7-9. Starting with FIG. 7, inlet motive air enters the pneumatic pump. A small portion of the motive air is used as control air and is channeled to directional valve 510, pressurizing chamber 512 acting on the small surface area of directional valve piston 511 inside directional valve 510. Also, control air is channeled out of chamber 512 and directional valve 510 and enters pilot valve 540, passes through pilot valve piston 541 and is channeled back to directional valve 510 where it pressurizes chamber 513 acting on the large surface area of directional valve piston 511, moving and holding directional valve piston 511 to the left inside directional valve 510. The balance of the inlet motive is segmented into left and right process air. Left process air enters efficiency valves 570, passes around efficiency valve piston 571 and exits efficiency valve 570 unrestricted in its flow. Right process air enters efficiency valves 580, passes around efficiency valve piston 581 and exits efficiency valve 580 maximally restricted in its flow. Both unrestricted left process air and maximally restricted right process air are channeled to directional valve 510. Directional valve piston 511 inside directional valve 510 blocks maximally restricted right process air and passes through unrestricted left process air. Unrestricted left process air exits directional valve 510 and is channeled to pump unit 530 where it expands and pressurize air chamber 532 causing piston 531 to displace liquid from liquid chamber 533. At the same time, shaft 554 being connected to pistons 531 and 521 moves piston 521 inside pump unit 520, drawing liquid into liquid chamber 523 as once used process air is released from air chamber 522 out of pump unit 520 and channeled through directional valve 510 and directional valve piston 511 to atmosphere.
(13) In FIG. 8, toward the end of its stroke, piston 521 in pump unit 520 engages and moves efficiency valve piston 571 in efficiency valve 570. Efficiency valve piston 571 moves to a position that maximally restricts left process air flow rate out of efficiency valve 570. The maximally restricted left process air continues to be channeled to directional valve 510. Right process air moves efficiency valve piston 581 inside efficiency valve 580, allowing right process air to exit efficiency valve 580 unrestricted and continues to be channeled to directional valve 510. Piston 521 in pump unit 520 also engages and move shaft 564 which is connected to pilot valve piston 541 inside of pilot valve 540.
(14) In FIG. 9, the pilot valve system with pilot valve piston 541 in pilot valve 540 is moved to a position that allows channeled control air to be released to atmosphere from chamber 513 inside of directional valve 510. Control air pressure in chamber 512, moves directional valve piston 511 to the right inside of directional valve 510. During the movement of directional valve piston 511, maximally restricted left process air continues to flow at its maximally restricted flow rate channeled into air chamber 532 of pump unit 530, reducing over filling or over pressurizing of air chamber 532. Directional valve piston 511 is held stationary to the right inside directional valve 510 by the control air pressure in chamber 512 of directional valve 510. Maximally restricted left process air exiting efficiency valve 570 is channeled to directional valve 510 and blocked by directional valve piston 511. Unrestricted right process air exiting efficiency valve 580 is channeled through directional valve 510 and directional valve piston 511 to pump unit 520, expanding into air chamber 522 as once used process air is channeled to atmosphere from air chamber 532 out of pump unit 530 and through directional valve 510 and directional valve piston 511. Pistons 521, 531 and shaft 554 reverse their directions. Unrestricted right process air acts on piston 521 in pump unit 520 to discharge liquid from liquid chamber 523 as piston 531 in pump unit 530 draws liquid into liquid chamber 533.
(15) While this example refers to an embodiment with two efficiency units, one for left process air and the other for right process air, an alternative single efficiency unit embodiment could process both left and right process air inclusive. Such an embodiment would, therefore, combine certain elements of, for example, FIGS. 4 and 7.
Example 3
(16) The air-driven pump system described in Example 3 is shown in FIGS. 10-13. Starting with FIG. 10, inlet motive air enters the pneumatic pump. The inlet motive air enters both efficiency valves 440, 460 and is segmented into control air, left process air and right process air by efficiency valve piston 441, 461 respectively. Inlet motive air passes through restrictive orifice 462 inside efficiency valve piston 461 and control air exits efficiency valve 460 through port 463 and is channeled to directional valve 410 where it enters and pressurizes chamber 412 acting on the directional valve piston 411. Simultaneously, lower pressure once used left control air from second stage air chamber 422 in pump unit 420 enters efficiency valve 440 and passes around efficiency valve piston 441 exiting efficiency valve 440 through port 443 and is channeled to directional valve 410 where it enters and pressurizes chamber 413 acting on directional valve piston 411, allowing directional valve piston to move and be held to the left in directional valve 410. Left process air passes around efficiency valve piston 441, maximally restricted in its flow rate. Right process air passes through efficiency valve 460, unrestricted in its flow rate by efficiency valve piston 461. Both left and right process air are channeled to directional valve 410 from their respective efficiency valves 440, 460. Directional valve piston 411 positioned to the left in directional valve 410, blocks maximally restricted left process air and allows unrestricted right process air to pass through and exit directional valve 410. Unrestricted right process air is then channeled to first stage pump unit 470 where it expands and pressurize first stage air chamber 473 acting on piston 471. Pistons 471, 421 and 431 are conjoined by shaft 454. Once used fixed volume left process air in first stage air chamber 472 of first stage pump unit 470 exits first stage pump unit 470 and is channeled through directional valve 410 and directional valve piston 411 to pump unit 420 where it expands into and pressurizes larger volume second stage air chamber 422 to a lower pressure acting on piston 421. Both second stage air chamber 422 and first stage air chamber 472 are at equal lower pressures. Simultaneously, twice used right process air is released from second stage air chamber 432 out of pump unit 430 and channeled through directional valve 410 to atmosphere. The combined air pressure forces acting on pistons 471, 421 and 431, all conjoined by shaft 454, moves piston 471, 421 and 431 in a direction that displaces liquid from liquid chamber 423 in pump unit 420 and draws liquid into liquid chamber 433 in pump unit 430.
(17) In FIG. 11, inlet motive air moves efficiency valve piston 441 in efficiency valve 440 allowing left process air to exit efficiency valve 440 unrestricted in its flow as it is channeled to directional valve 410 where it continues to be blocked by directional valve piston 411 in directional valve 410. Inlet motive air passes through restrictive orifice 442 inside efficiency valve piston 441 and control air exits efficiency valve 440 through port 443 and is channeled to directional valve 410 where it continues to pressurize chamber 413 inside directional valve 410. Inlet motive air passes through restrictive orifice 462 inside efficiency valve piston 461 and control air exits efficiency valve 460 through port 463 and is channeled to directional valve 410 where it continues to pressurize chamber 412 inside directional valve 410. Both chambers 412, 413 in directional valve 410 are at equal pressures acting on directional valve piston 411 continuing to hold directional valve piston 411 to the left inside of directional valve 410. Towards the end of its stroke, piston 431 in pump unit 430 engages and moves efficiency valve piston 461 inside efficiency valve 460. Efficiency valve piston 461 in efficiency valve 460 is moved to a position that maximally restricts right process air flow rate out of efficiency valve 460 as it is channeled to directional valve 410.
(18) In FIG. 12, efficiency valve piston 461 in efficiency valve 460 is moved with annular seal 464 traversing port 463 to a position that redirects and releases channeled control air from chamber 412 in directional valve 410 through second stage air chamber 432 in pump unit 430 coupling with residual twice used right process air and then channeled through directional valve 410 to atmosphere.
(19) In FIG. 13, the combined control air pressure forces in chambers 412 and 413 of directional valve 410 have acted on and moved directional valve piston 411 to the right inside of directional vale 410 from the valve position of FIG. 12. During the movement of directional valve piston 411, maximally restricted right process air continues to flow at its maximally restricted flow rate channeled into first stage air chamber 473 of first stage pump unit 470, reducing over filling or over pressurizing of first stage air chamber 473. Directional valve piston 411 is held stationary by the control air pressure in chambers 412 and 413 inside directional valve 410. Maximally restricted right process air exiting efficiency valve 460 and channeled to directional valve 410 is blocked by directional valve piston 411. Unrestricted left process air exiting efficiency valve 440 and channeled to directional valve 410, passes through directional valve piston 411 and directional valve 410 channeled to first stage pump unit 470 where it expands and pressurize first stage air chamber 472 acting on piston 471 in first stage pump unit 470. Pistons 471, 421 and 431 are conjoined by shaft 454. Once used fixed volume left process air in first stage air chamber 473 of first stage pump unit 470 exits first stage pump unit 470 and is channeled through directional valve 410 and directional valve piston 411 to pump unit 430 where it expands into and pressurizes larger volume second stage air chamber 432 to a lower pressure acting on piston 431. Both second stage air chamber 432 and first stage air chamber 473 are at equal lower pressures. Simultaneously, twice used right process air is released from second stage air chamber 422 out of pump unit 420 and channeled through directional valve 410 to atmosphere. The combined air pressure forces acting on pistons 471, 421 and 431, all conjoined by shaft 454, moves piston 471, 421 and 431 in a direction that displaces liquid from liquid chamber 433 in pump unit 430 and draws liquid into liquid chamber 423 in pump unit 420. Simultaneously, lower pressure once used right control air from second stage air chamber 432 in pump unit 430 enters efficiency valve 460 and passes around efficiency valve piston 461 exiting efficiency valve 460 through port 463 and is channeled to directional valve 410 where it enters and pressurizes chamber 412 acting on directional valve piston 411, allowing directional valve piston 411 to remain held to the right in directional valve 410.
DEFINITIONS
(20) The following definitions are provided for claim construction purposes:
(21) pThe word restrict does not mean to shut off completely. Accordingly, if a flow is restricted, the flow is not completely shut off.
(22) Present invention: means at least some embodiments of the present invention, and the use of the term present invention in connection with some feature described herein shall not mean that all claimed embodiments include the referenced features.
(23) Embodiment: a machine, manufacture, system, method, process and/or composition that may (not must) be within the scope of a present or future patent claim of this patent document; often, an embodiment will be within the scope of at least some of the originally filed claims and will also end up being within the scope of at least some of the claims as issued (after the claims have been developed through the process of patent prosecution), but this is not necessarily always the case; for example, an embodiment might be covered by neither the originally filed claims, nor the claims as issued, despite the description of the embodiment as an embodiment.
(24) Although the present invention has been described in connection with a preferred embodiment, it should be understood that modifications, alterations, and additions can be made to the invention without departing from the scope of the invention as defined by the claims.
