A PNEUMATIC ACTUATION SYSTEM AND METHOD THEREOF

Abstract

ABSTRACT A PNEUMATIC ACTUATION SYSTEM AND METHOD THEREOF The present disclosure relates to a pneumatic actuation system (100) comprising a Directional Valve Subsystem (102) with adjustable flow paths for precise gas flow control, enabling bidirectional motion in a Double-Acting Actuator Subsystem (104). The actuator subsystem includes two chambers (Chamber A, Chamber B) for independent gas input, a piston rod for translating pneumatic pressure into mechanical motion, and a thermal convection subsystem (106) integrated to dissipate heat generated during operation. The system further includes a Control Subsystem (108) to process control inputs and regulate valve operations and actuator movements via spool adjustments. A Feedback Subsystem (110) provides real-time monitoring of actuator displacement and thermal conditions, enabling closed-loop control for stable and efficient operation. This system is designed for high-demand industrial applications, offering precision motion control, efficient thermal management, and seamless automation capabilities. Its versatility and robustness make it ideal for automation, robotics, and other industrial processes.

Specification

Description:FIELD
The present disclosure relates to the industrial automation domain. More particularly, focusing on pneumatic actuation systems and their simulation.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Pneumatic systems play a crucial role in a wide range of industries, including automation, robotics, manufacturing, and medical devices. These systems rely on compressed air to generate motion and perform tasks that require significant force. Their simplicity, reliability, and cost-effectiveness make them an attractive choice for many applications. However, despite their widespread use, traditional pneumatic systems face challenges in achieving precise motion control, bidirectional actuation, and efficient thermal management.
One of the key limitations of conventional pneumatic systems lies in their control mechanisms. Many systems struggle to provide accurate, repeatable control over actuator movements, particularly in applications requiring both extension and retraction phases. This lack of precision can lead to inefficiencies, reduced productivity, and difficulties in meeting the demands of modern automation and robotics systems.
Another challenge is the lack of effective thermal management. Pneumatic systems generate heat during operation due to air compression, expansion, and flow through components. In high-duty cycles or continuous-use scenarios, this heat can accumulate, leading to overheating, reduced performance, and increased maintenance requirements. Most traditional systems fail to adequately model or address these thermal effects, resulting in unrealistic simulations and suboptimal configurations.
Additionally, the configuration and optimization of pneumatic systems often require detailed simulation tools to model the dynamic behaviour of components such as actuators, valves, and airflow paths. However, many existing simulation tools cannot accurately represent real-world conditions, including thermal interactions, flow dynamics, and system responsiveness. This gap hinders engineers and designers from developing efficient and reliable systems tailored to specific applications.
Therefore, there is a need for a pneumatic actuation system and method thereof that alleviates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.
An object of the present disclosure is to provide a pneumatic actuation system.
Another object of the present disclosure is to provide a system that offers precise and bidirectional control of pneumatic actuators for complex motion applications.
Still another object of the present disclosure is to provide a system that provides better control mechanisms and efficient airflow management.
Yet another object of the present disclosure is to provide a system that prevents overheating and simulates real-world operating conditions accurately.
Still another object of the present disclosure is to provide a system that provides detailed and realistic simulations of pneumatic dynamics, enabling better configuration, analysis, and optimization.
Yet another object of the present disclosure is to provide a system that simplifies setup and operation while offering advanced functionality for engineers and technicians in various industries.
Still another object of the present disclosure is to provide a system that can be easily customized and applied to diverse applications, from industrial automation to medical devices.
Yet another object of the present disclosure is to provide a method for operating a pneumatic actuation system.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure provides a pneumatic actuation system, comprising: a directional valve subsystem, a double-acting actuator subsystem, a thermal convection subsystem, a control subsystem, and a feedback subsystem.
The directional valve subsystem is configured with adjustable flow path paths for selectively controlling gas flow direction and pressure, the directional valve subsystem includes one or more valves (TA, PA, TB, PB) with dynamically adjustable flow restrictions based on a spool input (S) to enable precise opening and closing of flow paths.
The double-acting actuator subsystem operatively connected to the directional valve subsystem, the double-acting actuator subsystem including at least two chambers (Chamber A, Chamber B) configured to receive pressurized gas independently for generating bidirectional linear motion, and a mechanical converter having an actuator (piston rod) interfacing with the chambers configured to translate pneumatic pressure into mechanical motion.
The thermal convection subsystem, integrated into the flow paths, including pipes and chambers configured to dissipate heat generated during gas compression and flow via thermal convection to the surrounding environment to mitigate overheating.
The control subsystem is operatively coupled to the directional valve subsystem and the double-acting actuator subsystem, configured to receive control inputs and process the control inputs to generate spool input for the directional valve subsystem for regulating valve operations and actuator movements.
The feedback subsystem comprises sensors for real-time detection of actuator displacement and thermal conditions, enabling closed-loop control of system operation.
In an embodiment, the directional valve subsystem includes a spool mechanism configured for dynamic positioning, enabling precise control of gas flow in response to the control inputs.
In an embodiment, the system further comprises: a first Pipe A and a second Pipe B, a supply pipe, and a return pipe.
The first Pipe A and the second Pipe B are connected to the actuator chambers (QA, QB) for gas supply and exhaust.
The supply pipe for providing pressurized gas.
The return pipe for exhaust air to flow back to the environment, both equipped with convection elements (Convection Pipe A to Atm, Convection Pipe B to Atm, Convection Supply to Atm, and Convection Return to Atm) for thermal interactions with ambient surroundings.
In an embodiment, the double-acting actuator subsystem includes a piston mass and chamber walls.
The piston mass is coupled to the actuator (piston rod), facilitating bidirectional force transmission by balancing pneumatic pressure across the chambers (Chamber A, Chamber B).
The chamber walls are modelled with thermal mass (Wall Thermal Mass) to simulate heat transfer during actuation cycles.
In an embodiment, the thermal convection subsystem comprises a heat exchange interface configured to facilitate thermal convection between the pipes and the ambient environment under varying operational loads.
In an embodiment, the directional valve subsystem is capable of operating in multiple states, including a full-extension state, a full-retraction state, and a hold state.
The full-extension state to move the actuator rod (rod) outward.
The full-retraction state pulls the rod inward.
The hold state to maintain the rod in a stable position without additional locking mechanisms.
In an embodiment, the system further comprises a load simulation module coupled to the actuator for replicating resistance conditions encountered in real-world applications.
In an embodiment, the system further comprises a visualization interface configured to display system dynamics, including actuator movements, gas flow paths, and temperature gradients, in real time.
In an embodiment, the control subsystem comprises a closed-loop control mechanism for automatically adjusting actuator movements for bidirectional actuator motion and load stabilization.
In an embodiment, the system further comprises an integrated software module configured to execute thermal and flow dynamic simulations and provide actionable recommendations for system optimization based on real-time data.
The present disclosure provides a method for operating a pneumatic actuation system, comprising:
o receiving a control input at a control subsystem to initiate actuation, wherein the control input directs a directional valve subsystem to open a selected pathway for pressurized gas;
o channelling the gas to a designated chamber of a double-acting actuator subsystem to generate bidirectional motion;
o monitoring, a feedback subsystem, and system parameters using real-time feedback sensors to track actuator displacement and thermal conditions, enabling closed-loop control of system operation; and
o dissipating, by a thermal convection subsystem, heat from pressurized gas through thermal convection mechanisms embedded in gas pathways, based on the monitoring.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The pneumatic actuation system and method thereof, of the present disclosure will now be described with the help of the accompanying drawing in which:
Figure 1 illustrates a block diagram of a pneumatic actuation system in accordance with the present disclosure;
Figure 2 illustrates a method for operating a pneumatic actuation system, in accordance with the present disclosure;
Figure 3 illustrates the pneumatic actuation system, including the directional valve subsystem, double-acting actuator, and the pipe network with integrated thermal management elements, in accordance with the present disclosure;
Figure 4 shows the double-acting actuator with its chambers, piston mass, actuator rod, and convection elements for thermal dissipation between the chambers and walls, in accordance with the present disclosure;
Figure 5 depicts the directional valve subsystem, highlighting the spool mechanism, orifice blocks (TA, PA, TB, PB), and leakage flow paths for realistic airflow control, in accordance with the present disclosure;
Figure 6 illustrates a graphical plot of the mass flow rates through the valve orifices (Orifice TA, PA, TB, and PB) over time, showing the dynamic control of airflow during actuator operation, in accordance with the present disclosure;
Figure 7 illustrates a graphical plot of the pressures and temperatures in the actuator chambers (Chamber A and Chamber B) during the extension and retraction phases, highlighting the thermodynamic changes, in accordance with the present disclosure;
Figure 8 illustrates a graphical plot of the negative stroke of the spool versus the orifice area, showing how spool movement reduces orifice size to regulate air flow during actuator retraction, in accordance with the present disclosure;
Figure 9 illustrates a graphical plot of the positive stroke of the spool versus the orifice area, demonstrating how spool adjustments increase orifice size to control airflow during actuator extension, in accordance with the present disclosure;
Figure 10 illustrates a graphical plot of the heat flux (Q) and temperature gradient (K) between Chamber A and the wall, showing the thermal exchange during pressurized air compression and expansion, in accordance with the present disclosure;
Figure 11 illustrates a graphical plot of the heat flux (Q) and temperature gradient (K) between Chamber B and the wall, highlighting the thermal behaviour during the actuator's retraction phase, in accordance with the present disclosure; and
Figure 12 illustrates a graphical plot of the transitional damper results, showing the damping force (f), power dissipation, and rod displacement, which ensure actuator stability during motion transitions.
LIST OF REFERENCE NUMERALS
100 Pneumatic Actuation System
102 Directional Valve Subsystem
104 Double-Acting Actuator Subsystem
106 Thermal Convection Subsystem
108 Control Subsystem
110 Feedback Subsystem
112 Pipe A (first pipe for gas supply and exhaust)
114 Pipe B (second pipe for gas supply and exhaust)
116 Supply Pipe (pressurized gas inlet)
118 Return Pipe (exhaust air outlet)
120 Piston Mass (in the double-acting actuator)
QA, QB Actuator chamber ports (Chamber A and Chamber B ports)
200-208 Method and method steps
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a," "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," "including," and "having," are open ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof.
When an element is referred to as being "engaged to," "connected to," or "coupled to" another element, it may be directly engaged, connected, or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
Therefore, the present disclosure envisages a Pneumatic Actuation System and method thereof. (hereinafter referred to as system (100), and method (200)). The present disclosure is explained with reference to Figure 1 and Figure 12.
Referring to Figure 1, The present disclosure provides a pneumatic actuation system (100), comprising: a directional valve subsystem (102), a double-acting actuator subsystem (104), a thermal convection subsystem (106), a control subsystem (108), a feedback subsystem (110).
The directional valve subsystem (102) is configured with adjustable flow path paths for selectively controlling gas flow direction and pressure, where the directional valve subsystem (102) includes one or more valves (TA, PA, TB, PB) with dynamically adjustable flow restrictions based on a spool input (S) to enable precise opening and closing of flow paths.
The double-acting actuator subsystem (104) is operatively connected to the directional valve subsystem (102), the double-acting actuator subsystem (104) including at least two chambers (Chamber A, Chamber B) configured to receive pressurized gas independently for generating bidirectional linear motion, and a mechanical converter having an actuator (piston rod) interfacing with the chambers configured to translate pneumatic pressure into mechanical motion.
The thermal convection subsystem (106), integrated into the flow paths, including pipes and chambers configured to dissipate heat generated during gas compression and flow via thermal convection to the surrounding environment to mitigate overheating.
The control subsystem (108) operatively coupled to the directional valve subsystem (102) and the double-acting actuator subsystem (104), configured to receive control inputs and process the control inputs to generate spool input for the directional valve subsystem (102) for regulating valve operations and actuator movements.
The feedback subsystem (110) comprises sensors for real-time detection of actuator displacement and thermal conditions, enabling closed-loop control of system operation.
In an embodiment, the directional valve subsystem (102) includes a spool mechanism configured for dynamic positioning, enabling precise control of gas flow in response to the control inputs.
In an embodiment, the system (100) further comprises: a first Pipe A (112) and a second Pipe B (114), a supply pipe (116), and a return pipe (118)
The first Pipe A (112) and a second Pipe B (114) are connected to the actuator chambers (QA, QB) for gas supply and exhaust.
The supply pipe (116) for providing pressurized gas.
The return pipe (118) for exhaust air to flow back to the environment, both equipped with convection elements (Convection Pipe A to Atm, Convection Pipe B to Atm, Convection Supply to Atm, Convection Return to Atm) for thermal interactions with ambient surroundings.
In an embodiment, the double-acting actuator subsystem (104) includes a piston mass (120), and chamber walls.
The piston mass (120) is coupled to the actuator (piston rod), facilitating bidirectional force transmission by balancing pneumatic pressure across the chambers (Chamber A, Chamber B).
The chamber walls are modelled with thermal mass (Wall Thermal Mass) to simulate heat transfer during actuation cycles.
In an embodiment, the thermal convection subsystem (106) comprises a heat exchange interface configured to facilitate thermal convection between the pipes and the ambient environment under varying operational loads.
In an embodiment, the directional valve subsystem (102) is capable of operating in multiple states, including a full-extension state, a full-retraction state, and a hold state.
The full-extension state to move the actuator rod (rod) outward.
The full-retraction state pulls the rod inward.
The hold state to maintain the rod in a stable position without additional locking mechanisms.
In an embodiment, the system (100) further comprises a load simulation module coupled to the actuator for replicating resistance conditions encountered in real-world applications.
In an embodiment, the system (100) further comprises a visualization interface configured to display system dynamics, including actuator movements, gas flow paths, and temperature gradients, in real time.
In an embodiment, the control subsystem (108) comprises a closed-loop control mechanism for automatically adjusting actuator movements for bidirectional actuator motion and load stabilization.
In an embodiment, the system (100) further comprises an integrated software module configured to execute thermal and flow dynamic simulations and provide actionable recommendations for system optimization based on real-time data.
Figure 2 illustrates a method for operating a pneumatic actuation system, in accordance with an embodiment of the present disclosure.
At step 202, the method (200) includes receiving a control input at a control subsystem (108) to initiate actuation, wherein the control input directs a directional valve subsystem (102) to open a selected pathway for pressurized gas.
At step 204, the method (200) includes channelling the gas to a designated chamber of a double-acting actuator subsystem (104) to generate bidirectional motion.
At step 206, the method (200) includes monitoring, a feedback subsystem (110), and system parameters using real-time feedback sensors to track actuator displacement and thermal conditions, enabling closed-loop control of system operation.
At step 208, the method (200) includes dissipating, by a thermal convection subsystem (106), heat from pressurized gas through thermal convection mechanisms embedded in gas pathways, based on the monitoring.
Figure 3 shows the pneumatic actuation circuit (100) illustrates a complete pneumatic system configured for precise motion control and effective thermal management. The circuit begins with the Supply Pipe (116), which delivers compressed air to the Directional Valve Subsystem (102). The valve regulates airflow through its internal spool mechanism (S) and directs it toward the Double-Acting Actuator (104) via Pipe A (112) and Pipe B (114). These pipes connect to Chamber A and Chamber B of the actuator, respectively, controlling the movement of the Piston Mass (120) and the Rod (rod). Exhaust air is routed back through the Return Pipe B (114) to the atmosphere (Atm) for release. Integrated thermal convection elements, such as Convection Pipe A (112) to Atm and Convection Pipe B (114) to Atm, dissipate heat from the pipes to the surrounding environment. Similarly, Convection Supply to Atm and Convection Return to Atm manage heat exchange at the air intake and exhaust points, ensuring thermal stability during high-duty cycles. Atmospheric reference points (Atm) are strategically included at various locations in the circuit to release air pressure and simulate real-world conditions. The spool input controller (Spool Input) dynamically adjusts the spool's position to control air distribution between the chambers of the actuator. The circuit is configured to achieve precise bidirectional motion, stable load holding, and efficient airflow regulation, while also modelling heat dissipation realistically.
In an embodiment, the pneumatic actuation circuit is designed with a precise configuration of components and parameters to achieve efficient and reliable operation in industrial applications. The system includes a network of pipes-Pipe A, Pipe B, Supply Pipe, and Return Pipe-each with a length of 1 meter and a cross-sectional area of 5×10−6m2The pipes are constructed with a wall density of 1500kg/m3and a specific heat capacity of 1250k/(kg⋅K), ensuring durability and effective thermal management. The initial gas pressures are set at 0.10132MPa for Pipe A (112), Pipe B (114), and the Return Pipe (118), while the Supply Pipe (116) operates at a higher pressure of 0.70132MPa to provide the necessary force for actuation. The system (100) is initialized at a temperature of 293.15K, replicating standard ambient conditions. The operation of the system begins with the Directional Valve Subsystem (102), which dynamically regulates the airflow by directing compressed air through either Pipe A (112) or Pipe B (116) into the respective chambers of the Double-Acting Actuator (104). The actuator is configured to convert the pneumatic pressure into precise bidirectional motion of the piston and actuator rod. Used air is efficiently expelled through the Return Pipe (118), maintaining pressure balance and enabling continuous operation. Thermal convection elements integrated within the circuit dissipate heat generated by air compression and flow, preventing overheating and ensuring stable system performance as shown in Table 1.
Table 1 : Block parameters for pipe A, pipe B, supply pipe and return pipe

Figure 4 shows double-acting actuator (104) is a central component of the pneumatic system, responsible for converting pneumatic pressure into bidirectional linear motion. It comprises two chambers: Chamber A and Chamber B, which are separated by a Piston Mass (120) connected to the actuator rod (rod). Compressed air enters these chambers through ports QA (1) and QB (2), supplied by Pipe A (108) and Pipe B (110), respectively. The differential pressure across the chambers generates linear motion, either extending or retracting the rod to perform mechanical tasks. Thermal management is integrated through a Wall Thermal Mass, which simulates the heat storage and dissipation behaviour of the chamber walls. Convection Chamber A to Wall and Convection Chamber B to Wall model the heat transfer from the chambers to the surrounding environment, preventing overheating during prolonged operations. Port R (4) serves as the exhaust outlet for air leaving the actuator. This precise combination of airflow and thermal management ensures smooth, efficient operation in various industrial and automation applications.
In an embodiment, the Double-Acting Actuator Subsystem is configured to generate linear motion in both extension and retraction modes, controlled by the flow of pressurized gas into its dual chambers: Chamber A and Chamber B. The subsystem operates by directing pressurized gas through Pipe A (112) into Chamber A to extend the actuator, or through Pipe B (114) into Chamber B to retract it. This bidirectional motion provides precise and repeatable movement, essential for automation and robotics applications where stable positioning is critical. The actuator block parameters are carefully defined to ensure realistic and reliable operation. The piston area (A piston) is represented as ApistonApiston, matching the cross-sectional area of the connected port (ApipeApipe). The maximum stroke length (X max) is equivalent to LpistonLpiston, with an initial displacement (X init) set to 0 for a neutral starting position. The mechanical damping coefficient (Damp mech) is set to 200, minimizing oscillations during motion. To simulate real-world constraints, a stiff hard stop with a value of 1.00E+07 N/m1.00E+07N/m and a damping hard stop of 1500 N⋅s/mN⋅s/m are included, preventing excessive piston displacement. The actuator's thermal properties are configured with a heat transfer coefficient (Heat Coeff) of 100 W/(m2⋅K)W/(m2⋅K) and a specific heat capacity (Cp) of 870 J/(kg⋅K)J/(kg⋅K). These parameters enable the actuator to manage heat dissipation effectively during high-duty cycles, ensuring thermal stability. The actuator is initialized with an operating pressure (Pinit) of pinitpinit and a temperature (T init) of TinitTinit, matching the pneumatic circuit's ambient conditions. Additionally, the subsystem includes a simulated load element, allowing for the evaluation of performance under various operational resistances. This configuration ensures the actuator can maintain consistent and precise operation even under varying load conditions, making it highly versatile for industrial and automation applications as shown in Table 2.
Table 2: Double Acting Actuator Block Properties.

Figure 5 shows the directional valve (102) is the control mechanism that regulates the airflow between the Supply Pipe (114), Return Pipe (118), and the actuator chambers (Chamber A and Chamber B). The valve features a Spool Mechanism (S), which dynamically adjusts its position to direct airflow through the appropriate paths. The airflow is routed through adjustable orifice blocks: Orifice TA, PA, TB, and PB (5, 6), which control the flow rate and direction. When the spool is positioned to supply air to Chamber A, the piston extends the rod outward, and when air is directed to Chamber B, the rod retracts. The valve also incorporates leakage models (X_leakage and A_leakage) to simulate minor air leaks that naturally occur in real-world pneumatic systems. These leakage paths are essential for achieving a realistic simulation of system performance. The reverse-direction functionality enables smooth transitions between extension and retraction modes. The detailed "stroke-to-area" relationships within the valve allow for precise control of airflow, ensuring accurate actuator performance. The Directional Valve Subsystem (102) plays a critical role in maintaining the overall functionality and precision of the pneumatic circuit (100).
In an embodiment, the Directional Valve Subsystem is configured with specific block properties to optimize airflow control and system performance. The flow coefficient (Cd) is set to 0.82, ensuring efficient flow dynamics through the valve. The maximum orifice area (A max) is represented as A_valve_max, while the maximum spool displacement (X max) is configured at 5×10−3m. These values enable precise modulation of airflow as the spool adjusts during operation. Leakage parameters are incorporated to simulate real-world inefficiencies, with the minimum leakage area (A leakage) defined as Avalve_min and the leakage area per spool displacement (X leakage) set to 2×10−4m2. These parameters enhance the simulation's accuracy by accounting for small-scale airflow losses inherent in pneumatic systems. Additionally, the valve port area (A port) is matched to the cross-sectional area of the connected pipes (Apipe), ensuring seamless integration and consistent airflow management as shown in Table 3.
Table 3: Directional Valve Block Properties.

Figure 6 is a graphical plot that the mass flow rate through the orifices of the Directional Valve Subsystem (102) over time. The top plot shows the flow rates through Orifice PA and Orifice TB, while the bottom plot represents the flow through Orifice PB and Orifice TA. These curves demonstrate the dynamic control of the valve spool (S) as it regulates airflow between the Supply Pipe (112), actuator chambers (Chamber A and B), and the Return Pipe (114). The sharp transitions in flow rates indicate spool adjustments during the extension, retraction, and holding phases of the actuator (104). The negative flow values represent exhaust flow being directed out of the chambers, highlighting the valve's ability to reverse airflow efficiently.
Figure 7 provides a graphical plot that an overview of the pressure and temperature variations within the Double-Acting Actuator (104). The top plot shows the pressures in Chamber A and Chamber B, controlled by the Directional Valve Subsystem (102). The transitions in pressure correspond to the extension and retraction of the actuator rod (rod), driven by differential pressure. The bottom plot displays the temperature changes in the chambers, reflecting the thermodynamic effects of air compression and expansion. The cooling and heating phases are influenced by the convection elements (Convection Chamber A to Wall and Convection Chamber B to Wall), which dissipate heat to the surrounding environment, ensuring system stability.
Figure 8 represents a graphical plot that shows the relationship between the Negative Stroke (S) of the spool and the corresponding orifice area (AR) over time. As the spool moves into the negative stroke position, the orifice area dynamically changes to control the airflow rate. This precise adjustment ensures optimal airflow during the actuator's retraction phase. The plot highlights how the orifice area responds to spool movements, achieving a smooth transition between airflow states and maintaining stability within the pneumatic system.
Figure 9 shows a graphical plot of the correlation between the Positive Stroke (S) of the spool and the orifice area (AR). Similar to the negative stroke results, the orifice area increases or decreases based on the spool position to control airflow during the actuator's extension phase. The linearity of the curves indicates the system's ability to maintain precise airflow regulation, ensuring consistent performance during the extension of the actuator rod (rod). These adjustments are crucial for achieving the desired motion control in the Double-Acting Actuator (104).
Figure 10 depicts the thermal behaviour of Chamber A and its interaction with the chamber wall through the Convection Chamber A to Wall element. The top plot shows the heat flux (Q) exchanged between the air in the chamber and the wall, while the bottom plot displays the temperature gradient (K) across the wall over time. Peaks in heat flux correspond to pressure increases in Chamber A, indicating air compression and subsequent heat generation. The convection element effectively dissipates this heat, maintaining a stable temperature profile within the actuator.
Figure 11 provides a graphical plot that a similar analysis for Chamber B, focusing on its thermal interaction with the wall through the Convection Chamber B to Wall element. The top plot illustrates the heat flux (Q) as air expands or compresses within the chamber, while the bottom plot represents the temperature gradient (K) across the chamber wall. These results demonstrate the effectiveness of the convection element in dissipating heat during the actuator's retraction phase, ensuring consistent thermal management in high-duty applications.
Figure 12 is a graphical plot that highlights the behaviour of the Transitional Damper within the system, which models the damping forces acting on the actuator rod (rod). The top plot shows the damping force (f) applied over time, while the middle plot represents the power dissipated due to damping. The bottom plot displays the rod displacement, reflecting the damper's influence on actuator motion. The damper plays a crucial role in stabilizing the actuator during transitions, minimizing oscillations, and enhancing the system's overall precision and reliability.
In the operative configuration of the pneumatic actuation circuit, the process begins with a control signal sent to the Spool Input (S) of the Directional Valve Subsystem (102). This signal adjusts the position of the spool mechanism within the valve, which selectively opens either Pipe A (112) or Pipe B (114). If Pipe A is opened, the pressurized air flows toward Chamber A of the Double-Acting Actuator (104), causing the Piston Mass (120) to move and extend the Actuator Rod (rod). Conversely, if Pipe B is opened, the pressurized air flows into Chamber B, resulting in the retraction of the rod. During this operation, the Position Sensor provides continuous real-time feedback on the rod's displacement, enabling precise control over the actuator's extension or retraction in accordance with the system's requirements. As the compressed air flows through the Supply Pipe (116), Pipe A (112), Pipe B (114), and the Return Pipe (118), heat generated by air compression and movement is managed by the system's thermal elements. The Thermal Convection elements dissipate heat into the surrounding environment, preventing overheating and ensuring that the actuator, directional valve, and other components operate efficiently and reliably, even under high-duty cycles. Once the actuation process is complete, the Return Pipe (118) channels the used air back to the atmosphere or a storage unit, preventing pressure buildup and enabling the circuit to reset automatically. This closed-loop configuration ensures the system is ready for the next cycle without requiring manual intervention, maintaining smooth and efficient operation.
Advantageously, the pneumatic actuation system is highly effective due to its combination of precision, reliability, and integrated thermal management. By utilizing a well-coordinated directional valve and double-acting actuator, the system ensures accurate and controlled motion in both extension and retraction phases, which is crucial for applications requiring repeatable and precise performance. Its built-in thermal management system efficiently dissipates heat generated during operation, preventing overheating and ensuring consistent performance over extended use. The closed-loop configuration, which incorporates automatic reset functionality, reduces downtime and eliminates the need for manual intervention, enhancing overall system efficiency. Additionally, the system's ability to model real-world dynamics, such as airflow regulation and thermal interactions, makes it a robust and adaptable solution for various industrial and automation applications. This combination of features makes the system effective, reliable, and versatile in meeting the demands of modern pneumatic operations.
The functions described herein may be implemented in hardware, executed by a processor, firmware, or any combination thereof. Other examples and implementations are within the scope and spirit of the disclosure and appended claims. The present disclosure can be implemented by a processor, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described hereinabove has several technical advantages including, but not limited to, a pneumatic actuation system and method thereof, that;
• offers precise and bidirectional control of pneumatic actuators for complex motion applications;
• provides better control mechanisms and efficient airflow management;
• prevents overheating and simulates real-world operating conditions accurately;
• provides detailed and realistic simulations of pneumatic dynamics, enabling better configuration, analysis, and optimization;
• simplifies setup and operation while offering advanced functionality for engineers and technicians in various industries; and
• can be easily customized and applied to diverse applications, from industrial automation to medical devices.
The foregoing disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Any discussion of devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
, Claims:WE CLAIM:
1. A pneumatic actuation system (100), comprising:
• a directional valve subsystem (102) configured with adjustable flow path paths for selectively controlling gas flow direction and pressure, wherein said directional valve subsystem (102) including one or more valves (TA, PA, TB, PB) with dynamically adjustable flow restrictions based on a spool input (S) to enable precise opening and closing of flow paths;
• a double-acting actuator subsystem (104) operatively connected to said directional valve subsystem (102), said double-acting actuator subsystem (104) including at least two chambers (Chamber A, Chamber B) configured to receive pressurized gas independently for generating bidirectional linear motion, and a mechanical converter having an actuator (piston rod) interfacing with the chambers configured to translate pneumatic pressure into mechanical motion;
• a thermal convection subsystem (106), integrated into the flow paths, including pipes and chambers configured to dissipate heat generated during gas compression and flow via thermal convection to the surrounding environment to mitigate overheating;
• a control subsystem (108) operatively coupled to said directional valve subsystem (102) and said double-acting actuator subsystem (104), configured to receive control inputs and process the control inputs to generate spool input for said directional valve subsystem (102) for regulating valve operations and actuator movements; and
• a feedback subsystem (110) comprising sensors for real-time detection of actuator displacement and thermal conditions, enabling closed-loop control of system operation.
2. The system (100) as claimed in claim 1, wherein the directional valve subsystem (102) includes a spool mechanism configured for dynamic positioning, enabling precise control of gas flow in response to the control inputs.
3. The system (100) as claimed in claim 1, further comprises:
• a first Pipe A (112) and a second Pipe B (114), connected to the actuator chambers (QA, QB) for gas supply and exhaust;
• a supply pipe (116) for providing pressurized gas; and
• a return pipe (118) for exhaust air to flow back to the environment, both equipped with convection elements (Convection Pipe A to Atm, Convection Pipe B to Atm, Convection Supply to Atm, Convection Return to Atm) for thermal interactions with ambient surroundings.
4. The system (100) as claimed in claim 1, wherein the double-acting actuator subsystem (104) includes:
• a piston mass (120) coupled to the actuator (piston rod), facilitating bidirectional force transmission by balancing pneumatic pressure across the chambers (Chamber A, Chamber B); and
• chamber walls modelled with thermal mass (Wall Thermal Mass) to simulate heat transfer during actuation cycles.
5. The system (100) as claimed in claim 1, wherein the thermal convection subsystem (106) comprises a heat exchange interface configured to facilitate thermal convection between the pipes and the ambient environment under varying operational loads.
6. The system (100) as claimed in claim 1, wherein the directional valve subsystem (102) is capable of operating in multiple states, including:
• a full-extension state to move the actuator rod (rod) outward;
• a full-retraction state to pull the rod inward; and
• a hold state to maintain the rod in a stable position without additional locking mechanisms.
7. The system (100) as claimed in claim 1, further comprises a load simulation module coupled to the actuator for replicating resistance conditions encountered in real-world applications.
8. The system (100) as claimed in claim 1, further comprises a visualization interface configured to display system dynamics, including actuator movements, gas flow paths, and temperature gradients, in real-time.
9. The system (100) as claimed in claim 1, wherein the control subsystem (108) comprises a closed-loop control mechanism for automatically adjusting actuator movements for bidirectional actuator motion and load stabilization.
10. The system (100) as claimed in claim 1, further comprises an integrated software module configured to execute thermal and flow dynamic simulations, and provide actionable recommendations for system optimization based on real-time data.
11. A method (200) for operating a pneumatic actuation system, comprising:
• receiving a control input at a control subsystem (108) to initiate actuation, wherein the control input directs a directional valve subsystem (102) to open a selected pathway for pressurized gas;
• channelling the gas to a designated chamber of a double-acting actuator subsystem (104) to generate bidirectional motion;
• monitoring, a feedback subsystem (110), system parameters using real-time feedback sensors to track actuator displacement and thermal conditions, enabling closed-loop control of system operation; and
• dissipating, by a thermal convection subsystem (106), heat from pressurized gas through thermal convection mechanisms embedded in gas pathways, based on the monitoring.
Dated this 22nd day of November, 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA - 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

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