GB2385902A

GB2385902A - Pneumatic valve module with offset valves for compactness

Info

Publication number: GB2385902A
Application number: GB0204970A
Authority: GB
Inventors: Hugh Christopher Bramley; Matthew De Lecq Legresley; Michael H Hoey
Original assignee: IMI Vision Ltd; IMI Cornelius Inc
Current assignee: IMI Vision Ltd; Cornelius Inc
Priority date: 2002-03-02
Filing date: 2002-03-02
Publication date: 2003-09-03
Anticipated expiration: 2022-03-02
Also published as: GB0204970D0; GB2385902B

Abstract

A valve module comprises a plurality of pneumatic valves 1 arranged in groups 2, 3 with the valves 1 in one group 2 offset vertically and horizontally relative to the valves 1 in another group 3. Offsetting the valves 1 provides a compact arrangement in which the valves 1 can be mounted in stages 5, 6 stacked on top of one another and connected to ports in a base stage 7, via passageways between the valves 1.

Description

PNEUMATIC VALVES This invention concerns improvements in or relating to pneumatic valves and in particular, but not exclusively, a module for mounting a plurality of pneumatic valves in a compact manner.

Pneumatic valves are available in different sizes characterised by the width of an individual valve (18mm, 14mm, lOmm). The smaller pneumatic valves have a lower flow capability than the larger pneumatic valves. There is ever increasing market pressure to make pneumatic valve systems smaller, while maintaining the flow capability, to enable machines to fit into smaller footprints.

Various methods of mounting pneumatic valves on machines are known.

Pneumatic valves mounted individually onto a machine tend to be rectilinear in shape to allow them to be easily mounted onto frames, panels of the machine. Where more than one pneumatic valve is to be mounted onto a machine, manifold systems may be used in which several pneumatic valves are mounted side by side with common supply and exhaust systems.

A development of the manifold system employs pneumatic and electrical connections integrated into a common base with individual pneumatic valves mounted on the base. In this way, the pneumatic valves are mounted onto a machine in a more compact manner than would be the case if the pneumatic valves were mounted individually.

Another development uses a series of complete valve stages bolted together with tie rods to form a complete block of valves. Each stage contains a pneumatic valve assembly with associated solenoids and fluid passageways.

A limiting factor on the size of existing designs is that all the valve components have to fit within the width of the stage/manifold. To reduce the size of the pneumatic valve would result in a reduction in flow capability of the valves.

The present invention has been made from a consideration of the aforementioned problems and disadvantages of existing systems.

Thus, it is an object of the invention to provide an improved system of mounting a plurality of pneumatic valves in a compact manner.

It is a preferred object of the invention to provide a module for a plurality of pneumatic valves which is more compact than the known designs.

According to the present invention, we provide a module comprising a plurality of pneumatic valves and fluid passageways for each pneumatic valve wherein the valves are arranged in at least two groups offset relative to each other.

By arranging the valves in groups offset relative to each other, a more compact module containing a plurality of pneumatic valves can be obtained. In particular, the groups only need to be offset to leave sufficient space for the fluid passageways to both groups and will typically be less than the space required to accommodate another pneumatic valve.

Preferably, the groups are offset in two directions, for example horizontally and vertically. This arrangement allows the fluid connections of both groups to be arranged on one side of the module. The module can therefore be mounted on a machine with this side available for fluid connection to external devices. This facilitates mounting of the module and simplifies the fluid connections to the module.

In its simplest form, the module of the present invention can be constructed with two valves, one in each group. More usually, however, the module will include a plurality of valves in each group, for example two or four valves in each group.

The advantage of the offset arrangement of the groups in reducing the overall size of the module is particularly beneficial where each group contains a plurality of valves. Thus, we have found that a reduction in overall size of approximately one third can be achieved with the offset arrangement of the present invention compared to existing designs with the same number of valves. Further reductions in overall size may be possible by careful design of the fluid passageways and connections to the module.

Preferably, each main valve is a pneumatic valve controlled by one or more electro-pneumatic switching devices for actuating the valve. In a preferred arrangement, the module is provided with a main air feed common to all the valves and each switching device controls a pilot air feed for actuating the associated valve to control connection of the main air feed to a connector port.

The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings in which :- Figure 1 shows a side view of a module according to the invention; Figure 2 shows a bottom view of the module; Figure 3 shows a perspective view of the module; Figure 4 shows an exploded perspective view of the module; and Figure 5 shows a perspective view of the module having a section cut-away along line A-A of Figure 1.

With reference to the drawings, a module according to invention is shown containing eight pneumatic valves 1 arranged in first and second groups 2 and 3. It will be understood, however, that the invention has application to modules having a larger or smaller number of valves and, its simplest form, the invention may be applied to a module containing two valves.

The module 1 comprises four stages, a control stage 4, an upper valve stage 5 containing the first group 2 of four pneumatic valves 1, a lower valve stage 6 containing the second group 3 of four pneumatic valves 1 and a base stage 7. The stages 4,5, 6 and 7 are stacked on top of each other to form an integrated unit for mounting on a machine. In this embodiment the stages are moulded as single units, however it will be understood that each stage can be constructed of a number of components.

The stages 4,5, 6,7 are provided on front and rear edges of facing sides with trepezial abutment formations 8. The abutment formations 8 define

indent regions 9 for receiving the abutment formations 8 of the adjacent stage 4,5, 6,7 to align the stages 4,5, 6,7 during assembly of the module and prevent lateral movement of the stages 4,5, 6,7 when the module is assembled.

The pneumatic valves 1 are positioned in transverse through bores 10 in the upper and lower valve stages 5 and 6 with the valves 1 of the upper stage 5 being offset vertically and horizontally relative to the valves 1 of the lower stage 6. In this way, the space required to accommodate the valves 1 is reduced compared to an arrangement in which all the valves are positioned side by side.

As best shown in Figure 2, the base stage 7 is provided with a main air feed port 50, a pair of air exhaust ports 51,52, a pair of pilot air feed ports 53,54 and sixteen connector ports 55.

The main air feed port 50 communicates with a main air feed gallery 56 within the module and is connectable to an external air source (not shown.

The air exhaust ports 51,52 communicate with air exhaust galleries 57,58 respectively within the module and are connectable to air exhaust collectors (not shown).

The pilot air feed ports 53,54 communicate with pilot air feed galleries 59,60 respectively within the module and are connectable to external pilot air sources (not shown). In a modification (not shown), the pilot air feed galleries 59,60 may be connected to an internal pilot air source.

Each connector port 55 communicates with a respective fluid passageway 61 within the module and is connectable to an external device (not shown).

Each valve 1 of the upper stage 5 controls fluid connections to fluid passageways 61a, 61b of a pair of ports 55a, 55b respectively and each valve 1 of the lower stage 6 controls fluid connections to fluid passageways (not shown) of a pair of ports 55c, 55d respectively.

The valves 1 of the lower stage 6 are uniformly spaced apart a sufficient distance that the fluid passageways 61a, 61b of pairs of ports 55a, 55b associated with valves 1 of the upper stage 5 can pass between adjacent valves 1 of the lower stage 6.

In this way, all the fluid connections to the module can be made via base stage 7 on one side of the module. It will be understood, however, that the compact arrangement of the valves 1 may be employed with the fluid connections being provided at other positions on one or more sides of the module.

In addition, a compact arrangement of the ports in the base stage 7 is provided by positioning the pairs of ports 55a, 55b associated with valves 1 of the upper stage 5 between and offset relative to the pairs of ports 55c, 55d associated with the valves of the lower stage 6.

This facilitates connecting fittings of external devices to the ports 55 and provides space to accommodate the other ports for the main and pilot air supplies and the exhaust collectors in a compact manner that reduces the overall space required for the fluid connections to the module. As

shown, the arrangement of the ports in the base stage is symmetrical about the line X-X.

Referring now to Figures 3 to 5, each pneumatic valve 1 is similar and consists of a tubular spacer pack 11 received in a central section of the bore 10 and two control units 12,13 received in enlarged end sections of the bore 10.

The spacer pack 11 defines a fluid channel 14 separated into five regions 16,17, 18,19, 20 by annular flanges 21 having aligned holes 22 of identical. size. Each region 16,17, 18,19, 20 includes a radial port' 16a, 17a, 18a, 19a, 20a.

The centre port 18a communicates with the main air gallery 56. The intermediate ports 17a, 19a communicate with fluid passageways 61 of a pair of ports 55. The port 16a communicates with the exhaust air gallery 57 the port 20a communicates with the exhaust air gallery 58.

Each control unit 12,13 is similar and comprises a spool 30, a sleeve 31 and an end cap 32. The sleeve 31 is received in the enlarged end section of the bore 10 and is releasably secured by the end cap 32.

In this way, the control units 12,13 can be detached and the spacer pack 15 removed to allow the valve 1 to be replaced by another valve for repair, maintenance of the module or to fit a different size of valve.

In this embodiment, the end cap 32 is provided with opposed ears 33 engageable with notches 34 in the appropriate stage 5,6 in the manner of a bayonet fitting to secure releasably the sleeve 31.

The end cap 32 is also provided with a blind slot 80 for insertion of a tool (not shown) such as a screwdriver for rotating the end cap 32. during assembly/disassembly of the valve 1.

The front end of the spool 30 is received in the spacer pack 15 and is slidable in the spacer pack for controlling fluid flow between regions of the fluid channel 14 as described later herein.

The rear end of the spool 30 has a portion 35 of enlarged diameter that is slidable in the sleeve 31 and divides the sleeve 31 internally into a rear chamber 36 and a front chamber 37.

The rear chamber 36 is connected via a radial hole 38 in the end cap 32 to a pilot passage 39 and the front chamber 37 is connected via a radial hole in the sleeve 31 to a pilot return gallery 40.

Each control unit 12,13 is operable via a respective solenoid 41,42 mounted in the control stage 4.

The solenoid 41 is connected to the pilot air gallery 59 and is operable to connect selectively the pilot passage 39 of the control unit 12 to the pilot air gallery 59 or to a vent channel 44. The pilot air gallery 59 is common to the solenoids 41 controlling the control units 12 of all the valves 1 in both stages 5,6.

The solenoid 42 is connected to the pilot air gallery 60 and is operable to connect selectively the pilot passage 39 of the control unit 13 to the pilot air gallery 60 or to a vent channel 46. The pilot air gallery 60 is common to the solenoids 42 controlling the control units 13 of all the valves 1 in both stages 5,6.

The control stage 4 further includes a control board 47 with electrical connectors 48 and a removable cover 81. The connectors 48 are accessible externally of the cover 81 for connecting each solenoid 41,42 to a voltage source for controlling actuation of the valves 1 as now described with particular reference to Figure 5 which shows a section through a control valve 1 of the upper stage 5.

The control unit 13 on the left hand side is shown with its spool 30 in a retracted position in which fluid passageway 61b is connected to exhaust gallery 58 via land 49 in the spool 30. In this position, the spool 30 isolates the passageway 61b from the main air feed gallery 56 and solenoid 42 connects the rear chamber 36 to vent channel 46.

The control unit 12 on the right hand side is shown with its spool 30 in an extended position in which fluid passageway 61a is connected to main air feed gallery 56 via land 49 in the spool 30. In this position, the spool 30 isolates the passageway 61a from the exhaust gallery 57 and the solenoid 41 connects the rear chamber 36 to pilot air feed gallery 59.

Actuation of the solenoids 41,42 to reverse the fluid connections to the rear chambers 36 of both control units 12,13 causes the positions of the spools 30 to reverse so that the fluid passageway 61b is connected to the main air feed gallery 56 and the fluid passageway 61a is connected to the exhaust gallery 57.

In this way, the control units 12,13 of each valve 1 can be operated in tandem to connect opposite sides of an external device connected to ports 55a, 55b to an air pressure source and to an exhaust collector and these connections can be reversed, for example to reciprocate a working piston.

As will now be appreciated, the offset arrangement of valves in two or more groups enables several pneumatic valves to be mounted in a single block (module) which is more compact than existing systems for mounting pneumatic valves.

It will be understood, moreover, that the invention is not limited to the above described embodiment and various modifications and alterations can be made.

For example, the module can be designed to hold any number of pneumatic valves arranged in two or more offset groups as desired.

The module can be made of up any number of separate stages with locating formations for assembly of the stages as described.

Alternatively, the stages may be formed integrally in one piece for assembly of the valves and other components.

Fluid tight connections may be provided by close fitment along interfaces of adjacent components of the module. This simplicity construction and assembly of the module. It will be understood, however, that fluid tight connections could be made with gaskets, elastomer seals or other similar devices.

The arrangement of the passageways within the module has been described for valves having a pair of spools controlling fluid connections to a pair of fluid passageways. This is not essential, however, and the invention has application to a variety of spool configurations to vary the output.

As used herein, the terms, horizontal, vertical, upper and lower are used for convenience and refer to the orientation of the module illustrated in the drawings. It will be understood, however, that the invention is not limited thereby and that all arrangements and orientations of the module are envisaged within the scope of the invention.

Furthermore, it will be appreciated that the term"pneumatic"includes any fluid medium and is not limited to air.

Claims

CLAIMS 1. A module comprising a plurality of pneumatic valves and fluid passageways for each pneumatic valve wherein the valves are arranged in at least two groups offset relative to each other.
2. A module according to claim 1 wherein the groups are offset in two directions.
3. A module according to claim 2 wherein the two directions are mutually perpendicular.
4. A module according to any preceding claim wherein each group comprises a plurality of valves.
5. A module according to any preceding claim wherein each pneumatic valve is controlled by one or more electro-pneumatic switching devices for actuating the valve.
6. A module according to claim 5 wherein a main air feed is provided common to all the valves and each switching device controls a pilot air feed for actuating the associated valve to control connection of the main air feed to a connector port.
7. A module according to any preceding claim comprising a plurality of stages including a control stage, an upper valve stage containing a first group of pneumatic valves, a lower valve stage containing a second group of pneumatic valves and a base stage.

<Desc/Clms Page number 13>
8. A module according to claim 7 wherein the stages are stacked on top of each other to form an integrated unit for mounting on a machine.
9. A module according to claim 7 or claim 8 wherein adjacent stages are provided with interengageable formations to align the stages and prevent lateral movement of the stages.
10. A module according to any one of claims 7 to 9 wherein the base stage is provided with a main air feed port, a pair of air exhaust ports, a pair of pilot air feed ports and a plurality of connector ports.
11. A module according to claim 10 wherein the main air feed port communicates with a main air feed gallery within the module and is connectable to an external air source.
12. A module according to claim 10 or claim 11 wherein the air exhaust ports communicate with respective air exhaust galleries within the module and are connectable to air exhaust collectors.
13. A module according to any one of claims 10 to 12 wherein the pilot air feed ports communicate with respective pilot air feed galleries within the module and are connectable to pilot air sources.
14. A module according to any one of claims 10 to 13 wherein each connector port communicates with a respective fluid passageway within the module and is connectable to an external device.
15. A module according to claim 14 wherein each valve controls fluid connections to fluid passageways of a respective pair of connector ports.

<Desc/Clms Page number 14>
16. A module according to claim 15 wherein the valves of the lower stage are uniformly spaced apart a sufficient distance that the fluid passageways of pairs of connector ports associated with valves of the upper stage can pass between adjacent valves of the lower stage.
17. A module according to claim 15 or claim 16 wherein the arrangement of the connector ports in the base stage is symmetrical.
18. A module according to any of claims 10 to 17 wherein the pneumatic valves are positioned in transverse through bores in the upper and lower valve stages.
19. A module according to claim 18 wherein each pneumatic valve consists of a tubular spacer pack received in a central section of the bore and two control units received in enlarged end sections of the bore.
20. A module according to claim 19 wherein the spacer pack defines a fluid channel separated into five regions and each region includes a radial port.
21. A module according to claim 20 as dependent on claim 11 wherein a centre port communicates with the main air gallery, intermediate ports on either side of the centre port communicate with respective fluid passageways of a pair of connector ports and outer ports communicate with respective exhaust air galleries.
22. A module according to claim 19 wherein each control unit comprises a spool, a sleeve and an end cap.

<Desc/Clms Page number 15>
23. A module according to claim 22 wherein each control unit is detachable.
24. A module according to claim 22 or claim 23 wherein a front end of the spool is received in the spacer pack and is slidable in the spacer pack for controlling fluid flow between regions of the fluid channel.
25. A module according to claim 24 wherein a rear end of the spool is slidable in the sleeve and divides the sleeve internally into a rear chamber and a front chamber.
26. A module according to claim 25 wherein the rear chamber is connected via a radial hole in the end cap to a pilot passage and the front chamber is connected via a radial hole in the sleeve to a pilot return gallery.
27. A module according to claim 26 wherein each control unit is operable via a respective solenoid mounted in the control stage.
28. A module according to claim 26 wherein the solenoid is connected to the pilot air gallery and is operable to connect selectively the pilot passage of the control unit to the pilot air gallery or to a vent channel.
29. A module according to claim 28 wherein the pilot air gallery is common to solenoids controlling the control units of all the valves in both stages.
30. A module according to claim 27 wherein the control stage further includes a control board with electrical connectors for connecting each solenoid to a voltage source for controlling actuation of the valves.

<Desc/Clms Page number 16>
31. A module according to claim 27 wherein the control units of each valve are operable to connect one of the connector ports to the main air feed gallery and the other connector port to the exhaust gallery and to reverse the connections in response to actuation of the solenoids.
32. A module substantially as hereinbefore described with reference to the accompanying drawings.