Question 1

Proportional Flow Control Valve

Accepted Answer

These are some of our proportional flow control valve applications:
1. Torque control
2. Vacuum generator
3. Gas control
4. Gas blending
5. Cooling

We have been offering various models of proportional flow control valve that can be used to control the flow rate of gas, liquid, oil. Customers often uses our valves to replace solenoid valves, where our FC series could act as on/off control and at the same time control the flow rate. We have succesfully replaced Clippard (SCPV), and Burkert flow control valve.

Advantage:

Compact
Low cost
High sensitive
Analog / Digital signal
Easy-control
Full scale linearity flow rate control
control up to 20 L/min of water flow (customisable)

We hope you have enjoyed reading the article. Please remember to visit our product page.

Question 2

Electronic Flow Valve

Accepted Answer

What is an Electronic Flow Valve?

An Electronic Flow Valve is a device that is able to control the flow rate of fluid (liquid and gas) with electronic signal. Ideally, the output flow rate is linearly proportional to input signal. Depend on the type of medial it is regulating, when it’s air, it is called electronic flow regulator, electronic air flow control valve, electronic pneumatic flow control valve; and when the media is water, it’s called electronic water flow control valve, digital flow control valve, digital flow controller, or proportional needle valve for both types.

There are different types of working principle, and in this article we will be introducing you the proportional needle valve type driven by a stepper motor powered linear actuator. We will firstly introduce you what type of electronic flow valve we offer, followed by the working principle and with what is the main advantage of KaoLu’s proportional needle valve, and then conclude with what you should think about before purchasing an electronic flow valve.

What type of Electronic Flow Valve does KaoLu offer?

KaoLu offers 5 types of digital flow control valve. One advantage is that it can control both gas and liquid. Please click on the photo link below for further information

FC20 : Flow rate up to 65 L/min of nitrogen gas @ 6 bar or 750 mL/min of water @ 6 bar
FC120: Flow rate up to 230 L/min of nitrogen gas @ 6 bar or 3.5 L/min of water @ 6 bar
FC300: Flow rate up to 400 L/min of nitrogen gas @ 6 bar or 8 L/min of water @ 6 bar
FC1000: Flow rate up to 1200 L/min of nitrogen gas @ 5 bar or 12 L/min of water @ 5 bar
FC1500: Flow rate up to 2200 L/min of nitrogen gas @ 7 bar or 30 L/min of water @ 5 bar
FC3000: Flow rate up to 5000 L/min of nitrogen gas @ 10 bar or 30 L/min of water @ 5 bar

Please refer to our youtube channel for some of the interesting applications:

What is working principle of an Electronic Flow Regulator?

There are different types of Electronic Flow Regulator. Here we will be explaining the type that utilizes a linear stepper motor actuator and proportional needle valve.

So, what is the advantage of KaoLu’s electronic air flow control valve or electronic water flow control valve?

Our parameters tells all the story. With FC series electronic flow valve, we are able to withstand 7 bar of perpendicular operating pressure, with a resolution as high as 20 mL/min of air, repeatability of 0.1% F.S, and 0.1% of linearity. This is due to the motor we used, the extremely low tolerance of mechanical parts, the fine thread needle we used which is extremely difficult to reproduce by others, and the control system we designed.

What should you consider when purchasing an electronic flow regulator?

You should consider 3 main factors ( we called CPR)

Compatibility: Medium, flow range, compatibility with the valve material, and operating pressure
Performance: Resolution, starting flow point, and linearity
Control system

It is important to understand whether the media you used falls into the flow range of the operating valve. As each media has different density so the flow range would be different from the nominal flow range. Next is whether the media used is compatible with the wet material and whether you would also need the body to be special material. The operating pressure is another caveat, where if you simply needs flow control, sometimes it would not be a very important factor.

Next is the performance, with some applications that needs fine control and adjustment between steps, such as laser cutting, the resolution dictated by the control logic and motor performance plays an important role here. Furthermore, as the motion system requires to overcome initial inertia, the start flow point is should be considered.

Then comes the control system where the you should check what type of control system do suppliers offer? Here we provide an external driver that has a cable connected to the control valve. The great advantage that we offer is that should you want to operate the valve from distant away from the site, we offer RS485 modbus where you could control the valve up to half a mile away from the valve.

We hope you have enjoyed reading the article, understand about stepper motor driver electronic flow control valve, understand about our products, and finally help you with selecting the right valve.

We hope you have enjoyed reading the article. Please remember to visit our product page.

Question 3

Technical Scheme of Vacuum Precision Control in Lunar Soil Environment Ground Simulation Test Device

Accepted Answer

Abstract: In the lunar exploration project, it is necessary to collect lunar soil samples in the vacuum environment of the lunar surface. It is necessary to establish a ground test device to simulate the vacuum thermal environment of the lunar surface to test the performance of the sample in vacuum thermal environment. Therefore, the degree of vacuum is required and it can achieve precise control. In this article, a technical scheme for accurate vacuum control using FC series proportional flow control valve is proposed for the ground simulation test device of vacuum thermal environment.

1. Question
In the lunar exploration project, it is necessary to collect lunar soil samples in the vacuum environment of the lunar surface. Therefore, a ground test device needs to be established to simulate the vacuum thermal environment of the lunar surface to test the performance of sample in the vacuum thermal environment, and accurate vacuum control is required to reach precise control. Due to the particularity of the lunar soil, vacuum control in current lunar soil ground model test device still needs to solve the following problems:
(1) Lunar soil and simulated lunar soil samples are generally powdery particles, so the pumping rate in the initial time should be strictly controlled to avoid dust generation.
(2) The current vacuum measurement and control also uses a Pirani vacuum gauge, which makes the matching control system unable to reach precise control of the vacuum, resulting in poor repeatability of the test results.
(3) The lunar soil ground simulation test device is generally small in size, and it has always been difficult to achieve precise control within a wide range of vacuum degrees. The fluctuation of vacuum degree is large, which is also one of the reasons for the poor repeatability of test results. Aiming at the above problems existing in the lunar soil ground model test device, this article focuses on corresponding technical solutions and introduces the detailed implementation process.

2. Technical Scheme
The overall structure of vacuum density control system of lunar soil environment ground simulation test equipment is shown in Figure 1. The whole system mainly includes a vacuum gauge, two proportional flow control valve, a PID controller and a vacuum pump. In order to do the precise control of the full range of vacuum degree, three capacitance vacuum gauges are generally required, and the measurement accuracy of vacuum gauge is 0.25%. In order to match the measurement accuracy of capacitance vacuum gauge, the controller adopts a high-precision PID controller with 24-bit A/D and 16-bit D/A, and the independent dual-channel facilitates the gas flow adjustment and control of the upstream proportional flow control valve and downstream proportional flow control valve control. The precise control of vacuum degree uses dynamic control mode, that is, the downstream proportional flow control valve is adjusted under low vacuum conditions, and the upstream proportional flow control valve is adjusted under high vacuum conditions. This is a typical forward and reverse control method, which can effectively ensure the control accuracy of vacuum degree. In conclusion, with this proven accurate vacuum control scheme, a control accuracy of better than 1% vacuum over the full scale range can be achieved.

For further information on different models of proportional flow control valve, please visit https://www.genndih.com/proportional-flow-control-valve.htm

Question 4

Precision Vacuum Control to Reduce Solvent Loss in Evaporation and Concentration Process

Accepted Answer

Abstract: Aiming at the problems of precision vacuum control to reduce solvent loss in evaporation and concentration process, this article focuses on vacuum evaporation techniques, including the precise control method of vacuum degree, the simultaneous control method of vacuum degree and temperature, and the use of strong resistance of the corrosive electronic valve acts as a vacuum regulator.

1. Question
In the process of solvent extraction, the vacuum evaporation and concentration process is generally used. Since the solvent often has good volatility, the solvent is prone to loss during the vacuum extraction process, and sometimes the loss can reach 5~8%. Therefore, in order to solve the loss of solvent in the evaporation and concentration process, the following problems need to be solved:
(1) The precise control problem of vacuum degree, such as fixed-point control and program control, which is the key to reducing solvent loss.
(2) Simultaneous control problem of vacuum degree and temperature. This is because different vacuum degrees determine the boiling point of the solution. Through coordinated control of vacuum degree and temperature at the same time, the yield of the solvent can be greatly improved.
(3) In the vacuum evaporation and concentration process, many solvents and solutions are often corrosive to a certain extent, which requires the vacuum regulating valve to have good corrosion resistance. In order to solve the requirement of reducing solvent loss in the evaporation and concentration process, this article proposes a solution for precise control of vacuum degree, including the use of electronic flow control valve with strong corrosion resistance as vacuum degree control valves.

2. Solution
For the precise control of vacuum degree and temperature in the evaporation and concentration process, the overall structure of control system is shown in Figure 1.

(Figure 1 Schematic diagram of the vacuum degree and temperature control system structure of the evaporation and concentration process)

The basic principle of precise vacuum control is the dynamic control method, that is, according to the control set value and the measured value of vacuum gauge, the intake flow and exhaust flow of vacuum container are adjusted respectively, so that the flow in and out can reach a dynamic balance. If automatic control is required, PID control algorithms and corresponding controllers are required.

As shown in Figure 1, the accurate control proposal for vacuum degree control in this article adopts a dynamic control method, using an electronic flow control valve to adjust the intake flow, using an electronic ball valve or an electronic needle valve to adjust the exhaust flow, and the vacuum pump is used as a vacuum source. The automatic control of vacuum degree adopts PID controller.

In order to reach the temperature control function at the same time, this scheme adopts a dual-channel PID controller, one channel is used to control the vacuum degree, and another channel is used to control the temperature. This PID control has 24-bit A/D and 16D/A, with 47 input signal forms (thermocouple, thermal resistance, DC voltage), and can be connected to various vacuum and temperature sensors for measurement, display and control. It also has 2 independent measurement control channels, two-wire RS485, standard MODBUS RTU communication protocol.

(Figure 2 FC series electronic needle valve)

In order to reach high-precision adjustment in the vacuum degree control process, an electronic needle valve with fine adjustment by a numerically controlled stepping motor is used, as shown in Figure 2. The hysteresis of this FC series proportional needle valves is much smaller than that of solenoid valves, and has a high-speed response within 1 second, especially the use of fluorine rubber (FKM) sealing technology, which makes the valve have superior corrosion resistance. Equipped with a stepper motor drive circuit module with the numerical control proportional needle valve, it provides the required power supply (24VDC) and control signal (0~10VDC) for the numerical control needle valve, and can also provide direct control of RS485 serial communication.

For larger-diameter air-extraction pipelines, a miniature proportional needle valve is used in this scheme, as shown in Figure 2. This series of proportional needle valve is a small electronic valve. The valve opening can be adjusted continuously according to the change of control signal (0~10VDC). The fastest opening and closing time is less than 7 seconds, and the opening and closing time can also reach less than 1 second. The integrated design of the valve and the valve body reduces external volume and is low in price. It is often installed between the sealed container and the vacuum pump to adjust pumping rate.

In short, through the solution described in this article, the vacuum degree control accuracy in the evaporation and concentration process can reach 1%, and the corresponding temperature control can also be carried out. The vacuum regulating valve has super corrosion resistance, which can effectively reduce the loss of solvent concentration during the vacuum evaporation process.

Question 5

Proposal for Vacuum Precision Control in Low Pressure Carburizing (LPC) Process

Accepted Answer

Abstract: In order to meet the requirements of precise control of vacuum degree in low-pressure carburizing process (vacuum carburizing), corresponding solutions are proposed in this article, including adding a gas mixing tank for permeate gas mixing, using upstream and downstream dynamic vacuum level control methods and vacuum degree by coordinating the control method with the temperature, the rapid and precise control of the vacuum degree and temperature in the infiltration process can be reached.

1. Question
Low-pressure carburizing, also known as vacuum carburizing, is a process in which a carburizing medium is passed into a high-temperature furnace for rapid carburizing under a low-pressure vacuum state. The vacuum carburizing process can be divided into one-stage type, pulse type and swing type. Among them, the degree of vacuum, temperature and carburizing time will change according to the specific requirement, especially the degree of vacuum will change drastically with the temperature change. Therefore, in the vacuum carburizing process, the following problems need to be solved in terms of vacuum degree control:

(1) The problem of fast and accurate control of vacuum degree, such as fixed-point control, program control and fast pulse control, requires the vacuum control system to have high response speed and control accuracy. Especially to achieve precise control in the full range of vacuum, it is necessary to use different vacuum sensors and corresponding upstream and downstream control modes according to different ranges.

(2) Simultaneous control problem of vacuum degree and temperature. The carburizing is carried out in a high temperature environment, requiring simultaneous control of vacuum degree and temperature.
In order to meet the requirements of precise control of vacuum degree in low-pressure carburizing process, this article focuses on a solution for precise control of vacuum degree, and adopts dual-channel PID control to reach synchronous temperature control.

2. Solution
The overall structure of the vacuum degree and temperature control system in the low pressure carburizing process is shown in Figure 1.

Figure 1 Schematic diagram of the structure of vacuum degree and temperature control system in low pressure carburizing process

The basic principle of precise control of vacuum degree is the dynamic control method, that is, according to the control set value and the measured value of vacuum gauge, the air intake flow and exhaust flow of the carburizing chamber are adjusted respectively, so that the flow in and out can reach a dynamic balance. If automatic control is required, PID control algorithms and corresponding controllers are required.

As shown in Figure 1, the precision control solution for vacuum degree proposed in this article adopts a dynamic control method, using an electronic needle valve to adjust the air intake flow, using an electronic ball valve or an electronic needle valve to adjust the exhaust flow, and the vacuum pump is used as a vacuum source. The automatic control of vacuum degree adopts PID controller.

For different low pressure carburizing processes, the control range of the vacuum degree is 1Pa~100kPa. Therefore, in the specific process, different dynamic control modes need to be adopted for the control in different vacuum degree ranges. For the vacuum degree control in the high vacuum range of 1Pa~1kPa, the upstream control mode of fixed exhaust flow and adjustable intake flow is adopted; for the vacuum degree control in the low vacuum range of 1kPa~100kPa, fixed intake flow and adjustable exhaust downstream control mode of the flow.

As shown in Figure 1, in order to reach the adjustment and control of air intake flow, a gas mixing tank is added to the intake end of carburizing chamber, and a gas mass flow meter is used to distribute various permeated gases into the gas mixing tank. The gas flows through the electronic needle valve for flow regulation and control.

In order to reach the temperature control function at the same time, this scheme adopts a dual-channel PID controller, one channel is used to control the vacuum degree, and the other channel is used to control the temperature. This PID control has 24-bit A/D and 16-bit D/A, with 47 input signal forms (thermocouple, thermal resistance, DC voltage), and can be connected to various vacuum and temperature sensors for measurement, display and control of 2 independent measurement control channels, two-wire RS485, standard MODBUS RTU communication protocol.

Figure 2 FC series electronic needle valve

In order to reach high-precision adjustment in the vacuum degree control process, an electronic needle valve with fine adjustment by a numerically controlled stepping motor is used, as shown in Figure 2. The hysteresis of FC series of needle valves is much smaller than that of solenoid valves, and has a high-speed response within 1 second, especially the use of fluorine rubber (FKM) sealing technology, which makes the valve have superior corrosion resistance. Equipped with a stepper motor drive circuit module with the numerical control electronic needle valve, it provides the required power supply (24VDC) and control signal (0~10VDC) for the numerical control needle valve, and can also provide direct control of RS485 serial communication.

In conclusion, through the solution described in this article, the vacuum degree control accuracy in the low pressure carburizing process can reach 1% in the full scale range, and the corresponding temperature control can also be carried out.

Question 6

Ultra-Low Loss Single-Mode Optical Fiber Fused Taper Production by Accurate Vacuum Level Control Adsorption Fixture

Accepted Answer

Abstract: In the fiber fused taper system of fusion method, the fiber coupling with minimal loss corresponds to the optimal vacuum degree for adsorbing and fixing the optical fiber. Therefore, it is necessary to precisely control the adsorption vacuum degree and find the optimal vacuum degree value. In this article, focusing on the stable batch production of fiber fused taper system with minimal loss, an improvement scheme of vacuum system using FC series proportional flow control valve is proposed, which can reach precise control of vacuum degree.

1. Question
In the process of making optical fiber couplers and optical fiber cones in the optical fiber taper system, two or more optical fibers are generally positioned and clamped on the optical table by means of vacuum adsorption and special fixtures, and the two or more optical fibers are fixed in a certain way. A plurality of bare fibers are rotated and moved closer to the axis, heated and melted by a hydrogen-oxygen flame or a laser, and stretched to both sides at a certain speed, and finally a special waveguide structure in the form of a double cone is formed in the heating zone.

The current optical fiber taper technology is difficult to produce optical fiber couplers stably with a loss of less than 0.1 in batches, which is mainly due to the fact that optical fibers are fixed too tightly by vacuum adsorption. Some literatures reported that the vacuum system for adsorption and fixation fixture was improved, and the corresponding fiber couplers were fabricated under a series of different adsorption and fixation vacuum degrees, and it was proved that coupling loss in the entire vacuum degree range has a minimum area, When the vacuum degree is 120mBar, the minimum loss is 0.05dB.

The higher the vacuum degree, the tighter the fiber is fixed, and the coupling loss will be larger. It can be seen that in order to obtain an ultra-low loss fiber coupling device, it is necessary to precisely control the vacuum degree of the vacuum adsorption device.

In this article, according to the requirements for precise control of vacuum degree in the process of fabricating ultra-low loss optical fiber coupling devices by fiber taper method, a technical scheme of vacuum control system and corresponding supporting contents are proposed to reach precise and rapid control of vacuum degree.

2. Technical Scheme
In order to reach the precise control of adsorption vacuum degree in the left and right stretching fixtures, a vacuum tank is added to the original vacuum system. As long as the vacuum pressure in the vacuum tank is controlled, the adsorption vacuum degree of the left and right stretching fixtures can be controlled which shown in figure.

The vacuum degree control system shown in Figure mainly includes an electronic needle valve, a vacuum gauge, a PID controller and a vacuum pump. The precise control of the vacuum degree adopts the dynamic control method, that is, according to the comparison between the measured value of the vacuum gauge and the set value, the PID controller adjusts the intake air flow and the exhaust air flow at the same time to quickly achieve dynamic balance and control the vacuum degree to the set value. , the control accuracy can reach ±1%.

In conclusion, through precise control of vacuum degree, stable mass production of ultra-low-loss fiber-coupled devices can be reached.

Figure Schematic diagram of the vacuum degree control system of the fiber taper machine

Question 7

A Precise Control Method of Temperature and Pressure in Rayleigh-Brillouin Scattering Spectrometry

Accepted Answer

A Precise Control Method of Temperature and Pressure in Rayleigh-Brillouin Scattering Spectrometry

Abstract: For the Rayleigh-Brillouin scattering (RBS) spectroscopy experimental device, users proposed to reach high-precision control of temperature and pressure of measuring gas chamber. This article introduces a specific implementation, in which high-precision temperature control is implemented using semiconductor TEC modules and proportional control flow valve. Pressure control adopts a high-precision vacuum pressure control system, which includes a high-precision pressure sensor, a precision proportional control flow valve and a 24-bit acquisition precision PID controller. This temperature and pressure control scheme has been widely used and proven.

The introduced proportional flow control valve is introduced in https://www.genndih.com/proportional-flow-control-valve.htm

1. Technique requirement
According to customer requirements, temperature and pressure in Rayleigh-Brillouin scattering (RBS) spectroscopy as shown in Figure 1(the content of the red box area) for precise control, the specific requirements are as follows:
(1) Temperature range is 300K~318K; temperature control accuracy is ±0.02K.
(2) Pressure range is 30kPa~90kPa (absolute pressure); pressure control accuracy is ±0.1kPa; atmosphere is 99.9trogen.

2. Temperature control scheme
For high-precision temperature control near room temperature, it is proposed to use semiconductor heating and cooling technology shown in Figure 2 to reach, the specific contents include:
(1) Heating refrigerator: TEC module.
(2) Sensor: platinum resistance or thermistor temperature.
(3) PID controller: high-precision 24-bit temperature and pressure controller.

3. Pressure control scheme
The absolute pressure range required for experimental device to work is 30kPa~ 90kPa, and pressure within this range is required to be accurate and constant at any set point. Using KaoLu’s proportional control flow valve is the best choice.

(1) Using a capacitance pressure gauge with a range of 1000torr for pressure measurement, its accuracy can reach ±0.2%. A vacuum pressure sensor with a higher accuracy of ±0.05% can also be used for measurement.
(2) The high-precision PID vacuum pressure controller with 24-bit A/D acquisition is used to match the measurement accuracy of high-precision vacuum pressure sensor and ensure control accuracy.
(3) Install a proportional flow control valve at air inlet and exhaust port of air chamber respectively. The proportional flow control valve is directly installed at air inlet.

https://www.genndih.com/proportional-flow-control-valve/mid-flow-proportional-valve-0-130L-min.html

(4) During the control process, the pumping speed is guaranteed to be constant after vacuum pump is turned on. First, you need to set the air intake electronic needle valve so that pressure and flow of intake port are constant, and then perform self-tuning of PID parameters. Last, realize precise control of air chamber pressure by automatically adjusting the flow rate of exhaust port.

Question 8

Vacuum Level and Temperature Control Method in Glove Box

Accepted Answer

A Detailed Tutorial on Vacuum Degree and Temperature Control Method in Glove Box

Abstract: In order to reach powerful functions of glove box for two environmental variables of vacuum and temperature in glove box. This article focuses on integrated solution for accurate measurement and control of vacuum and temperature, and describes the upstream, downstream, bi-directional methods. Also introduces the specific application of switching control mode in different vacuum degree ranges, and demonstrates the new proportional flow control valve and 24-bit ultra-high-precision PID controller used in the control.

1. Questions
Vacuum glove boxes are often used for readily oxidizable and deliquescent substances. Chemical reactions, material processing and performance testing that require manual operations in an anaerobic and anhydrous environment are very helpful. The core function of glove box is to provide a vacuum environment and easy to use, but in current practical applications most glove boxes only use anaerobic environment and manual operation functions of glove box, and do not give full capacity to the role of glove box. The more powerful application of glove box is also reflected in the following two aspects:

(1) The vacuum glove box is a hermetic environmental box, and the ultimate vacuum degree can generally reach about 10Pa, so that vacuum degree in glove box can be controlled at any set point between 10Pa and atmospheric pressure as required. Various chemical reactions, experiments and tests that are sensitive to vacuum can be carried out; also various manual operations can be carried out without changing and destroying the vacuum environment.

(2) In addition to vacuum, temperature is another important environmental variable for many reactions, experiments and tests. By placing the corresponding heating device in the glove box, various experimental studies under the combined environment of temperature and vacuum degree can be carried out. And so on, other physical quantity environmental conditions can also be configured to form multi-physical quantity coupling test conditions under various boundary conditions. In order to achieve the full performance of a vacuum glove box, it focuses on two environmental variables of vacuum degree and temperature in the glove box.

This article introduces in detail the integrated solution for accurate measurement and control of vacuum degree and temperature, and introduces the different vacuum degree ranges of upstream, downstream and bidirectional control modes in vacuum control process.

2. Vacuum control in glove box
Glove box belongs to a low vacuum environment cavity. The vacuum degree of the glove box using a mechanical pump can generally reach an absolute pressure of about 10Pa. By vacuuming and filling with inert gas, the vacuum degree of the glove box can be controlled from 10Pa to one atmosphere (absolute pressure 0.1MPa). For control in such a vacuum range spanning four orders of magnitude, vacuum sensors with different precisions will be used according to actual needs, and there will be different control modes accordingly. The following is the specific content of each control mode.

2.1 Upstream Control Mode
As shown in Figure 1, under the condition that the pumping speeds of downstream vacuum pump is kept constant. The upstream control mode is to adjust the opening of proportional flow control valve of upstream air intake port through PID vacuum pressure controller according to the measurement signal of vacuum gauge, that is, by controlling intake flow to keep pressure in glove box at the set point. Upstream mode is often used for high vacuum control.

2.2 Downstream Control Mode
As shown in Figure 2, under the condition that the pumping speed of downstream vacuum pump is kept constant, the downstream control mode is to adjust the opening of proportional flow control valve of downstream air outlet through PID vacuum pressure controller according to the measurement signal of vacuum gauge, that is, by controlling the air flow rate, the pressure in glove tank is controlled at the set value. We can see that downstream mode is often used for low vacuum control.

2.3 Bi-directional Control Mode
The above upstream and downstream control modes have their own advantages, and are rarely used alone in practical applications. Generally, the upstream and downstream modes are integrated together, which is the so-called bi-directional control mode, as shown in Figure 3. In bi-directional control mode, the vacuum pressure controller is required to have forward and reverse control functions, that is, reverse control for upstream proportional flow control valve and reverse control for downstream proportional flow control valve.

2.4 Dual sensor automatic switching mode
As mentioned above, if the accurate measurement and control of vacuum degree is carried out in the full range of 10Pa~0.1MPa, it is generally necessary to configure two high-precision diaphragm pressure gauges of 1000Torr and 10Torrswitch automatically. As shown in Figure 4, the high switching point (2-3) is the high point where low vacuum sensor works, and the low switching point (1-2) is the low point where high vacuum sensor works. The controller performs smoothing calculation between these two points. When the continuous sampling of low vacuum measurement PV1 and high vacuum measurement PV2 is below the lower switching point, switching to the rough vacuum sensor. When continuous sampling of low vacuum measured value PV1 and high vacuum measured value PV2 is above the upper switching point, the switch to high vacuum sensor is made.

3. Selection of vacuum gauge, valve and controller

3.1 Selection of vacuum sensor
Like other sensors, various vacuum sensors also have a certain measurement range and accuracy. The basic rule is that a sensor with a wide measurement range has poor accuracy; a sensor with high measurement accuracy has a narrower measurement range. For glove box, as shown in Figure 5, the used vacuum sensors generally have the following three categories:
(1) Conventional vacuum gauge: Pirani vacuum gauge, the accuracy is ±(15~50)% of the full scale, but one vacuum gauge can cover the full scale.
(2) High-precision vacuum gauge: diaphragm pressure gauge, the accuracy is ±2.5% of the full scale, if it covers the range of 10Pa~0.1MPa, two vacuum gauges of 1000Torr and 10Torr are generally required.
(3) Ultra-high precision vacuum gauge: semiconductor vacuum gauge, the accuracy is ±0.05% of the full scale, and the effective range is 50Pa ~ 0.1MPa, which cannot cover higher vacuum.

3.2 Selection of electric valve
In glove box of vacuum control, two types of valves are generally involved: one is an air intake valve that adjusts the flow at air intake, and the other is an exhaust valve that adjusts the exhaust flow. Air intake valves are mostly used for small flow regulation, so needle valves are generally selected. Exhaust valves are mostly used for vacuuming, so ball valves with larger diameters are generally required.

Due to the automatic control, both needle valves and ball valves are required to be driven by DC voltage, DC current or digital signal (RS485) which is the so-called proportional flow control valve. Proportional flow control valve selects a small-sized stepper motor-driven proportional flow control valve, as shown in Figure 6. This proportional flow control valve has high response speed (within 1s) and linearity (within 1%). For FC series proportional flow control valve, please visit https://www.genndih.com/proportional-flow-control-valve.htm

3.2 Selection of controller
From the above various control modes of vacuum degree of glove box, it can be seen that control process of vacuum degree puts forward high requirements for the controller. As shown in Figure 7, the selected controller must meet the following criteria:

(1) At least it is a PID controller, and has the function of PID parameter self-tuning.
(2) The accuracy of vacuum gauge itself is high. In order to give full play to the measurement accuracy of vacuum gauge, PID controller that needs data acquisition and control must have high accuracy. It is recommended that controller should be 24-bit A/D acquisition and 16-bit D/A output. (3) At least 2 channels are required to achieve simultaneous measurement and control of temperature and vacuum degree, also to reduce installation space.
(4) Multiple input signal access functions, which can directly connect the input signals of different types of sensors such as thermocouple, thermal resistance, DC voltage, etc., to achieve simultaneous testing, display and control of different parameters.
(5) Forward and reverse control function to reach two-way control mode.
(6) With dual sensor switching function, each channel can support dual sensor switching of high and low temperature and high and low vacuum. Two channels can form a control combination with a total of four sensors connected.
(7) Program control function, you can create and save multiple control programs by yourself, and you only need to select and call to start (program control mode).
(8) It has a communication interface to connect with computer, such as the RS485 interface of the standard MODBUS protocol.

4. Temperature control of the glove box
In addition to providing a vacuum environment, the glove box can also put a heating device in the glove box to perform various experiments and tests at different temperatures, so it is necessary to introduce temperature control function into glove box application. Temperature control is a very mature and classic technology, which is generally realized by using a PID controller in combination with a temperature sensor. In order to reduce the cost and installation volume, a multi-channel PID controller is generally used to control temperature and vacuum degree at the same time. The controller communicates with a computer to display and store measurement control data and curves. The working temperature in glove box is generally not required to be too high, but if thermal protection and cooling are done well, the working temperature range above 1000°C can also be achieved. The temperature measurement sensor generally chooses a thermocouple. If the measurement accuracy is high, the thermal resistance and the thermistor temperature sensor can also be selected. These sensors can be directly connected to the above-mentioned high-precision PID controller.

5. Conclusion
Through the introduction of above content, the various control methods of vacuum degree and temperature in glove box and the main sensors, proportional flow control valve and PID controllers involved are basically explained. In specific applications, partial improvements can be made to the specific structure and function of glove box, and the overall design, installation and integration of glove box can also be carried out according to actual requirements.
Although this article only introduces the measurement and control of vacuum degree and temperature in glove box, these methods and specific implementation contents can also be extended and applied to the control of test parameters in other fields that are more sensitive to the atmosphere environment, such as low temperature, geometric quantity, optics and acoustics.

Question 9

KaoLu's Electronic Air Flow Control Valve

Accepted Answer

KaoLu's Electronic Air Flow Control Valve

1. Overview
KaoLu's Electronic Air Flow Control Valve is actually the exact same control valve, only the OEM is different. As shown in Figure 1, this gas control valve is a needle valve driven by a stepper motor, which can convert an external control signal into a prescribed valve needle position, thereby adjusting the opening of the valve to reach gas flow control. The external control signal can be in the following three types :
(1) DC simulation voltage (0~10VDC)
(2) Interface module
(3) RS232 interface
For this gas control valve, INFICON and Pfeiffer provided matching controllers, as shown in Figure 2, the models are: INFICON: VCC500-Z; Pfeiffer: RVC 300.
This article will introduce the corresponding technical indicators for the above-mentioned control valves and controllers, and introduce the corresponding localized alternative products and their technical indicators, so as to provide cost-effective products for localized substitution.

2. Technical indicators of foreign products

2.1 Controller Technical Indicators

Operating Mode Pressure Control, Gas flow regulation Analog Output 4 channels: vacuum pressure sensor signal, valve signal(0-10VDC), valve position, +10VDC reference voltage(10mA) Number Output 8 channels: open valve, closed valve, valve position, valve error, sensor error, preparation, divergence, sensor condition Analog Input 2 channels: vacuum pressure set point (standard value),flow set point (standard value) Number Input 8 channels: flow reduction, flow addition, external closure, external open, flow mode, pressure mode, discharge open, exhausting open Characteristic After power outage, turn on output "reach the standard value", then it can adjust tolerance Display Unit mbar, Pa, Torr, mV Language English, German Communication Interface RS232C, RS485

Controller type PI automatic: it can choose control speed step 1-99
PID: Users can define parameters Control Accuracy ±5% FS sensor Display Accuracy ±0.2% FS sensor Power Supply Voltage90 ~250VAC Weight 1.65kg
From the above-mentioned controller technical indicators and practical application experience, it can be found that:
(1) Single-channel measurement and control: that is, only one vacuum gauge signal and one control valve can be collected. Although there are multiple analog and digital input and output channels, only one closed-loop control can be performed. This single channel controller will not be able to cover the wide range that requires two vacuum gauges to cover.
(2) No PID self-regulating function: Sometimes the optimal PID parameters cannot be obtained in the end, which seriously affects the control effect.
(3) Poor control accuracy: The control accuracy is ±5% of the full scale of sensor, which basically shows that acquisition and control circuit in the controller uses 12-bit A/D and D/A converters, which is the key to determining the control accuracy.

3. KaoLu’s electronic air flow control valve replaces INFICON and PFA control valves
The control valve of KaoLu's Electronic Air Flow Control Valve is a typical electronic air flow control valve driven by stepper motor. The performance indicator is very superior. The only disadvantage is that the opening of needle valve is small, thus it causes a small flow. Moreover, the price is too expensive.
In order to reach the replacement of gas flow control valve and improve the low cost high performance, KaoLu also used stepper motor in needle valve technology for localization, and developed a series of electronic air flow control valve with different flow rates.

As shown in Figure 3, fully realized it has been replaced, and the price is only one-third of foreign products. The detailed technical indicators are shown in Figure 4. Please visit https://www.genndih.com/proportional-flow-control-valve.htm

(Figure3 KaoLu’s FC electronic air flow control valve)

Model FC-20 FC-120 FC-300 FC-1000 Valve type Needle Valve Spool Drift Diameter 0.9mm 2.25mm 2.75mm 4.10mm Actuator Bipolar stepper motor control Response time 0.8sec(Open to close) Standard size G1/8” G3/8” Fluid Inert gas and liquid Contact Materials Stainless Steel Pressure Range -1 ~ 7bar -1 ~ 5bar Maximum Flow 50L/min @7bar 240L/min @7bar 290L/min @7bar 600L/min @7bar Linearity ±2% ±0.1 ~ 1% ±0.2 ~ 5% ±11% Repeatability
(Full scale) ±0.1% Flow Resolution (Step length) 0.1L/min 0.1 ~ 0.2L/min 0.2 ~ 0.75L/min 1L/min Shift Resolution (Step length) 12.7um 25.4um Operating Temperature Range 0 ~ 84ºc Seal Standard FKM or other choices of seals Control Signal DC: 0 ~ 10V (or 4 ~ 20mA) Power Supply DC: 24V (12W)

(Figure4 Technical indicators of KaoLu’s FC electronic air flow control valve)

3. Localized high-precision dual-channel PID controller replaces INFICON and PFA controllers
In order to use the measurement accuracy of vacuum gauges fully (such as capacitive film pressure gauges), at least 16-bit analog-to-digital and digital-to-analog converters are required for data acquisition and control of controller. In recent years, KaoLu have developed the FC series of high-precision 24-bit general-purpose PID controllers, as shown in Figure 5. This series of PID controllers is far more powerful than foreign products, but the price is only one-eighth of foreign products. Its main performance indicators are as follows:
(1) Precision: 24-bit A/D, 16-bit D/A.
(2) Multi-channel: independent 1-channel or 2-channel. 2 channels can realize the simultaneous measurement and control of temperature and pressure.
(3) A variety of output parameters: 47 kinds of input signals (thermocouple, thermal resistance, DC voltage) can reach simultaneous test, display and control of different parameters.
(4) Multi-function: forward, reverse, forward and reverse two-way control.
(5) PID control: The improved PID algorithm supports PV differential and differential advance control. There are 20 groups of PIDs.
(6) Dual sensor switching: Each channel can support dual sensor switching of high and low temperature and high and low vacuum. Two channels can form a control combination with a total of four sensors connected.
(7) Program control: You can create and store up to 20 condensation programs by yourself, and you only need to select and call to start condensation (program control mode).

In the vacuum degree control, downstream control mode is more suitable for vacuum degree close to atmospheric pressure, but upstream air intake control mode is required for vacuum degree control of less than 10mbar. Therefore, in order to satisfy the full control degree of vacuum, the dual sensor and two-way control mode as shown in Figure 6 can be used.
In the control mode shown in Figure 6, it is necessary to use the forward and reverse control and dual sensor automatic switching functions of the above FC-20 series dual-channel controller, that is, during different air pressure control processes; the controller automatically switches the corresponding range. Vacuum gauge, and select the corresponding electronic air flow control valve for control.

Question 10

Atmosphere Pressure Control in Vacuum Laser Powder Bed Fusion

Accepted Answer

Atmosphere Pressure Control in Vacuum Laser Powder Bed Fusion

Low pressure SLM fusion process
Features: The molten pool is more stable and reduces porosity. Low-pressure atmosphere requirements: Fast and accurate air pressure control is reached within the process window of 5kPa~101kPa.

Pressure Control
Control method: two-way control method, adjusting upstream air intake electronic air flow control valve and downstream electric ball valve at the same time. It can also adjust the air intake flow and vacuum pump exhaust rate. For further information on electronic air flow control valve, please visit https://www.genndih.com/proportional-flow-control-valve.htm

Sensor: vacuum pressure sensor, the measurement range is 5kPa~101kPa, and the accuracy is ±0.2%.
Controller: two-way PID controller, two-way control function

Question 11

Common errors of proportional valves and cause root analysis

Accepted Answer

What are the common errors of proportional valves? What is the reason of these errors? How to avoid them?

1. Proportional electromagnet error
① Due to the aging of wiring socket (base) of plug assembly, poor contact, and de-soldering of electromagnet lead, the proportional electromagnet cannot work (cannot pass current). At this time, the meter can be used for testing. If the resistance is found to be infinite, the lead wire can be re-soldered, the socket can be repaired and the socket can be inserted firmly.

② The errors of coil components include coil aging, coil burnout, internal disconnection of the coil, and excessive temperature rise of the coil. If the temperature of coil is too high, the output force of proportional electromagnet will be insufficient, and the rest will make the proportional electromagnet unable to work.

If the temperature of coil rises too high, you can check whether the passing current is too large, whether the insulation of enameled wire of coil is poor, whether the valve core is stuck due to dirt to find out the reasons and eliminate them one by one. For disconnection, burnout, the coil must be replaced.

③ The error of armature assembly is mainly due to the wear of the friction pair formed by the armature and the magnetic guide sleeve during use, which leads to an increase in the force hysteresis of the valve. There is also a misalignment between the push rod guide and the armature, which will also cause an increase in the force hysteresis, which must be ruled out.

④ The welding part of the magnetic guide sleeve is broken due to the weak welding or the pulse pressure of the proportional valve during use, so that the proportional electromagnet loses its function.

⑤ The magnetic guide sleeve is deformed under the impact pressure, and the friction pair formed by the magnetic guide sleeve and the armature is worn during use, resulting in an increase in the force hysteresis of the proportional valve.

⑥ The proportional amplifier is shut down, causing the proportional electromagnet not working. At this time, various components of amplifier circuit should be checked to eliminate the error of proportional amplifier circuit.

⑦ The connection between proportional amplifier and the electromagnet is broken or the connection of amplifier terminal is disconnected, so that the proportional electromagnet does not work. At this time, the broken wire should be replaced and reconnected firmly.

2. Error analysis and elimination of proportional pressure regulator
Since the proportional pressure regulator is just based on the ordinary pressurevalve, the pressure regulating handle is replaced by a proportional electromagnet. Therefore, the various errors caused by ordinary pressure valves will also cause error and troubleshooting methods of ordinary pressure valves, which are also completely applicable to the corresponding proportional pressure valves (such as the relief valve corresponding to proportional relief valve), and can be handled with reference.
Beside this there is:

① When the voltage regulation fails, you can first check the current value with electric meter to determine whether there is a problem with the control circuit of electromagnet, proportional electromagnet, or valve part, which can be treated symptomatically.

②Although the current flowing through proportional electromagnet is the rated value, but the pressure cannot go up at all, or the required pressure cannot be obtained, between proportional pilot pressure regulating valve (relief valve) and the main relief valve. The pilot-operated manual pressure-regulating valve of common pilot-operated relief valve is still retained, which acts as a safety valve here. When the regulating pressure of valve is too low, although the passing current of proportional electromagnet is the rated value, the pressure cannot rise. If the set pressure of valve is too low, the pilot flow will flow back to the tank from valve, so that the pressure cannot rise. At this time, the set pressure of valve should be adjusted to be about 1MPa higher than the maximum working pressure of valve.

③ The current flowing through proportional electromagnet has been too large, but the pressure still cannot go up, or the required pressure cannot be obtained. At this time, the coil resistance of proportional electromagnet can be checked. If it is far less than the specified value, then the coil of electromagnet is internally open circuited. If the solenoid coil resistance is normal, then the connection line connected to proportional amplifier is short-circuited. At this time, the proportional electromagnet should be replaced, the wiring should be connected, or the coil should be rewound
and installed.

④ When the pressure is changed stepwise, the pressure fluctuation of small amplitude is continuous, and the reason for the instability of the set pressure is mainly due to the adhesion of dirt between the iron core of the proportional electromagnet and the guide part (guide sleeve), which hinders the movement of the iron core. In addition, the sliding part of the main spool is stuck with dirt, which hinders the movement of the main spool. Due to the influence of these contaminants, the hysteresis is increased. In the range of hysteresis, the pressure is unstable and the pressure fluctuates continuously. Another reason is the wear of the iron core and the magnetic guide sleeve, the gap increases, and the adjusted pressure (through a certain current value) is unstable.

⑤ The pressure response is delayed and the pressure changes slowly because the air in the proportional electromagnet is not cleaned. It is blocked by dirt, and the movement of proportional electromagnet core and the main valve core is unnecessarily hindered. In addition, air enters the system, which usually occurs when the equipment starts to run after being installed or after an occasion of long-term shutdown.

The solution is to loosen the bleed screw before the proportional pressure regulator starts to use, and let out clean air until the oil flows out. In the case of dirt blocking the damping hole, the proportional solenoid and the main valve should be disassembled for cleaning, and at the highest position of the system oil circuit where the air is easy to concentrate, it is best to set the air release valve to release air or loosen the pipe joint to release air.

⑤ The pressure response is delayed and the pressure changes slowly because the
air in the proportional electromagnet is not cleaned. It is blocked by dirt, and the
movement of proportional electromagnet core and the main valve core is
unnecessarily hindered. In addition, air enters the system, which usually occurs
when the equipment starts to run after being installed or after an occasion of long-
term shutdown.

⑤ The pressure response is delayed and the pressure changes slowly because the
air in the proportional electromagnet is not cleaned. It is blocked by dirt, and the
movement of proportional electromagnet core and the main valve core is
unnecessarily hindered. In addition, air enters the system, which usually occurs
when the equipment starts to run after being installed or after an occasion of long-
term shutdown.

⑤ The pressure response is delayed and the pressure changes slowly because the
air in the proportional electromagnet is not cleaned. It is blocked by dirt, and the
movement of proportional electromagnet core and the main valve core is
unnecessarily hindered. In addition, air enters the system, which usually occurs
when the equipment starts to run after being installed or after an occasion of long-
term shutdown.

⑥Two faults of electro-hydraulic proportional relief valve
a. When the rated current (50mA) is input to the coil, the inlet pressure cannot reach the rated working pressure (21MPa), but is 2-6MPa lower than the rated pressure. The reason is: after long-term use, due to the loosening of the fastening screws of the magnetic gap adjustment gasket, the magnetic gap increases, and the magnetic resistance of the magnetic gap (air gap) in the magnetic circuit is very large.

F=k(iN/Rm)2S

where k-constant;
i——the coil input current;
N - the number of turns of the coil;
Rm - magnetoresistance;
S - the cross-sectional area of the magnetic circuit.

It can be seen that as long as the magnetic gap is slightly increased, the reluctance Rm increases significantly, and the electromagnetic force F decreases in a square relationship. The hydraulic clearance increases, the pressure upstream of the nozzle decreases, so the pressure in the upper chamber of the main spool decreases. The force added by reduced pressure and weak spring in the upper chamber of the main valve decreases, so that the opening pressure of the main spool decreases, that is, the inlet pressure decreased, and the maximum pressure (21MPa) could not be reached.

Solution: Appropriately increase or decrease the thickness of the magnetic gap adjustment gasket, tighten the fastening screws of the magnetic gap adjustment gasket, and reduce the magnetic gap, which can increase the inlet pressure. The initial setting of the magnetic gap should be 0.89 ~ 0.94mm.
b. When the input current of the coil is zero, the initial pressure of the valve is too high (4-7MPa). Normally, the initial pressure should be about 1MPa. The minimum set pressure mainly depends on the initial gap 8 of the nozzle baffle. The normal gap is 0.1 to 0.13 mm. If it is too small, the initial pressure will be too high.

3. Error analysis and elimination of proportional flow valve
①The flow cannot be adjusted, and the throttling adjustment function is invalid. In addition to the error analysis and troubleshooting method of speed control valve, there are the following two points: a. Proportional electromagnet failed to energize.
The reasons are: aging of the proportional electromagnet socket and poor contact; unsoldering of the electromagnet lead; wire breakage inside the coil, you can refer to the above "(1) Proportional electromagnet error" method for troubleshooting.

b. Proportional amplifier error. Same as ①, ⑤, ⑥ in the above (2).
②The adjusted flow is unstable. The flow adjustment of the proportional flow valve is reached by changing the current flowing into its proportional electromagnet. When the input current value remains unchanged, the adjusted flow rate should remain unchanged. But in fact, the adjusted flow rate (when the same signal value is input) often changes in the working process, which is caused by the increase of the force hysteresis. Hysteresis means that when the same signal (current) value is input, the maximum change value of the output flow (or pressure) is caused when the same current signal value is passed due to different input directions (forward and reverse directions).

The factors affecting the force hysteresis are mainly caused by the existence of radial unbalanced force and mechanical friction. Then measures such as reducing the radial unbalanced force and reducing the friction factor can reduce the influence of mechanical friction on the hysteresis. The hysteresis is reduced, and the natural change of the adjusted flow is small. The following measures can be taken specifically:
a. Minimize the wear of the armature and the magnetic guide sleeve.
b. The push rod guide rod and the armature should be same.
c. Pay attention to the cleaning of the oil to prevent the dirt from entering the gap between the armature and the magnetic guide sleeve and jam the armature, so that the armature can move evenly in proportion to the input current value without sudden jumping. Once the sudden jump phenomenon occurs, the output flow of the proportional flow valve will also follow the sudden jump and make the adjusted flow unstable.
d. After the magnetizing sleeve armature is worn, noticing repair, so that the gap between the two is kept within an appropriate range. These measures are quite beneficial and effective to maintain the stability of the flow rate adjusted by the proportional flow valve.

In addition, the hysteresis of proportional valve driven by the general proportional electromagnet is 3% to 7%, the hysteresis of proportional valve driven by the torque motor is 1.5% to 3%, and the proportional valve driven by the servo motor is about 1.5%. The proportional flow valve driven by the servo motor has a relatively small change in flow.

For further information about electro-pneumatic pressure regulator, please visit https://www.genndih.com/proportional-pressure-regulator.htm

Question 12

What is the minimum flow valve for pump?

Accepted Answer

The minimum flow valve, also known as the automatic recirculation valve, is a pump protection valve installed at the outlet of water pump to prevent damage to the water pump due to overheating, severe noise, instability and cavitation when it is operating below load. As long as the flow rate of water pump is lower than a certain value, the bypass return port of valve will automatically open to ensure the minimum flow required by liquid water pump.

1. Working principle
The minimum flow valve is connected to the outlet of pump. Like the check valve, the valve flap is opened by the thrust of medium. When the pressure of main channel remains unchanged, the flow rate of main channel is different, and the opening of the valve flap is different. The flap will be determined at a certain position, and the valve flap of main circuit transmits the action of main valve flap to the bypass through a lever to reach the switch state of bypass.

2. Working process When the main valve disc is opened, the valve disc drives the lever action, and the lever force closes the bypass. When the flow rate of the main channel decreases and the main valve disc cannot be opened, the main valve disc will return to the sealing position, closing the main channel. The valve disc drives the lever action again, the bypass is opened, and the water flows from the bypass to the deaerator. Under the action of pressure, the water flows to the inlet of the pump for recirculation, thus protecting the pump.

3. Advantages
The minimum flow valve (also called automatic control valve, automatic recirculation valve, automatic return valve) is a valve that integrates various functions. It has the following significant advantages: 1. The minimum flow valve is a self-operated control valve. The function of the lever will automatically adjust the bypass opening according to the flow (flow adjustment of the system). It is complete mechanical structure, relying on flow control valve, and does not require additional energy.
2. The bypass flow can be adjusted and controlled, and the overall operation of valve is highly economical.
3. Both main channel and bypass have the function of check valves.
4. Three-way T-shaped structure, suitable for recirculation pipeline.
5. Bypass does not require continuous flow, reducing energy consumption.
6. The multi-function is integrated into one, reducing the design workload.
7. It has significant cost advantages in terms of product procurement in the early stage, installation and adjustment, and maintenance in the later stage. It can reduce installation and maintenance costs, and the overall cost is lower than traditional control valve system.
8. Reduce the possibility of error, minimize the possibility of error caused by high-speed fluid. It doesn’t have the problems of cavitations and electrical wiring costs.
9. The stable operation of pump can still be guaranteed under low flow conditions.
10. The protection of pump only needs one valve and no other additional components. Because it is not affected by error, the main channel and the bypass become a whole, which is almost maintenance-free.

4. Installation
The minimum flow valve is installed at the pump outlet and should be installed as close as possible to the protected centrifugal pump. The distance between the pump outlet and the valve inlet should not exceed 1.5 meters to prevent low-frequency water caused by the pulsation of liquid hit. The direction of flow is from bottom to top. Vertical installation is the priority, but horizontal installation is also possible.

5. Maintenance and use precautions
1. The valve should be stored in a dry and ventilated room, and both ends of the valve channel should be blocked.
2. Valves stored for a long time should be checked regularly to remove dirt. Special attention should be paid to cleaning of sealing surface to prevent damage to the sealing surface.
3. It should check carefully whether the valve mark conforms to the use requirements before installing.
4. Check the inner cavity and sealing surface of valve before installing. If there is any dirt, use a cleaning cloth to wipe it clean.
5. After the valve is used, it should be checked regularly to check the sealing surface and O-ring. If the damage fails, it should be repaired or replaced in time.

If you are interested in flow control valve, please visit
https://www.genndih.com/proportional-flow-control-valve.htm

Question 13

Solution of Vacuum Precision Control in Drying Process of Temperature Sensitive Materials

Accepted Answer

Solution of Vacuum Precision Control in Drying Process of Temperature Sensitive Materials
Abstract: Nowadays, some vacuum drying ovens that we often used are equipped with digital temperature control, but basically use manual vacuum control valves. In response to some customers' requirements for upgrading and transforming the automatic vacuum control of the drying oven, this article introduces the vacuum precision control solution. The solution introduces several different control methods in detail, and also includes solutions for simultaneous control of temperature and vacuum to meet the automation control needs of different customers' vacuum drying equipment.

1. Introduction
Temperature-sensitive materials are a class of materials whose physical properties change dramatically and discontinuously with temperature. Drying of temperature-sensitive materials is required in many different industries, such as various additive manufacturing, life sciences, tissue engineering, liquid chromatography, drug delivery, and research and development. Other temperature-sensitive materials include fruits, vegetables and other plants. The ideal method for drying heat- and/or oxygen-sensitive materials is vacuum drying, as it has the advantage of removing moisture at lower temperatures and minimizing possible oxidation reactions. In addition, vacuum drying has the advantage of faster drying and can be performed in an oxygen-deficient processing environment.

The drying of temperature-sensitive materials needs to be carried out in a vacuum drying device. In order to avoid damage to product, it is necessary to precisely control the temperature and vacuum degree in vacuum drying device. The vacuum degree control is particularly important, because it is based on the principle of saturated vapor pressure. In the vacuum drying process, the degree of vacuum determines the upper limit of evaporation temperature of water.

At present, some commonly used vacuum drying ovens are equipped with digital temperature control, but basically use manual vacuum control valve. In response to some customers' requirements for upgrading the automatic vacuum control of drying oven, this article will introduce the vacuum precision control solution. The solution introduces several different control methods in detail, and also includes solutions for simultaneous control of temperature and vacuum to meet the automation control needs of different customers' vacuum drying equipment. Customized solutions to meet the automation control needs of different customers' vacuum drying equipment.

2. Technical Scheme
There are many forms of vacuum drying process and equipment, which can be summarized into the following three types:
(1) Closed cavity type.
(2) Fill with inert gas.
(3) Containers of different volumes.

For the above-mentioned types of vacuum drying devices, corresponding vacuum degree control devices need to be used.
The solution proposed in this article is shown in Figure 1. The selection of the corresponding components in this solution can fully meet the needs of the above-mentioned several types of vacuum drying devices. The different types of controls would be described in detail below.

2.1 Pressure regulation method of closed cavity
For vacuum drying equipment with a closed cavity structure, the precise control of vacuum degree inside the drying equipment can be reached directly by controlling the pressure. The specific pressure control device is only connected to the right part of drying box in Figure 1 (back pressure regulator and vacuum pump), and uses an external vacuum gauge combined with a PID controller to adjust the degree of vacuum.

The back pressure regulator is a vacuum type of back pressure regulator, and the vacuum back pressure regulator is driven by an electric proportional valve. The external vacuum gauge, PID controller and electric proportional valve form a closed-loop control loop, so that the vacuum degree in drying box can be controlled according to any set value, and the vacuum degree curve can also be controlled according to the set program.

2.1 Pressure regulation method of closed cavity
For vacuum drying equipment with a closed cavity structure, the precise control of vacuum degree inside the drying equipment can be achieved directly by controlling the pressure. The specific pressure control device is only connected to the right part of the drying box in Figure 1 (back pressure valve and vacuum pump), and uses an external vacuum gauge combined with a PID controller to adjust the degree of vacuum.

The back pressure valve is a vacuum type back pressure valve, and the vacuum back pressure valve is driven by an electric proportional valve. The external vacuum gauge, PID controller and electric proportional valve form a closed-loop control loop, so that the vacuum degree in the drying box can be controlled according to any set value, and the vacuum degree curve can also be controlled according to the set program.

2.2 The flow adjustment method of the inflation process
For the vacuum drying of some oxygen-sensitive materials, it is necessary to fill in an inert gas for oxygen replacement sometimes. In this case, the control of vacuum degree of drying box needs to adjust the intake and exhaust flow to reach dynamic balance. At this time, the entire vacuum degree control system structure is completely shown in Figure 1.

As shown in Figure 1, the air intake flow is adjusted by an electric needle valve, and the outgoing air flow can be adjusted by a vacuum back pressure valve or an electric ball valve (not shown in the figure). The adjustment of air flow in and out is reached by a closed loop composed of a vacuum gauge and a 2-channel PID controller. Similarly, the vacuum degree in the drying box can be controlled according to any set value, and the vacuum degree curve control can also be performed according to the set program.

2.3 Large-diameter pressure regulating regulator method for large-sized cavity
For some large-sized chambers for vacuum drying of large-volume products, the key point to vacuum degree control is to use a large-diameter regulating regulator, that is, the vacuum back pressure valve (or electric ball valve and electric butterfly valve) in Figure 1 requires a larger diameter in order to reach rapid control of large pumping speed and vacuum degree. At present, the technology of various large-diameter control valves has matured and there are standard products.

2.4 Simultaneous control method of temperature and vacuum degree
For most vacuum drying equipment, two variables, temperature and vacuum degree, need to be controlled at the same time. In the technical solution proposed in this article, a 2-channel high-precision PID controller is used, and two channels can be used to control temperature and vacuum degree at the same time, that is, two independent closed-loop loops are formed by connecting the temperature sensor and the vacuum degree sensor to control.

In addition to the 0-10V voltage signal output by vacuum sensor, the two-channel PID controller can also be connected to the input signal of various temperature sensors (thermocouple, platinum resistance, thermistor, etc.). Especially using 24-bit A/D analog-to-digital and 16-bit D/A digital-to-analog converter, this two-channel PID controller can reach high control accuracy.

3. Summary
Through the above technical solutions, the requirements for automatic control of temperature and vacuum degree in the drying process of temperature-sensitive materials can be fully met, and high control accuracy can be reached (absolute pressure 10Pa - 0.1MPa, control accuracy better than 2%).

Are you interested in KaoLu's Proportional Flow Control Valve? You can feel free to visit our website!

Question 14

High Precision Pressure Control Solution for PVT Method SIC Crystal Growth Process and Localized Replacement of Its Supporting Equipment

Accepted Answer

High Precision Pressure Control Solution for PVT Method SIC Crystal Growth Process and Localized Replacement of Its Supporting Equipment

1. What is Silicon carbide single crystal material?
Silicon carbide single crystal material, which is also known as a wide band gap semiconductor material. It has excellent physical and electrical properties, especially suitable for manufacturing high temperature, high frequency, high power, radiation resistance, short wavelength light emitting and optoelectronic integrated devices, so it is widely used in aviation, aerospace, radar, communications and other fields. At present, the growth of silicon carbide single crystal generally adopts the PVT method.

Since the ultimate purpose of growing silicon carbide single crystal is to obtain large-sized, low-defect silicon carbide single crystal, as the size of silicon carbide single crystal increases, the vacuum pressure control in the single crystal furnace is extremely demanding, and the process gas Pressure changes have a great influence on the growth rate and crystal quality of SiC crystals. Figure 1 shows the time-dependent curves of pressure, temperature and process gas in a typical SiC single crystal growth process.

It can be seen from the process curve shown in Figure 1 that the pressure control in the crystal growth furnace is a precise change process in the whole vacuum degree range, and the whole vacuum degree change range spans between low vacuum and high vacuum (-4 5 -1 510 Pa ~10 Pa), especially in the low vacuum range of 10 Pa~10 Pa, which requires precise control. At present, when using PVT method to prepare SiC single crystal, there are still the following problems:

(1) The downstream mode (adjusting the gas outlet rate) is generally used to control the change of vacuum degree in the whole process. The control accuracy is extremely poor in higher vacuum range of 0.1~1000Pa, and the pressure fluctuation in the crystal growth vessel is large (about ±10%).
(2) The regulating valve and PID controller used in vacuum control device basically use Upstream Flow Control Valves, Downstream Exhaust Throttle Valves and its PID Valve Controllers. Although there are various downstream exhaust throttle valves integrated with a PID controller in an integrated structure in order to reduce costs, the overall cost is still relatively high.
(3) Alternative products for vacuum pressure in Taiwan are also gradually emerging, but there are still problems such as large valve leakage rate, long valve adjustment response time, and inability to automatically switch vacuum gauges of different ranges, which makes it impossible to use both upstream and downstream control modes to reach high-precision control of vacuum pressure within the range.

This article will conduct a detailed technical analysis on the problems existing in vacuum pressure control of the above-mentioned PVT SiC single crystal growth process, and propose corresponding solutions. The core of solution is to adopt the upstream and downstream simultaneous control method to greatly improve the control accuracy and stability in the full pressure range, and introduce the corresponding low leakage rate and high response speed of KaoLu’s Proportional Pressure Regulator and ultra-high High-precision industrial PID controllers, thus reaching the replacement of corresponding imported products.

2. Analysis of Stress Change Process in Silicon Carbide Single Crystal Growth
Figure 1 shows the change curves of pressure, temperature and gas flow during the current PVT method for the growth of third-generation silicon carbide single crystal, in which red line represents a very typical vacuum pressure change process. By analyzing the change process of vacuum pressure at each stage, in order to deeply understand the requirements of vacuum pressure change during growth of SiC single crystal by PVT method.
As shown in Figure 1, the variation of vacuum pressure during the growth of SiC single crystal is divided into the following stages:
(1) High vacuum stage: In the high vacuum level, a high vacuum (1xPa - 1x Pa) to remove air and moisture from containers and materials. This high vacuum level requires that the air pressure needs to be depressurized at a slow and constant rate, thereby avoiding the formation of dust from the silicon carbide powder.
(2) Pre-growth stage: Similarly, in the pre-growth stage, with the filling of process gas and the gradual increase of temperature, the air pressure in container is also required to gradually increase to normal pressure or slightly positive pressure at a constant rate and gas displacement to further remove air and moisture.
(3) Growth stage: In the crystal growth stage, the pressure of container is required to be gradually reduced to a certain set value (growth pressure) at a constant speed and kept constant for a long time. Different growth equipment and processes generally use different growth pressures.
(4) Cooling stage: In the cooling stage, as the temperature gradually decreases, the air pressure in container is required to gradually increase to normal pressure or slightly positive pressure at a constant rate.

It can be seen from the several stages of pressure change during the above single crystal growth process that vacuum pressure control device must meet the following main technical indicators, and these are basically the technical indicators that imported products have reached:
(1) Leak rate: less than 1×Pa./s
(2) Control accuracy and long-term stability: Under any vacuum pressure, the control accuracy is better than 1% (or even 0.5%), and the long-term stability is better than 1% (or even 0.1%).
(3) Response speed: less than 1sec. The response speed also determines the control accuracy and long-term stability. Especially under the joint influence of temperature and flow, vacuum pressure will fluctuate rapidly. Fast response speed is the key to ensuring precise control.
(4) Connecting vacuum gauges with different ranges: 2 capacitance vacuum gauges with different ranges can be connected to cover the entire vacuum pressure measurement control range, and the sensor can be automatically switched and controlled according to the corresponding vacuum degree.
(5) Programmable control: The setting of any pressure control curve can be programmed, and multiple control curves can be stored for the calling of different process control.
(6) PID parameters: can be self-tuning, and can store and call multiple groups of PID parameters.
(7) Communication with the host computer: communicate with the host computer (such as PLC and computer), and has a standard communication protocol.

3. High precision vacuum pressure control solution
It can be seen from the above analysis that pressure required for different silicon carbide crystal growth processes is a wide range from 0.2Pa to 80kPa. At present, the downstream control mode is generally used in pressure process of crystal growth process around the world. A throttle valve is installed between growth vessels.

Vacuum pressure control is reached by constant upstream intake flow and adjusting downstream exhaust flow through throttle valve. For the high pressure range greater than 1kPa, this downstream control mode is very effective and can reach precise pressure control, but for low pressure range (0.1Pa~1kPa), the control effect of downstream mode is extremely poor, and it is necessary to adjust air intake flow and constant downstream. Upstream control mode is for pumping flow.

In addition, the upstream control mode has been widely used in the field of vacuum control, and we have also confirmed in the previous practical application and verification tests that upstream mode can reach precise control of low pressure below 1kPa.

In summary, to reach precise control of vacuum pressure in the full range of 0.2Pa to 80kPa, it is necessary to use upstream and downstream modes respectively. Therefore, we propose a high-precision control solution for vacuum pressure that can implement both upstream and downstream modes. The structure of vacuum pressure control system with simultaneous upstream and downstream control is shown in Figure 2.

In the solution shown in Figure 2, two capacitance vacuum gauges are used to cover the full vacuum range of 0.2Pa to 80kPa. The measurement signals of vacuum gauges are sent to PID controller, which drives upstream electronic proportional flow control valve respectively. And the downstream electric ball valve, the closed-loop control loop reaches the precise control of vacuum pressure in the full range. The specific control process of vacuum pressure is:
(1) When the pressure control setting value is in the high pressure range greater than 1kPa, the PID controller is in the downstream control mode, the PID controller adjusts upstream electronically controlled needle valve to a constant opening, and performs automatic PID control on downstream electronically controlled valve. The pressure measurement value in growth vessel can be quickly equal to the set value by quickly adjusting the opening degree change of electronically controlled ball valve.

(2) When the pressure control setting value is in the low pressure range of less than 1kPa, the PID controller is in upstream control mode, the PID controller adjusts downstream electronically controlled ball valve to a constant opening, and performs automatic PID control on upstream electronically controlled needle valve. The pressure measurement value in the growth vessel can be quickly equal to the set value by rapidly adjusting the opening of the electronically controlled needle valve.

4. Localized Substitution of Supporting Devices
The solution proposed in this article can reach high-precision vacuum pressure control on the premise that vacuum gauge, electronically controlled valve and PID controller meet the technical requirements. The highest accuracy, the stability can easily reach ±0.5% of the set value, and even in most vacuum pressure ranges, the stability can reach ±0.1% of set value.

In the process of vacuum degree control in the range of 0.1Pa~100kPa, foreign products are widely used in the current vacuum technology application field. With the development of localization technology, in addition to film capacitance vacuum gauges, the main supporting devices of other vacuum pressure control systems have completely reached breakthroughs in key technologies. Such as localization, low leak rate and fast response so that the overall technical indicators are similar to foreign products. The PID controller has higher measurement and control accuracy than foreign products, and also has a two-way mode control function that foreign products cannot temporarily reach.

The key supporting devices replaced by localization include electronically controlled needle valves and electronically controlled ball valves for high-speed and low-leakage vacuum, as well as multi-functional ultra-high-precision general-purpose PID controllers, as shown in Figure 3.

(Figure3 KaoLu’s Proportional Flow Control Valve)

KaoLu’s proportional flow control valve shown in Figure 3 all meet the technical requirements in Section 2, especially the high-precision industrial PID controller has excellent performance, among which 24-bit analog-to-digital conversion and 16-bit digital-to-analog conversion. The 0.01% minimum output percentage of double-precision floating-point operation is currently the top index of industrial PID controllers around the world, which can reach ultra-high-precision control of process parameters such as pressure, temperature and flow.

5. Conclusion
For the PVT single crystal growth process, the upstream and downstream bidirectional control solution proposed in this article can reach fast and high-precision control of vacuum pressure in the full range. This solution has been applied in many vacuum technology fields, and the corresponding electronic proportional flow control valve and electric ball valve have similar technical indicators of foreign products, and industrial ultra-high-precision PID controller has excellent performance. These supporting devices combine various vacuum pressure sensors and bidirectional control methods to achieve high-precision control of vacuum pressure.

Further information about KaoLu's Proportional Flow Control Valve, please visit our website.

Question 15

Application of Vacuum Precision Control - The Secret of Drying Fine Powder in Vacuum Oven

Accepted Answer

1. What is Vacuum Drying?

Vacuum drying is a drying method that puts materials under vacuum negative pressure conditions, and appropriately heats them to reach the boiling point under negative pressure, or cools down to make the materials solidify and then dry the materials through the melting point. Common dryer types mainly include tray, fluidized bed, spray, rotary, and vacuum oven dryers.

Vacuum drying process is carried out in a closed chamber connected to a vacuum pump, while vacuum oven uses the balance of temperature and vacuum pressure to reduce the humidity in chamber and product being dried. This technology is the most common laboratory, research and industrial drying for heat sensitive, hygroscopic or toxic powders and granules. For example, industries that commonly use dry powders include pharmaceuticals, food processing, plastics, and chemical processing.

For the vacuum drying of fine powder, one of the common problems is that no matter what type of drying equipment is adopted, the dry powder will accumulate into lumps or layers in various positions in dryer or in downstream process equipment such as vacuum pumps, thus affecting normal operation and service life of vacuum pump. Other potentially dangerous problems can arise if fine powder expelled from vacuum pump.

Recently, a vacuum oven manufacturer clearly proposed to upgrade the existing vacuum oven technology, and asked us to provide corresponding technical supporting measures to completely solve the above-mentioned problems in process of drying fine powder in vacuum oven. This article will introduce the corresponding solutions in detail. The core of solution is to reach the controlled discharge of vacuum oven, so that vacuum degree of oven has a slow and controllable change process. This article also introduces in detail the key technical parameters and functions of the corresponding supporting devices in the solution.

2. How to solve the problem of Vacuum Drying?

In the process of vacuum drying fine powder without dust and accumulation, two measures need to be taken:

Emission control: Lead a small amount of dry air or nitrogen into vacuum box to remove water vapor in box, and also heat it at the same time, so that cycle flushing through exhaust/intake will help to speed up drying process. However, when drying fine powder, if exhaust is not controlled, the process can also wash away it, so a precise and controllable exhaust valve is used to control exhaust flow.
Vacuum control: The change of vacuum degree in drying process must be precise and controllable, especially as drying time prolongs, the change of vacuum degree should be slower to avoid possible dust generation and being brought into air outside dryer.

It can be seen that the key to solving problem of vacuum drying of fine powder is to reach the program control of vacuum degree. The vacuum degree control program includes two types: linear change and constant, and control program can be set arbitrarily, so that various vacuum drying processes can be carried out. The technical transformation plan of vacuum oven designed according to the idea of vacuum program control is shown in Figure 1. The entire vacuum control system mainly includes KaoLu's Proportional Flow Control Valve, vacuum gauge, programmable PID controller and vacuum pump, PID controller to adjust the opening of KaoLu's Proportional Flow Control Valve respectively to reach the change of vacuum degree in box according to set procedure.

For the vacuum degree control of fine powder drying process, the key is to make vacuum degree change according to a certain set rate, which will change vacuum degree in oven from atmospheric pressure to air pressure in a long period of time (such as 10-20 minutes) and slowly reduce to desired low pressure. The so-called rate is amount of change per unit time, such as slope of 10Torr /min means that vacuum degree changes gradually by 10Torr within 1 minute.

For a dry powder process of one of our customers, they chose a depressurization rate of about -150Torr/min. They would start at 750 Torr, and pressure would go to 600 Torr about one minute. Then the next minute to 450 Torr until they reached their set target pressure. After the target pressure is reached, automatic constant control can also be continued at target pressure. In this way, through this automatic vacuum control method, it can be

This vacuum degree control system for fine powder drying process has the following characteristics:

Vacuum degree control is reached by adjusting air intake flow through Proportional Flow Control Valve. In vacuum degree control process of high pressure range, KaoLu's Proportional Flow Control Valve responsible for upstream air intake is adjusted to a certain opening and kept constant, and exhaust flow is adjusted through downstream Proportional Flow Control Valve to reach vacuum control.

In addition, KaoLu's Proportional Flow Control Valve equipped here are all high-speed valves, and the time from fully closed to fully opened is less than 1 second, which is very suitable for dynamic control of vacuum degree. The use of 0~10V or 4~20mA analog signals can directly driven, and KaoLu's Proportional Flow Control Valve has a low vacuum leakage rate, which is suitable for high vacuum requirements of various closed equipment.

To sum up, the programmable vacuum degree control solution described in this article is highly mature in technology. After a large number of experiments, the feasibility and reliability of this solution have been verified. The vacuum degree control accuracy can easily reach within ±1%, which can be completely solve the problem of dust and fouling caused by drying fine powder in vacuum oven, this solution has also been applied in many other vacuum equipment and processes.

For further information about KaoLu's Proportional Flow Control Valve, please refer to our website.

Question 16

Electronic Flow Controller Features Explained

Accepted Answer

Introduction of Electronic Flow Controller (EFC)

EFC is an electronically controlled regulator that provides excellent repeatability over a wide flow range. It features a fast flow response time and a higher flow rating than do mechanical flow controllers. The EFC can be used in automatic control, high resolution and repeatability applications where count-by-count control is necessary.

Because the EFC is an electronically controlled regulator, the opening of the control valve has been increased to provide faster response times. The EFC is ideal for use in critical applications where count-by-count control is necessary.

Its high resolution and accurate repeatability make it ideal for use in critical applications where count-by-count control is necessary.

The EFC's high resolution and accurate repeatability make it ideal for use in critical applications where count-by-count control is necessary. Examples of critical applications include:

Chemical process systems requiring extremely precise mixing or dilution rates, such as those used in the semiconductor industry.
Food processing plants where precise amounts of ingredients are added to each batch, such as chocolate manufacturers.

EFCs are also used in non-critical applications, such as water treatment plants that require consistent measurement of flow rate over time periods longer than a day but not on the order of years or decades (as would be required for nuclear power plant cooling towers).

It also features a fast flow response time and a higher flow rating than do mechanical flow controllers.

The EFC is a high-tech, electronically controlled regulator that provides excellent repeatability over a wide flow range. It has a fast flow response time and a higher flow rating than do mechanical flow controllers.

The Electronic Flow Controller (EFC) is a high-tech, electronically controlled regulator that provides excellent repeatability over a wide flow range.

The Electronic Flow Controller (EFC) is a high-tech, electronically controlled regulator that provides excellent repeatability over a wide flow range. The EFC has a faster response time than mechanical flow regulators and offers greater rangeability. The remote display indicates both the actual and setpoint values in real time. It also features an auto-lock feature to prevent accidental movement of the knob when transporting or storing your machine.

Automatic control, high resolution, high repeatability, compatible with air/water/oil

Before we get into the important details of what makes an Electronic Flow Controller (EFC) different from other types of flow controllers, let's look at some of the benefits that make it an attractive choice:

Automatic control - Your EFC does not require manual adjustment. Once set up and programmed, it runs on its own to provide consistent and accurate process control.
High resolution - You can program a full range of values from 0% to 100%. The resolution will depend on your device, but typically they have up to 8 bits worth of precision (256 possible settings). This means you can fine-tune your system with extremely accurate measurements at very low flow rates or high ones; anywhere in between is no problem either!
High repeatability - With any kind of controller, repeatability refers to how closely two successive measurements will correspond with one another over time as long as input conditions remain constant. For example, if you were using a manual valve for open/close control instead and wanted 20 mL/min flow rate adjusted by hand every second based on some meter readings from upstream or downstream equipment (you would do this because manually adjusting valves is easier than programming instructions into a computer), then each successive measurement would result in slightly different values because there would be human error involved each time--maybe someone accidentally moved their finger too fast when setting up their positioner valve housing! But once again we're talking about automatic control here...and if your EFC has been configured properly then every value should match up perfectly every single time regardless how many times per second data needs updating via PLC communication link!

Features

The EFC is fully automatic, with a high resolution and high repeatability for stable and accurate control. It is compatible with air/water/oil users have the option to select the best working fluid for their application.

Low cost, easy to use electronic flow controller

The electronic flow controller is a low-cost, easy-to-use device that can be used in any application where it is necessary to control the flow of fluid through a pipeline. It works by measuring the pressure drop across its sensing element and then transmitting this information back to your controller via an analogue signal. The device uses very little power and has no moving parts, making it ideal for environments where space and reliability are at a premium.

Higher resolution

The EFC is capable of providing a flow control resolution of 0.1% of the full-scale flow rate, or 1% of the full-scale flow rate. In addition, the EFC provides closed loop proportional control that can be commanded from 0% to 100%. The minimum step size is 0.1% (or 1%) of full scale for proportional control and 0.01% (or 1%) for integral action.

Faster response time

A faster response time means that the EFC can respond more quickly to changes in flow, which can be critical when it comes to medical applications.
Better repeatability and higher resolution means that the EFC can more easily maintain consistent flow rates over time with less drift.

Better repeatability

Repeatability is the ability to reproduce a value multiple times. Repeatability is a measure of how well a process can be reproduced and it's important for manufacturing and quality control, as well as scientific research. For example, if you are trying to test whether your new sunscreen blocks UV rays or not and you want to determine whether it works by measuring how much UV light passes through the solution, you would need to have consistent measurements in order for them to be useful.

Greater rangeability

In a mechanical controller, there is always some flow loss. This is due to the pressure drop that occurs in the control valve and piping from the pump. In contrast, an EFC can control flow within one percent accuracy with no pressure drop. Additionally, EFCs have a faster response time than their mechanical counterparts because they use electrical signals rather than pneumatic ones to open and close valves (which require power).

Conclusion

The Electronic Flow Controller (EFC) is a high-tech, electronically controlled regulator that provides excellent repeatability over a wide flow range. Automatic control and high resolution make it ideal for use in critical applications where count-by-count control is necessary. Its fast flow response time also makes it ideal for high flow applications such as cooling towers and process water systems. The EFC has been approved by the factory for use with air/water/oil based fluids at pressures up to 100 psi and temperatures up to 400°F (204°C).

Question 17

比例圧力調整器&電子流量制御

Accepted Answer

比例圧力調整器に関するお問い合わせは、以下の項目をお知らせください：

1. バルブへの入口空気圧

2. 出力圧力範囲

3. 流体タイプ

4.最低圧力出力要求

5.用途

電子流量制御バルブに関するお問い合わせは、以下の項目をお知らせください：

1.バルブの入口圧力

2. 出力流量範囲

3. 流体タイプ

4. 必要最小流量

Question 18

How Does a Proportional Valve Work?

Accepted Answer

A proportional valve is an advanced control valve that regulates pressure, flow, or force by adjusting its opening based on an electrical input signal. Unlike traditional on/off valves, proportional valves allow for variable control, making them essential in precision applications.

Working Principle of a Proportional Valve

Proportional valves function by using an electric current to control the position of an internal spool or plunger. The higher the current, the more the valve opens, allowing for fine-tuned adjustments in pressure or flow. This smooth modulation is what sets proportional valves apart from conventional solenoid valves, which only operate in fully open or closed states.

Key Components of a Proportional Valve

Solenoid Coil – Converts electrical signals into mechanical movement.
Plunger or Spool – Regulates the flow by moving in response to the coil’s magnetic force.
Spring Mechanism – Helps return the plunger or spool to its default position when power is reduced.
Valve Body – Houses the internal components and directs the flow of fluid or gas.

Advantages of Proportional Valves

Precise Control – Enables real-time regulation of pressure and flow.
Energy Efficiency – Minimizes power consumption by reducing unnecessary actuation.
Smooth Operation – Prevents sudden pressure surges, ensuring stable system performance.
Compact Design – Suitable for applications with space constraints.
Extended Lifespan – Reduces wear and tear due to gradual modulation instead of frequent switching.

Applications of Proportional Valves

1. Laser Cutting Machines

Proportional valves control assist gas pressure, ensuring clean and precise cuts with optimal efficiency.

2. Blow Molding Machines

These valves regulate air pressure to maintain uniform plastic molding, improving product consistency.

3. Medical and Semiconductor Equipment

In high-precision industries, proportional valves help maintain stable vacuum or pressure levels for delicate operations.

Choosing the Right Proportional Valve

When selecting a proportional valve, consider:

Pressure and Flow Requirements – Ensure compatibility with your system’s specifications.
Response Time – Choose a valve with fast, accurate response for dynamic applications.
Material Compatibility – Verify that the valve materials suit the working fluid.
Voltage and Electrical Characteristics – Ensure proper integration with the power supply.

Proportional valves are critical for applications that require precise pressure and flow control. Their ability to provide variable modulation enhances efficiency, performance, and durability compared to traditional on/off valves.

For industries like laser cutting, blow molding, medical, and semiconductor manufacturing, selecting a high-quality proportional valve can significantly enhance system performance and reliability.

Looking for high-performance proportional valve? Explore KaoLu’s cutting-edge solutions designed for precision control and efficiency.

Question 19

What Voltage Does a Proportional Valve Control?

Accepted Answer

A Proportional Valve is a type of control valve that regulates pressure, flow, or force by adjusting its opening in response to an electrical input signal. Unlike traditional on/off solenoid valves, proportional valves allow for smooth and precise control, making them essential in industries such as laser cutting, blow molding, medical devices, and semiconductor manufacturing.

Common Voltage Ranges for Proportional Valve

Proportional valves operate using different voltage levels depending on their design and application. The most common voltage ranges include:

1. Low Voltage (12V - 24V DC)

12V DC – Common in automotive and mobile hydraulic systems where battery power is used.
24V DC – The standard voltage for industrial automation, pneumatic control, and precision fluid regulation.
Advantages:
- Energy-efficient operation.
- Safe and widely compatible with industrial control systems.
- Smooth and precise modulation of flow or pressure.

2. High Voltage (110V - 240V AC)

110V - 120V AC – Used in North America for certain industrial and HVAC applications.
220V - 240V AC – More common in Europe and high-power applications.
Advantages:
- Suitable for high-power applications.
- Reduces the need for voltage conversion in specific regions.
- Often used in heavy industrial environments.

Choosing the Right Voltage for a Proportional Valve

When selecting a proportional valve based on voltage, consider the following factors:

Application Requirements – Ensure the voltage range matches the system’s control and power needs.
Power Supply Compatibility – Verify that the available power source aligns with the valve’s voltage specifications.
Response Time – Lower voltage valves (such as 24V DC) typically provide finer and more precise control.
Safety Considerations – Lower voltage options (12V or 24V DC) are often preferred in sensitive or mobile applications for safety and efficiency.

KaoLu's Proportional Flow Control valve are designed to operate at different voltage levels, with 12V and 24V DC being the most common for industrial automation and precision control. Higher voltage options, such as 110V to 240V AC, are used in specialized high-power applications. Selecting the right voltage ensures optimal performance, safety, and efficiency in various industries.

For industries like laser cutting, blow molding, medical, and semiconductor manufacturing, choosing the correct proportional valve voltage can enhance system reliability and precision.

Looking for high-quality proportional valves? Explore KaoLu’s advanced solutions designed for precision control and efficiency.

Question 20

Proportional Regulator in Robotic Grippers

Accepted Answer

In the rapidly evolving world of industrial automation, robotic grippers are becoming essential tools for tasks requiring speed, flexibility, and precision.
To enable accurate control of gripping force and pressure, many advanced systems now integrate a Proportional Regulator — a device that delivers real-time, fine-tuned pneumatic pressure control.
This article explores the crucial role of KaoLu's Proportional Regulators in robotic grippers and how they enhance performance in various industrial applications.

What is a Proportional Regulator?

A Proportional Pressure Regulator, also known as an electro-pneumatic regulator, precisely controls air pressure in response to an electrical input signal (typically 0–10V or 4–20mA).
Unlike on/off solenoid valves, KaoLu's Proportional Regulator can continuously modulate the output pressure to match dynamic system requirements.

Why Use KaoLu's Proportional Regulator in Robotic Grippers?

Robotic grippers are tasked with handling objects of varying shapes, sizes, and fragility.
In such scenarios, grip force must be carefully controlled to avoid damaging delicate items or failing to hold heavier parts securely.

Benefits of Using Proportional Regulators in Gripper Systems:

Precise Force Control

Proportional regulators enable gradual and responsive pressure adjustment, allowing robotic fingers to apply just the right amount of force for different materials — from fragile glassware to rigid metal parts.

Enhanced Safety

Soft-touch gripping reduces the risk of crushing or slipping, especially important in collaborative robots (cobots) working near humans.

Increased Flexibility

With programmable pressure control, a single gripper can be used across multiple SKUs or production lines, accommodating various part geometries and materials.

Faster Cycle Times

The fast response time of proportional regulators contributes to quicker adjustments between tasks, increasing overall throughput.

Repeatability and Accuracy

Digital control ensures consistent and repeatable pressure output, crucial for high-volume, high-precision assembly and packaging tasks.

Common Applications of Proportional Regulators in Robotics

Electronics assembly – handling circuit boards, sensors, or displays
Automotive manufacturing – gripping interior trim or sensitive parts
Food & packaging – automated picking of delicate items like pastries or fruit
Medical device handling – precise control in cleanroom environments
Laboratory automation – pipette gripping and test tube transfer

Integration with Robotic Control Systems

Proportional regulators are typically integrated into robot control architectures using:

Analog input from PLCs or robot controllers
Digital communication (Modbus, IO-Link, etc.)
Feedback sensors for closed-loop control

Many modern robotic grippers are now designed with internal pneumatic circuits ready for plug-and-play proportional regulators, simplifying system integration.

Key Features to Look For

When selecting a proportional regulator for robotic applications, consider:

Pressure range and resolution
Response time and hysteresis
Compact size for end-effector mounting
IP protection rating and vibration resistance
Compatible I/O and communication protocols

KaoLu's Proportional Regulator is suitable for advanced robotic systems!

Integrating a Proportional Regulator into robotic grippers significantly improves the flexibility, accuracy, and safety of automated handling systems.
As industries shift toward smarter, more adaptive manufacturing, digital pressure control becomes not just beneficial — but essential.

More information about KaoLu's Proportional Regulator, please refer to our website.