Energy saving vacuum system for particle, mist, and fume collection

• US 7,146,677 B2
• Filed: 11/19/2002
• Issued: 12/12/2006
• Est. Priority Date: 11/19/2002
• Status: Active Grant

• Current Assignee: Ales Litomisky, Ivan Litomisky, Petr Litomisky
• Original Assignee: Ales Litomisky, Ivan Litomisky, Petr Litomisky
• Inventors: Litomisky, Ivan, Litomisky, Ales, Litomisky, Petr
• Primary Examiner(s): Till, Terrence R.
• Application Number:
  US10/300,179
• Publication Number:
  US 20040093682A1
• Time in Patent Office: 1,484 Days
• Field of Search: 153/01, 153/14, 153/31, 153/39, 137/240, 251/81, 251/129.11, 251/301, 251/302
• US Class Current: 15/301
• CPC Class Codes: A47L 5/38 Built-in suction cleaner installations, i.e. with fixed tube system to which, at different stations, hoses can be connected
• CPC Class Codes: A47L 9/2805 Parameters or conditions being sensed
• CPC Class Codes: A47L 9/2842 Suction motors or blowers
• CPC Class Codes: A47L 9/2857 User input or output elements for control, e.g. buttons, switches or displays
• CPC Class Codes: A47L 9/2868 Arrangements for power supply of vacuum cleaners or the accessories thereof
• CPC Class Codes: A47L 9/2889 Safety or protection devices or systems, e.g. for prevention of motor over-heating or for protection of the user
• CPC Class Codes: A47L 9/2894 Details related to signal transmission in suction cleaners
• CPC Class Codes: B23D 59/006 for removing or collecting chips
• CPC Class Codes: B23Q 11/0046 by sucking

Abstract

An improved energy-efficient vacuum system for machine shop dust, particulate matter, and the like. Blast gates, including large-diameter blast gates, control the flow of vacuum generated by a dust collector to individual machines that may or may not accommodate vacuum ductwork and the like. The blast gate has a rotating blade inside a chassis with a DC motor effectively using a slip clutch, an increased current feedback system, a biasing-spring assembly or otherwise to limit the rotation driving of the rotating blade. In one embodiment, the blast gate blade bears teeth about its perimeter. The DC motor engages the perimeter blade teeth with a gear. Greater mechanical advantage is achieved over the blast gate blade and less torque arises in contrast to a driving system located at the blade'"'"'s central pivot point. Additionally, sensing apparatus or system calculation allow the dust collecting vacuum system to operate in an energy-efficient manner. By supplying only the vacuum needed to collect present dust, energy is saved in comparison with a dust collection system operating continuously at full capacity.

Claims

1. A particle collecting system that saves energy due to reduced energy use, comprising:

a vacuum system, said vacuum system collecting particles by air flow created by reduced pressure drawn by said vacuum system;

a ductwork system, said ductwork system coupled to said vacuum system and transmitting said reduced pressure to a first particle collection point;

a first blast gate, said first blast gate coupled to said ductwork system, said blast gate controlling transmission of said reduced pressure and said air flow to said first particle collection point;

said first blast gate having;

1) a blast gate blade for selectably obstructing fluid flow, said blast gate blade pivoting on an axis and having teeth at a perimeter distal to said axis; and

2) a motor assembly, said motor assembly having a driving gear engaging said blade teeth;

whereby

3) selectable activation of said motor assembly controls disposition of said blade with respect to said axis, opening and closing said first blast gate by rotation of said driving gear;

a first sensor, said first sensor capable of sensing activity of a first machine generally creating particles when active;

a power controller, said power controller coupled to said vacuum system and controlling activity of said vacuum system, said power controller increasing activity of said vacuum system when additional vacuum power is needed and decreasing activity of said vacuum system when less vacuum power is needed;

a system controller, said system controller coupled to said first blast gate, said first sensor, and said power controller, said system controller controlling operation of said first blast gate, said system controller receiving machine-activity signals of said first sensor, said system controller coupled to said power controller and controlling activity of said power controller; and

a blast gate blade travel limiting system limiting the continued travel of said blast gate blade such that said blast gate blade ceases turning when it reaches a fully closed or fully open position and said blast gate blade ceases turning when it is obstructed, said blast gate blade travel limiting system including a biasing system, said biasing system biasing said motor assembly proximate said blast gate blade, said biasing system biasing said driving gear to engage said blade teeth, said biasing system allowing temporary disengagement of said driving gear from said blade teeth;

such that said blast gate blade may be manually adjusted, manually opened, and manually closed with said motor assembly urged to reengage said blast gate blade by said biasing system;

whereby

said vacuum system is activated in a limited manner to a degree required to ensure proper particle collection, said limited activation of said vacuum system generally avoiding an “

always full on”

condition of said vacuum system and reducing energy used by said vacuum system to collect particles.

2. A particle collecting system that saves energy due to reduced energy use as set forth in claim 1, further comprising:

said air-velocity being maintained at 4000–

4500 feet per minute (FPM).

3. A particle collecting system that saves energy due to reduced energy use as set forth in claim 1, wherein said blast gate blade travel limiting system further comprises:

an electronic clutch coupled to said first blast gate, said electronic clutch sensing load upon said motor assembly and causing said motor assembly to operate according said load sensed by said electronic clutch.

4. A particle collecting system that saves energy due to reduced energy use as set forth in claim 1, wherein said biasing system further comprises:

a first spring.

5. A particle collecting system that saves energy due to reduced energy use as set forth in claim 1, wherein said first blast gate further comprises:

a blast gate shell, said blast gate shell coupled to said blast gate blade, said blast gate shell defining an aperture through which air may travel, said air travel through said aperture controlled by said blast gate blade, said aperture having a large size and allowing a large volume of air to travel therethrough.

6. A particle collecting system that saves energy due to reduced energy use as set forth in claim 5, further comprising:

said aperture having a diameter of at least twelve (12) inches.

7. A particle collecting system that saves energy due to reduced energy use as set forth in claim 1, further comprising:

said first sensor selected from the group consisting of piezoelectric sensors, toroidal sensors, current sensors, voltage sensors, limit switches, hall sensors, magnets, magnetic sensors, vibration sensors, and energy use sensors.

8. A blast gate for use in controlling fluid flow, including gas flow, comprising:

a blast gate blade for selectably obstructing fluid flow, said blast gate blade pivoting on an axis and having teeth at a perimeter distal to said axis;

a motor assembly, said motor assembly having a driving gear engaging said blade teeth; and

a blast gate blade travel limiting system limiting the continued travel of said blast gate blade such that said blast gate blade ceases turning when it reaches a fully closed or fully open position and said blast gate blade ceases turning when it is obstructed, said blast gate blade travel limiting system including a biasing system, said biasing system biasing said motor assembly proximate said blast gate blade, said biasing system biasing said driving gear to engage said blade teeth, said biasing system allowing temporary disengagement of said driving gear from said blade teeth such that said blast gate blade may be manually adjusted, manually opened, and manually closed with said motor assembly urged to reengage said blast gate blade by said biasing system;

whereby

selectable activation of said motor assembly controls, disposition of said blade with respect to said axis, opening and closing said first blast gate by rotation of said driving gear.

9. A blast gate for use in controlling fluid flow, including gas flow, as set forth in claim 8, wherein said blast gate blade travel limiting system further comprises:

an electronic clutch coupled to said first blast gate, said electronic clutch sensing load upon said motor assembly and causing said motor assembly to operate according said load sensed by said electronic clutch.

10. A blast gate for use in controlling fluid flow as set forth in claim 8, wherein said biasing system further comprises:

a first spring.

11. A blast gate for use in controlling fluid flow as set forth in claim 8, wherein said first blast gate further comprises:

a blast gate shell, said blast gate shell coupled to said blast gate blade, said blast gate shell defining an aperture through which fluid may travel, said fluid travel through said aperture controlled by said blast gate blade, said aperture having a large size and allowing a large volume of fluid to travel therethrough.

12. A blast gate for use in controlling fluid flow as set forth in claim 11, further comprising:

said aperture having a diameter between four (4) to twenty (20) inches or larger.

13. A blast gate for use in controlling fluid flow, including gas flow, comprising:

a blast gate blade for selectably obstructing fluid flow, said blast gate blade pivoting on an axis and having teeth at a perimeter distal to said axis; and

a motor assembly, said motor assembly having a driving gear engaging said blade teeth

a blast gate blade travel limiting system limiting the continued travel of said blast gate blade such that said blast gate blade ceases turning when it reaches a fully closed or fully open position and said blast gate blade ceases turning when it is obstructed, said blast gate blade travel limiting system including a biasing system, said biasing system biasing said motor assembly proximate said blast gate blade, said biasing system biasing said driving gear to engage said blade teeth, said biasing system allowing temporary disengagement of said driving gear from said blade teeth such that said blast gate blade may be manually adjusted, manually opened, and manually closed with said motor assembly urged to reengage said blast gate blade by said biasing system;

a blast gate shell, said blast gate shell coupled to said blast gate blade, said blast gate shell defining an aperture through which fluid may travel, said aperture having a diameter of at least twelve (1.2) inches, said fluid travel through said aperture controlled by said blast gate blade, said aperture having a large size and allowing a large volume of fluid to travel therethrough;

whereby

selectable activation of said motor assembly controls disposition of said blade with respect to said axis, opening and closing said first blast gate by rotation of said driving gear.

14. An automatic machine shop vacuum system, comprising:

a dust collector, said dust collector creating a vacuum;

at least one machine, said machine generating dust or shavings to be collected by said dust collector, said machine coupled to said, dust collector by a duct, said duct transmitting vacuum pressure to said machine;

a blast gate valve, said blast gate valve coupled to said duct and selectably controlling transmission of said vacuum pressure to said machine;

said blast gate having;

1) a blast gate blade for selectably obstructing fluid flow, said blast gate blade pivoting on an axis and having teeth at a perimeter distal to said axis; and

2) a motor assembly, said motor assembly having a driving gear engaging said blade teeth such that selectable activation of said motor assembly controls disposition of said blade with respect to said axis, opening and closing said blast gate by rotation of said driving gear;

(3) a chassis, said chassis connectable to vacuum system duct work, said chassis defining a flow channel through which the vacuum pressure is transmitted, said chassis defining a central gap, said central gap extending outwardly away from said flow channel;

(4) said blast gate blade being a rotating blade, said rotating blade pivotably coupled to said chassis, said rotating blade having teeth at its perimeter, said rotating blade traveling within said central gap, said rotating blade having an optimal teardrop or pear shape for conserving materials and providing a lightweight and effective occlusion blade and so that a majority of said rotating blade serves as an occluding portion of said occlusion blade for the blast gate valve, said rotating blade passing entirely through said gap so that said rotating blade extends past a perimeter of said flow channel to better occlude transmission of vacuum pressure;

(5) an air inlet, said air inlet defined by said chassis adjacent said flow channel, said air inlet interconnecting an environment external to said chassis with said central gap whereby debris such as dust, shavings, and the like are kept clear of said central gap by airflow through said air inlet when vacuum pressure is transmitted by the blast gate valve, said air inlet optimally positioned so that it intersects said central gap adjacent said rotating blade at a widest point of said rotating blade when the blast gate valve is closed;

(6) a semi-circular cut out section, said semi-circular cut out section defined by said chassis and spaced apart from said flow channel, said semi-circular cut out section allowing manual access to said rotating blade while reducing weight and materials required of said chassis;

(7) a DC motor, said DC motor coupled to said chassis and said rotating blade whereby said motor may rotate said rotating blade with respect to said chassis by engagement of said perimeter teeth, polarity of current supplied to said DC motor controlling a direction of rotation of said rotating blade;

(8) a washer, said washer coupled to one side of said chassis and coaxial with a drive shaft of said motor;

(9) a spring washer, said spring washer coupled to another side of said chassis and coaxial with said drive shaft; and

(10) a nut, said nut engaging said drive shaft adjacent said spring washer and holding said spring washer against said rotating blade, said washers forming a slip clutch so that said rotating blade is urged against said washer by said spring washer sufficient to hold said rotating blade in place with respect to said drive shaft when said rotating blade is free to turn, yet insufficient to hold said rotating blade in place with respect to said drive shaft when said rotating blade is not free to turn;

whereby

said rotating blade may pivotably rotate to selectably occlude said flow channel thereby opening and closing the blast gate valve;

a sensor, said sensor coupled to said machine and transmitting a signal when said machine is on that is different from a signal transmitted by said sensor when said machine is off; and

a controller, said controller coupled to said dust collector, said blast gate valve, and said sensor, said controller operating said dust collector in a regulated manner sufficient to collect dust and said controller operating said blast gate valve in response to said sensor signals;

whereby

dust generated by said machine during a machining process is automatically collected by said dust collector when said machine is turned on, said controller energizing said dust collector sufficient to collect said dust and opening said blast gate valve in response to sensor signals indicating the operation of said machine, said controller de-energizing said dust collector and closing said blast gate valve in response to sensor signals indicating the non-operation of said machine, said controller saving energy by limiting operation of said dust collector to supply necessary, but not excessive, vacuum power sufficient to collect dust.

15. The automatic machine shop vacuum system of claim 14, wherein said sensor is a sensor selected from the group consisting of:

piezoelectric sensors, toroidal sensors, current sensors, voltage sensors, limit switches, hall sensors, magnets, magnetic sensors, vibration sensors, and energy use sensors.

16. A blast gate valve for controlling transmission of vacuum pressure in a machine shop vacuum system, comprising:

a chassis, said chassis connectable to vacuum system duct work, said chassis defining a flow channel through which the vacuum pressure is transmitted, said chassis defining a central gap;

a rotating blade for selectably obstructing fluid flow, said rotating blade having teeth about a perimeter, said rotating blade pivotably coupled to said chassis, said rotating blade traveling within said central gap; and

a rotating blade travel limiting system limiting the continued travel of said rotating blade such that said rotating blade ceases turning when it reaches a fully closed or fully open position and said rotating blade ceases turning when it is obstructed, said rotating blade travel limiting system including a biasing system, said biasing system adapted to bias a motor assembly proximate said rotating blade, said biasing system adapted for biasing a driving gear to engage said teeth, said biasing system allowing temporary disengagement of said driving gear from said teeth such that said rotating blade may be manually adjusted, manually opened, and manually closed with said motor assembly urged to reengage said rotating blade by said biasing system;

whereby

said rotating blade may pivotably rotate to selectably occlude said flow channel thereby opening and closing the blast gate valve; and

wherein said chassis further comprises an air inlet, said air inlet defined by said chassis and adjacent said flow channel, said air inlet interconnecting an environment external to said chassis with said central gap;

whereby

debris such as dust, shavings, and the like are kept clear of said central gap by airflow through said air inlet when vacuum pressure is transmitted by the blast gate valve.

17. The blast gate valve of claim 16, wherein said air inlet is optimally positioned to keep debris clear of said central gap.

18. The blast gate valve of claim 17, wherein said air inlet is positioned so that it intersects said central gap adjacent said rotating blade at a widest point of said rotating blade when the blast gate valve is closed.