Automated integrated input-output control system apparatus

• US 5,923,558 A
• Filed: 06/06/1997
• Issued: 07/13/1999
• Est. Priority Date: 06/06/1995
• Status: Expired due to Term

• Current Assignee: The Fusion Bonding Corporation
• Original Assignee: The Fusion Bonding Corporation
• Inventors: Fix, John William Jr.
• Primary Examiner(s): Grant, William
• Assistant Examiner(s): Marc, McDieunel, Marc, McDieunel
• Application Number:
  US08/870,949
• Time in Patent Office: 767 Days
• Field of Search: 364/474.02, 701/102, 701/103, 701/104, 701/105, 137/536, 137/540, 451/65, 706/903, 706/904, 706/906, 706/907, 706/911, 706/912, 706/919, 166/70, 166/153, 123/401
• US Class Current: 700/160
• CPC Class Codes: B23K 20/121 Control circuits therefor
• CPC Class Codes: B23K 20/1285 Portable friction welding machines
• CPC Class Codes: Y10S 706/903 Control
• CPC Class Codes: Y10S 706/904 Manufacturing or machine, e.g. agricultural machinery, machine tool
• CPC Class Codes: Y10S 706/906 Process plant
• CPC Class Codes: Y10S 706/907 Power plant

Abstract

The automated integrated input-output control system apparatus. A versatile industrial control apparatus that can be utilized as a modular unit or integrated into industrial machinery or tools to provide an apparatus and method for programmable control of industrial tools, industrial controls and manufacturing operation processes. The automated integrated input-output control system apparatus includes the following components: a control-power mechanism housing, a sensor, input attachment devices, output attachment device, and a control system.

Claims

1. An automated integrated input-output control system apparatus for programmable control of tools, machinery and manufacturing processes, where the control system comprises input capability, output capability, and programmable capability, said apparatus comprising:

an automated integrated input-output control system apparatus, comprising a control-power mechanism housing, a piston slidably and axially disposed in said automated integrated input-output control system apparatus housing so that axial movement is achieved when a differential pressure force is produced;

an input means disposed in said control-power mechanism housing to permit attachment of input devices;

an output means disposed in said control-power mechanism housing to permit attachment of output devices; and

and, for providing for controlling said input devices and output devices.

2. The apparatus of claim 1 wherein said control system is programmable.

3. The apparatus of claim 2 wherein said control system can be incorporated in said control-power mechanism housing or be made integral to a portable tool or fixed machine application.

4. The apparatus of claim 1 wherein said input means provides for input connection interface to external machinery, control systems, tools or other remote apparatuses.

5. The apparatus of claim 4 wherein said input connection interface may be a threaded, bolted, twist lock or other type connection.

6. The apparatus of claim 1 wherein said output means provides for output connection interface with external machinery, control systems, tools or other remote apparatuses.

7. The apparatus of claim 6 wherein said output connection interface may be a threaded, bolted, twist lock or other type connection.

8. The apparatus of claim 1 wherein said piston is generally cylindrical in shape and can be fabricated from a variety of materials.

9. The apparatus of claim 8 wherein said piston contains valve flow output ports matched to the output flow geometry of the housing and further matches the output flow geometry of said control-power mechanism housing, so as to provide two way, three way and four way valve flow outputs.

10. The apparatus of claim 1 wherein said control-power mechanism housing further comprises one or more pressurized chambers defined within said control-power mechanism housing, wherein said pressurization chambers are in fluid communication with a source of pressurized fluid.

11. The apparatus of claim 10 further comprising pressure seals disposed externally on said piston to prevent fluid pressure from escaping said pressurization chambers during control sequencing phases.

12. The apparatus of claim 10 wherein said piston is slidably and axially disposed within said control-power mechanism housing, and further wherein introduction of fluid in said pressurized chambers results in axial movement of said piston within said control-power mechanism housing, thereby permitting opening and closing of said valve flow output ports.

13. The apparatus of claim 1 wherein said housing comprises a support means to attach said housing to machinery.

14. The apparatus of claim 13 where said support means can be a bracket which may be bolted on to said housing and attached to machinery.

15. The apparatus of claim 1 wherein said apparatus components can be integrated into a specific machine or portable tool.

16. The apparatus of claim 1 wherein said automated integrated input-output control system apparatus can be used as a modular control system attached to a portable air tool.

17. An automated integrated input-output control system apparatus for programmable control of tools, machinery and manufacturing processes, where the control system comprises input capability, output capability, and programmable capability, said apparatus comprising:

a programmable control system for controlling the operation of said apparatus comprising control flow passages and control elements;

an automated integrated input-output control system apparatus, comprising a control-power mechanism housing, a piston slidably and axially disposed in said automated integrated input-output control system apparatus housing so that an axial force is produced;

a fluid supply system comprising a plurality of pressure-flow passages operably connected to said control-power mechanism housing, said fluid system conveying fluid to said control system to circulate fluid to said input devices and said output devices;

an input connection interface means disposed in said control-power mechanism housing to permit attachment of input devices;

an output connection interface means disposed in said control-power mechanism housing to permit attachment of output devices;

a remote adjustable programmable sensor element which is attachable to remote machinery and to said control-power mechanism housing;

one or more pressurization chambers defined with said control-power mechanism housing, wherein said pressurization chambers are in fluid communication with a source of pressurized fluid; and

a regulating device connected to said plant air is pressurized and is supplied to said apparatus through a releasable coupling element attached to said control-power mechanism housing.

18. The apparatus of claim 17 wherein said control-power mechanism housing output ports are arranged so as to provide two way valve, three way valve and four way valve high flow high pressure output characteristics, and further said output connection interface means disposed in said control-power mechanism housing to permit attachment of output devices as required to meet specific flow conditions.

19. The apparatus of claim 18 wherein said control-power mechanism housing output ports can be plugged so as to specifically provide for two way valve, three way valve and four way valve high flow high pressure output characteristics.

20. The apparatus of claim 17 wherein said piston geometry is designed to match said control-power mechanism housing output ports so as to provide two way valve, three way valve and four way valve high flow high pressure output characteristics.

21. The apparatus of claim 17 wherein said remote adjustable programmable sensor element can be mounted on machinery, further said remote adjustable programmable sensor element can be connected to said input connection interface means disposed in said control-power mechanism housing to permit the sensing of a component or machine operation.

22. The apparatus of claim 17 wherein said input connection interface means disposed in said control-power mechanism housing to permit the connection of input devices such as hydraulic, pneumatic, mechanical, electrical and other devices such as transducer devices that convert all input signals to pressurized fluid flow signals.

23. The apparatus of claim 17 wherein said output connection interface means disposed in said control-power mechanism housing to permit the connection of said apparatus to output devices such as machinery, tools, industrial equipment or other apparatuses that require pressurized fluid flow to operate.

24. A programmable control system for controlling the operation of automated integrated input-output control system apparatus comprising a control-power mechanism housing, a piston slidably and axially disposed in said automated integrated input-output control system apparatus housing so that various control functions are achieved when a differential axial force is produced so as to circulate pressurized fluid to specific areas under specific conditions;

a plurality of pressure-flow passages operably connected to said control-power mechanism housing, said flow system conveying fluid to said control system to circulate fluid to said input devices and said output devices;

a quick disconnect assembly through which plant air flow to said automated integrated input-output control system apparatus, said quick disconnect assembly releasably coupled to said control-power mechanism housing;

a piston seat to control the primary flow source entering said control-power mechanism housing;

a start valve connected to the control-power mechanism housing which permits an operator to start the circulation of plant air to said programmable control system and said output devices;

a stop valve connected to the control-power mechanism housing which permits an operator to stop the circulation of plant air to said programmable control system and said output devices;

a diagnostic ports disposed within said control-power mechanism housing which permits measurement of pressure at various points in the control system and output connections;

a programmable first timing means, disposed within said control-power mechanism housing, which overrides the programmable control system to shut down said automated integrated input-output control system apparatus after a preprogrammed time duration;

a programmable second timing means, analog or digital in operation, disposed within said control-power mechanism housing, which overrides the programmable control system after said start valve has been depressed for a preprogrammed time duration;

a multiport valve which overrides the control system connected to said control-power mechanism housing, so as to prevent premature operation of said automated integrated input-output control system apparatus;

a remote programmable sensor coupled to said control-power mechanism housing, which permits programming of a desired position of an industrial or machine tool component and measures the position of said machine tool component in a fixed relationship with a specific component in a manufacturing or machine tool application, so as to provide a pressure signal to start or stop the circulation of pressurized fluid to the output device when the desired relative position is reached;

a timed vent input disposed within said control-power mechanism housing, which permits depressurization of an external device;

a programmable regulator disposed within said control-power mechanism housing for supplying low pressure low flow output fluid; and

the said automated integrated input-output control system apparatus can be made integral to specific machinery or portable hand tools to provide programmable operational characteristics.

25. The apparatus of claim 24 wherein said control system will accept input signals from external tools, machinery or manufacturing processes.

26. The apparatus of claim 25 wherein said control system input signal can be an input signal an apparatus capable of providing an output signal.

27. The apparatus of claim 26 wherein said control system input signal from a pneumatic device can be directly fed into said control system.

28. The apparatus of claim 25 wherein said control system input signal from an electrical, electronic, hydraulic, mechanical or other apparatus is made compatible via a transducer.

29. The apparatus of claim 28 wherein said transducer will convert control system input signal from an apparatus to a pneumatic input.

30. The apparatus of claim 24 wherein said control system comprises a remote sensor mechanism.

31. The apparatus of claim 30 wherein said sensor is programmable adjustable and connected to said housing by means of a pressurized fluid line.

32. The apparatus of claim 31 wherein said sensor feeds its pressure signal to provide an input control signal by means of a matched pressure transducer which is disposed in said control-power mechanism housing.

33. The programmable control system of claim 24 wherein said plant air is pressurized and is supplied to said programmable control system and main output system through a pressure flow line releasably coupled to said control-power mechanism housing.

34. The programmable control system of claim 24 wherein said programmable first timing means and said programmable second timing means can be digital or analog devices.

35. The programmable control system of claim 24 wherein said programmable vent means provides for a timed vent operation of an externally attached device.

36. The programmable control system of claim 24 wherein said plant air is pressurized and is supplied to said programmable control system through a releasable coupling element attached to said control-power mechanism housing.

37. A control apparatus comprising:

a body;

a differential flow valve disposed within said body and defining upper, lower and inlet pressurization chambers, where each of said chambers are selectively coupled in flow communication to fluid flow passages disposed in said body; and

a second valve to control the circulation of pressurized fluid to said differential valve; and

one or more output portals disposed in said body in selective, fluid communication with said differential valve.

38. The control apparatus of claim 37 wherein said differential flow valve comprises a piston slidably disposed within said body between a first and second position, where the movement of said piston is induced by differential fluid pressure between said upper and lower pressurization chambers.

39. The control apparatus of claim 37 further including a control system disposed within said body and comprising one or more fluid flow passages operatively disposed with respect to said differential flow valve.

40. The control apparatus of claim 39 further including a first and second timing means, where said first timing means is adapted to override the control system after a pre programmed time period and said second timing means is adapted to override the control system to provide for the operation of the apparatus for a programmed timing period.

41. The control apparatus of claim 37 where said control system further comprises:

an inlet portal through which pressurized air is fed into said body;

diagnostic ports disposed in said body to measure pressure throughout said system; and

a multiport valve coupled in fluid communication to said differential valve to allow the override of said control system.

42. The control apparatus of claim 37 further comprising a sensor means coupled in fluid communication with said differential valve.

43. The control apparatus of claim 42 where said sensor means is remotely positioned from said body.

44. The control apparatus of claim 37 further comprising a sensor transducer disposed in said body in fluid communication with said sensor means, where said transducer operates to move the differential flow valve between the first and second position upon receiving a pressure signal from said sensor means.

45. An apparatus for controlling the transmissions of pressurized fluid signals comprising:

a housing defining therein a bore;

a piston slidably disposed in said bore between a first and a second position, said piston defining an upper, lower and intermediate chamber in said bore, where the reciprocation of said piston between said first and second position is caused by differential pressure between said upper and lower chambers;

a control system disposed within said housing and disposed in fluid communication with said upper, lower and intermediate chambers, said system comprising one or more fluid passages disposed in said housing and an inlet portal through which a pressurized fluid is introduced into one or more of said passage;

first and second timing means disposed in said housing in fluid communications with said control system, said first and second timing means operative to override said control system to control fluid flow therethrough;

a sensor means coupled in fluid communication to said control system; and

a pressure transducer disposed in said housing and in fluid communication with said sensor means and said control system to selectively introduce fluid into said upper or lower chambers to move said piston between said first and second positions upon receiving a pressurized signal from said sensor means.

46. The apparatus of claim 45 where said control system further comprises:

diagnostic ports disposed in said body to measure fluid pressure through said system;

a multiport valve coupled in fluid communication to said piston to allow an override of said control system; and

one or more exhaust ports coupled in fluid communication to one or more of said chambers.

47. The apparatus of claim 45 where said sensor means further includes a pressure seal and means to allow the adjustment of said seal from a workpiece.

48. The apparatus of claim 45 where said sensor is remotely situated from the housing.

49. The apparatus of claim 45 where fluid pressure in said control system is maintained at a range of 80-120 pounds per square inch.

50. The apparatus of claim 45 where flow valve through said control system is maintained in a range of 3-100 cubic feet per minute.