Question 1

Gas Blending

Accepted Answer

Our QKL electronic proportional pressure regulator ( I/P converter) products help with gas blending applications that need repeatable pressure control. By controlling the pressure of each specific gas to a process, a tailored blend can be achieved. Here two QKL proportional pressure regulator ( I/P converter) are controlling the pressure of two types of media in a gas blending application. Our proportional pressure regulator can also work in tandem with the proportional flow control valve to stabilise the inlet air pressure, and thus stabilise the flow rate after the flow control valve.
We also provide proportional flow control valve in this application, which can directly replace those of Burkert or Festo.

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Question 2

Screen printing of electronic air pressure regulator

Accepted Answer

At present, silicon solar cells occupy most market of photovoltaic power, and are very important in terms of efficiency improvement and cost control. As an important part of silicon battery production, the screen printing of silicon battery electrodes directly affects the competitiveness of screen printing equipment in the market on the accuracy, efficiency and cost of printing equipment.

Screen printing is to attach a stencil with an image or a pattern to the screen for printing. When the substrate is placed directly under the screen with the stencil, the screen printing ink or paint passes through the extrusion of the squeegee. The mesh in the middle of the screen is printed on the carrier. One of the most important steps is the precision and pressure of the squeegee drop, which directly affects the layer thickness and shape of the printing, and even causes the silicon wafer to be damaged because the drop distance of the squeegee is too large. Therefore, the control of the squeegee is an important part of screen printing. The proportional pressure valve manufactured by KaoLu provides a comprehensive solution for screen printing equipment manufacturers with the advantages of high precision and high response.

KaoLu’s electronic air pressure regulator controls the corresponding pressure by controlling the input signal, and the output controls the corresponding movement of the cylinder to push the scraper speed to accurately drop to the required height, and transmit it to the controller in real time through the feedback signal. This is a method of pre-calculating the electronic air pressure regulator, which uses the linear characteristics of the electronic air pressure regulator to accurately control the pressure of screen printing blade to meet the accuracy required by the power system of screen printing machine. KaoLu’s electronic air pressure regulator adopts new technology, which enables it to achieve high control accuracy, and is widely used in the printing industry at present. KaoLu’s electronic air pressure regulator uses pneumatic components and semiconductor sensors to improve accuracy and response by adjusting the proportional pressure signal. The pressure control system of screen printing machine is composed of a electronic air pressure regulator, a screen printing scraper, a touch screen, a cylinder and a programmable logic controller. The schematic diagram is as follows:

Set the working pressure of silk screen scraper on the touch screen, the PLC controller will calculate and convert it into the digital quantity required by the analog output module, and the analog output module will output a certain voltage value to the proportional pressure valve. The electronic air pressure regulator will output the pressure according to the voltage signal, and the internal pressure sensor detects that the set pressure value is reached, that is, the pressure adjustment is completed.

Proportional pressure valves are not only used in the screen printing machine industry, but KaoLu’s electronic air pressure regulator can be widely used in industrial applications, automotive industry, inkjet industry and blow molding industry.

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Question 3

Electropneumatic Proportional Valve and Control Valve

Accepted Answer

Electropneumatic proportional valve is referred to as proportional valve, ordinary pneumatic valve can control the fixed value of equipment through pre-adjusted liquid flow pressure and flow. The feedback is reached by continuous changing speed of slow, fast and slow, or by simulating a good control curve with a certain precision to realize the force control. The ordinary pneumatic valve is controlled by pneumatic system of electropneumatic proportional valve.

Control valve consists of two main assemblies: valve body assembly and actuator assembly (or actuator system), which are divided into four series: single-seat series control valve, double-seat series control valve, sleeve cylinder series control valve and self-operated series control valve. Variations of four types of valves can lead to many different applicable configurations, each with its own specific applications, features, advantages and disadvantages. While some control valves are used in a wider range of applications than others, control valves are not suitable for all applications to work together to create the best solution for enhanced performance and reduced cost.

The electropneumatic valve is a pneumatic component that drives the valve core by an electromagnetic coil, while the control valve is a component that generates electromagnetic force through electromagnetic induction. The greater the current of the control valve, the greater the thrust, so will different energization currents for the common solenoid valve coils make the original on-off valve become a proportional valve?

This problem is obviously negative. Generally speaking, the internal processing of ordinary solenoid valves cannot achieve the processing accuracy of proportional valves. In addition, its internal structure does not consider too many parameters such as pneumatic pressure balance. Therefore, when the electromagnetic force is not large, the valve core cannot be stabilized in the transition position, and the electromagnetic switch valve cannot represent the proportional performance. Or the proportional performance of the solenoid switch valve is very inconspicuous. Therefore, the design and manufacturing process of proportional valves must be very different from those of on-off valves, requiring more investment in research and development.

Another question: For the same proportional valve, can the drive current of the solenoid coil be directly powered by the DC model without using the proportional amplifier? This method is possible in principle. The variable resistance signal can be used for coil control. However, it will waste a lot of energy, and at the same time, it will be accompanied by a lot of heat, and there will be no flutter and current when the valve core moves. Due to the feedback effect, the performance of the valve cannot be optimized.

In addition to the internal current feedback of the amplifier, the high-frequency dither signal is also an important function. The high-frequency flutter signal can keep the proportional spool vibrating at all times, so that it can overcome the influence of static friction and try to eliminate the influence of hysteresis on its performance.

A proportional amplifier is an electronic device used to provide a specific performance current to a proportional electromagnet, and to perform open-loop or closed-loop regulation of an electropneumatic proportional valve or electropneumatic proportional control system. So, what performance does the so-called specific performance current refer to?

To sum up, using a proportional amplifier can achieve the following functions: control the amount of current applied to the coil by the valve, set the minimum and maximum input signal of the proportional valve, set the minimum and maximum output current, and also set the ramp-up and ramp-down time, and finally set The frequency of the dither signal is obtained through the built-in current negative feedback function.
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Question 4

Glass Bottle Blow Molding

Accepted Answer

This sketch shows a QKL Electronic proportional pressure regulator ( I/P converter) piloting a volume booster in a glass bottle blow molding application. Most glass bottles are manufactured via the "press & blow" method. In this method the pressure regulator is used at the final stage to fill air into the molten glass in a mold.

Our proportional pressure regulator is best suited for this application due to its high flow rate, fast response time, and high accuracy. Our regulators are capable of modulating from 2 bar to 65 bar with accuracy of 0.25% FS. (higher pressure range can be customised upon request)

QKL electronic pressure regulator can directly replace:
Proportion Air ( QB3H, QBS, GX, QBX, QPV, QB2 ), Festo ( VPPM, VPPL, VPPE, VEAA, VEAB, VEMD ), SMC (ITV1000, ITV2000, ITV3000), Clippard (Cordis), and ASCO (Sentronic)

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Question 5

Application of proportional pressure regulator in Bonding Machine

Accepted Answer

The function of bonding machine is to directly bond the flexible circuit board or cable to the electrodes on the edge of liquid crystal glass. That is, the process of installing flexible circuit boards and cables on liquid crystal glass. Therefore, the quality of bonding machine will directly affect the productivity of LCD glass and the service life of the LCD screen.

As can be seen from the above figure, the bonding machine is composed of brackets, motors, guide rails, piston rods, upper sliders, lower sliders, cylinders, bonding heads, solenoid valves, proportional pressure regulator, controllers and other parts.

Technical parameters of bonding machine:
1. Air source pressure: 0.5~0.7MPa
2. Binding pressure: 3~40Kgf
3. Pressure accuracy: ±0.2Kgf
4. Binding temperature: RT~499℃
5. Hot pressure time: 1~99 S 6. Hot pressure accuracy: 0.14mm

The working process of bonding machine:
1. ACF pre-paste: Under the pressure and temperature by working requirement, the flexible circuit board (FPC) and the liquid crystal glass need to be bonded to the pins of ACF with a specified length, and the surface should be flat and free of air bubbles.

2. Pre-bonding: Align the pins of FPC and the liquid crystal glass through the CCD camera, and pre-press at the required pressure and temperature to form a preliminary connection. In this step, the alignment of CCD camera is an important link. As the pitch of lifting leads is getting smaller and smaller in production, the small pitch has reached 0.05MM, and the alignment accuracy should be within ±0.005mm.

3. Main bonding: Under the required pressure and temperature, the pre-bonded LCD screen is subjected to the main bonding by using a pulse hot press. At the same time, the glue in the ACF is polymerized and hardened at high temperature to form a strong physical connection between the two different materials.

Detection of bonding machine: The LCD screen after the main bonding is detected through CCD camera.
1. Temperature control: The heating rate and the maximum temperature are both important factors affecting the curing of ACF. The heating rate determines the surface quality of ACF after curing, and the maximum temperature determines the bonding strength of ACF after curing.

2. Flatness of the bonding head: The unevenness of the bonding head causes the ACF conductive particles to be unevenly broken, because the ACF conductive particles are very small, usually about 4um in diameter, and the ACF is very sensitive to pressure. When the contact surface of the bonding head is not flat, part of the ACF conductive particles will be completely broken, while another part of the ACF conductive particles will not be broken normally, resulting in poor electrical conductivity between the liquid crystal glass and the FPC.

Proportional pressure regulator control principle:

1. When the equipment is in standby, the solenoid valve controls the cylinder to rise, and the proportional valve is in the exhaust state.

2. When working, the solenoid valve controls the cylinder to descend, and the proportional valve controls the pressure when the cylinder descends. The proportional valve can be adjusted in real time according to the bonding process. If you have any needs or questions, please subscribe to our YouTube channel or contact us to learn more about proportional pressure regulator.
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Question 6

Application of Proportional Pressure Regulator in Dispensing Industry

Accepted Answer

In recent years, with the rapid development of industrial robots and industrial automation, it has promoted the development of dispenser technology and the demand for dispenser equipment in downstream markets, such as: 3C electronics, automotive, etc. For dispensing equipment manufacturers, in addition to making the equipment highly intelligent, it is also necessary to ensure the stability of dispensing control system and the precise control of quantity.

With the continuous improvement of technical requirements in the dispensing industry, the stability of glue volume is very important. Proportional pressure regulators have become an integral part of modern dispensing equipment and dispensing controllers. With the advantages of high precision and high stability, the proportional pressure regulators made by KaoLu enables the dispensing machine to precisely control the amount of glue dispensed from the needle.

KaoLu’s proportional pressure regulators controls the corresponding pressure output of proportional pressure valve by controlling the input signal. When gas enters the main valve through the air inlet, the air inlet is isolated from the air outlet due to the sealing of valve core, so that the gas enters the pilot valve through the corresponding flow channel. The gas pressure changes, and the gas flowing out of pilot valve passes through another flow channel, pushing the valve core to move down, so that the air inlet and the air outlet are connected. At this time, the pressure sensor will detect the outlet pressure, and transmit the data to processor. The processor compares the difference between actual pressure value and calibrated pressure value, and dynamically adjusts the pressure to be the same.

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Question 7

Technological Performance and Application Fields of New Electronic Pressure Regulator

Accepted Answer

Introduction of KaoLu electronic pressure regulator:
The electronic pressure regulator is to adjust the cross-sectional area of the regulator core according to the size of control signal so as to achieve the process goals and requirements of adjusting the flow rate. The electronic pressure regulator of KaoLu optimizes the process performance, makes the structure compact and lightweight, and improves the requirements of stable performance and control accuracy.

Printing paper packaging industry
The contact roller is easy to slip during the process of winding the paper, which will cause some troubles for the subsequent correct cutting of paper. The main reason for this is the generation of accurate roller clamping pressure. Usually the higher the clamping pressure, the higher the tension and the tighter the roll. Different paper materials and quality require different roller clamping pressures for winding. The paper roll tightness information is transmitted to the main control system through the sensor, and the main controller compares it with the preset pressure value and outputs it to the electronic pressure regulator to adjust accordingly. The final output of suitable braking force ensures the smooth realization of paper rolling process and cutting process.

Grinding Industry
The grinding equipment usually adjusts the pressure of the grinding disc on the workpiece through a high-performance pressure control mechanism. In order to meet the ever-increasing customer demand, it is necessary to provide more precise grinding size and more efficient grinding speed, which have put forward higher requirements for the pressure controller. The electronic pressure regulator usually controls a grinding disc to repeat grinding action by outputting a stable pressure. The closed-loop control characteristics of the electronic pressure regulator provides an effective guarantee for a lower damage rate of the grinding equipment and a more accurate grinding pressure output.

Welding
In the field of automatic welding, in order to achieve high-speed, stable, and impact-free welding, the welding torch can contact the surface of the object for welding. The electronic pressure regulator can make the pressing force change steplessly according to the material and welding procedure, optimize the welding process, and ensure the final welding strength.

Machinery and equipment manufacturing industry
Stable, continuously varying pressure output is critical for equipment manufacturers such as winders and wire drawing machines. The roller must ensure that as the radius of the roller increases, the tension controlled by the swing arm decreases accordingly. The electronic pressure regulator can provide a high-precision variable pressure according to the pre-setting of the upper computer, and this pressure can control the displacement of cylinder to realize the swing arm, thereby controlling the tension change and ensuring the successful realization of uniform winding.

Rubber and plastic molding equipment industry
Forming and extrusion equipment is a common equipment in the field of rubber and plastic materials. Electronic pressure regulators are one of the key control elements in this type of equipment. In the entire thermoplastic process, the electronic pressure regulator can accurately output a continuous cut-off pressure to ensure that the forming production process is consistent, and the products are uniform and standard.

Custom measurement and control equipment
Some professional non-standard testing equipment and testing machines for airtight components can perform tests such as airtight performance testing, leak detection, dynamic response, etc., and electrical control components such as electronic pressure regulators are often required to execute the analog simulation control signal output by the controller, record the response of tested components and systems, and finally evaluate the performance of components/systems.

Spray and Lamination
For industrial sites that need spraying, such as automobile industry, sports equipment, packaging, etc., it is necessary to provide precisely controlled variable pressure to control spraying parameters such as switch, atomization, fan width, etc. to ensure uniform surface; for lamination technology, different materials are required. The end result is a consistent appearance, avoiding warping. All of this is reached because an electronic pressure regulator provides precise and constant pressure to the actuator.

Fluid Process Control
The pneumatic diaphragm pump is often used to pump the pressure of corrosive and high viscosity liquids to the pneumatic diaphragm pump, and finally achieve the purpose of infinitely controlling the pressure change of the pump port. In this way, the flow rate of liquid output from the pump port also changes accordingly, so as to reach the purpose of precise control of liquid.

Question 8

Application of Replacing Existing Electronically Controlled Pressure Regulator in Parallel Robot

Accepted Answer

The concept of parallel robot is based on the Steward platform used for flight simulation driving in 1965, and was proposed by Hunt, a well-known Australian institution professor, in 1978. At present, many experts and scholars have done a lot of theoretical and practical research in this field.

Compared with serial robots, parallel robots have the advantages of high stiffness, high load-to-weight ratio, uniform load distribution, no accumulation of position errors, and easy force feedback. It is suitable for occasions with high precision, large load and relatively small working space requirements.

At the same time, due to the great improvement in performance and function of pneumatic components, and with the development of science and technology such as electronics, materials, control theory and sensors, electronically controlled pressure regulator control technology has also been rapidly improved. The electronically controlled pressure regulator control system with proportional/servo control valve as the core can reach the high-precision control of continuous change of pressure and flow, and can meet the flexible production requirements of automation equipment. It makes the application of pneumatic drive in parallel robots possible.

Taking a typical 6-DOF parallel robot Steward platform as an example, its structure is shown in the figure below.

The structure is composed of upper and lower flat joints, and the flat joints are connected by a set of telescopic connecting rods with ball joints at both ends, so that the upper platform can move and rotate in three-dimensional space. Most parallel robots use screw rods or electro-hydraulic servo cylinders as motion actuators. Because the motions between the drive units of the parallel robot cannot be independent of each other, they must maintain a very strict combination relationship. The motion error of any link will lead to control failure. In our study, the hydraulic controlled pressure regulator is replaced by a more tolerant electronically controlled pressure regulator as the transmission medium of the parallel robot actuator.

The entire control flow path is shown in the following figure:

1. The extended position of the cylinder is obtained by the analog solver in the upper computer and transmitted to the lower computer.

2. The lower computer converts it into voltage (0~10v) through the D/A card and outputs it to the electronically controlled pressure regulator.

3. The electronically controlled pressure regulator controls size and direction of the opening according to the magnitude of voltage, and outputs the accurate gas flow to cylinder to promote the movement of the piston.

4. The moving position of piston is detected by the displacement sensor, and the feedback voltage of displacement sensor is output to the lower computer through the A/D card; the gas pressure at both ends of the piston is detected by the air pressure sensor, and the feedback voltage is output to the lower computer through A/D card.

5. The lower computer adjusts the control voltage of the electric proportional valve in real time according to the feedback value, so that the cylinder can reach the position accurately. 6. The position signal of the platform is fed back to the upper computer by position sensor, and the position of platform is further corrected by the upper computer.

In the entire control process, the focus is on single-cylinder control system. The experimental schematic diagram of the single-cylinder control system is shown in the following figure.

For the electronically controlled pressure regulator control system, the state single-cylinder control has better control characteristics; adding PI control in the optimal state feedback can significantly increase the stiffness of system and improve the tracking performance of system. It has good track tracking performance in the frequency range of 0.1Hz to 5Hz. The object of this test is the test platform model of the automobile suspension system, which does not require very high displacement accuracy, and is more sensitive to the speed and acceleration response speed. After the large cylinder is adopted, the load of whole system is greatly increased. The frequency response of system can reach 5~10Hz, which can meet the requirements of the test platform.

The 6-DOF parallel platform mainly composed of cylinder and electric proportional valve is adopted, which avoids the difficulty of control caused by the strict motion combination relationship between the six actuators required by hydraulic pressure and screw rod, and ensures the speed and acceleration response sensitivity. Simultaneous use of air cylinders and electronically controlled pressure regulator can greatly reduce costs, noise and pollution.

Question 9

Airbag Lifting

Accepted Answer

QKL electronic proportional pressure regulator( I/P converter) used to inflate air bags to raise a table. Pneumatically operated tables and lifts require air bag pressure control that is accurate and repeatable. These tables and lifts require less maintenance than conventional hydraulic lift tables, since there is no fluid to leak and contaminate processed goods.

Our proportional pressure regulator is best suited for this application due to its high flow rate, fast response time, and high accuracy. Our regulators are capable of modulating from 2 bar to 65 bar with accuracy of 0.25% FS. ( higher pressure range can be customised upon request)

Our electronic pressure regulator can directly replace:
Proportion Air ( QB3H, QBS, GX, QBX, QPV, QB2 ), Festo ( VPPM, VPPL, VPPE, VEAA, VEAB, VEMD ), SMC (ITV1000, ITV2000, ITV3000), Clippard (Cordis), and ASCO (Sentronic)

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

Question 10

Welding Application

Accepted Answer

In this sketch, QKL electronic proportional pressure regulator ( I/P converter) is controlling air pressure over oil to control the pressure of the oil to the cylinder. An orifice is used on the cylinder exhaust to soften the weld tip and help control overall speed during the process.

Our proportional pressure regulator is best suited for this application due to its high flow rate, fast response time, and high accuracy. Our regulators are capable of modulating from 2 bar to 65 bar with accuracy of 0.25% FS. (higher pressure range can be customised upon request)

QKL electronic pressure regulator can directly replace:
Proportion Air ( QB3H, QBS, GX, QBX, QPV, QB2 ), Festo ( VPPM, VPPL, VPPE, VEAA, VEAB, VEMD ), SMC (ITV1000, ITV2000, ITV3000), Clippard (Cordis), and ASCO (Sentronic)

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

Question 11

AODD Pump Speed Control

Accepted Answer

Air-Operated Double-Diaphragm (AODD) pump is used in many indsutrial environment to transfer liquids. The speed of pump is controlled by pilot air pressure. QKL can be used in combination with AODD to control the speed of the pump.

Our proportional pressure regulator is best suited for this application due to its high flow rate, fast response time, and high accuracy. Our regulators are capable of modulating from 2 bar to 65 bar with accuracy of 0.25% FS. (higher pressure range can be customised upon request)

QKL electronic pressure regulator can directly replace:
Proportion Air ( QB3H, QBS, GX, QBX, QPV, QB2 ), Festo ( VPPM, VPPL, VPPE, VEAA, VEAB, VEMD ), SMC (ITV1000, ITV2000, ITV3000), Clippard (Cordis), and ASCO (Sentronic)

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

Question 12

Steam Control

Accepted Answer

QKL electronic proportional pressure regulator ( I/P converter) assembly takes feedback from a downstream pressure transducer and closes the loop around pressure for tighter closed-loop control. Since temperature is directly related to the pressure of saturated steam, this assembly will provide tighter control of temperature.

Our proportional pressure regulator is best suited for this application due to its high flow rate, fast response time, and high accuracy. Our regulators are capable of modulating from 2 bar to 65 bar with accuracy of 0.25% FS. (higher pressure range can be customised upon request)

QKL electronic pressure regulator can directly replace:
Proportion Air ( QB3H, QBS, GX, QBX, QPV, QB2 ), Festo ( VPPM, VPPL, VPPE, VEAA, VEAB, VEMD ), SMC (ITV1000, ITV2000, ITV3000), Clippard (Cordis), and ASCO (Sentronic)

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

Electronic Proportional Pressure Regulator Applications