Methods and systems for air compressor with electric inlet valve control

Abstract

Systems and methods for an air compressor control system includes a user interface configured to receive a command from an operator, a sensor configured to measure one or more characteristics of the system, an electric inlet valve integrated within an air compressor and configured to regulate airflow of the air compressor based on a position of the electric inlet valve, and a controller configured to adjust a position of the electric inlet valve via an electrical control signal in response to a command from the user interface or a measurement from the sensor.

What is claimed is: 
     
         1 . An electric inlet valve configured to regulate airflow of an air compressor based on a position of the electric inlet valve, wherein a controller is configured to command an adjustment of a position of the electric inlet valve via an electrical control signal. 
     
     
         2 . The electric inlet valve as defined in  claim 1 , wherein a sensor is configured to measure one or more characteristics of the air compressor. 
     
     
         3 . The electric inlet valve as defined in  claim 2 , wherein the sensor is a pressure sensor. 
     
     
         4 . The electric inlet valve as defined in  claim 3 , wherein a user interface is configured to select a pressure level to the controller. 
     
     
         5 . The electric inlet valve as defined in  claim 4 , wherein the controller is configured to:
 receive a selected pressure level for the air compressor from the user interface;   receive a signal corresponding to a measured pressure level of the air compressor from the sensor;   compare the selected pressure level to the measured pressure level; and   calculate a pressure difference based on the comparison.   
     
     
         6 . The electric inlet valve as defined in  claim 5 , wherein an electrically controlled and powered motor is configured to adjust a position of the electric inlet valve, wherein the controller is configured to:
 determine a position of the electric inlet valve;   calculate a change in position of the electric inlet valve based on the pressure difference; and   control the motor to adjust the position of the electric inlet valve based on the calculated change in position.   
     
     
         7 . An air compressor control system comprising:
 a user interface configured to receive a command from an operator;   a sensor configured to measure one or more characteristics of the system;   an electric inlet valve integrated within an air compressor and configured to regulate airflow of the air compressor based on a position of the electric inlet valve; and   a controller configured to adjust a position of the electric inlet valve via an electrical control signal in response to a command from the user interface or a measurement from the sensor.   
     
     
         8 . The system as defined in  claim 7 , the controller further configured to automatically determine a desired pressure level in the air compressor based on the command or the measurement. 
     
     
         9 . The system as defined in  claim 8 , wherein the command corresponds to a gouging or plasma cutting operation. 
     
     
         10 . The system as defined in  claim 9 , wherein the controller is configured to:
 receive a selected gouging or plasma cutting operation from the user interface;   determine a desired air pressure for the air compressor based on the selected operation;   compare the desired air pressure level to a measured air pressure level; and   calculate a pressure difference based on the comparison.   
     
     
         11 . The system as defined in  claim 10 , further comprising a motor configured to adjust a position of the electric inlet valve, wherein the controller is configured to:
 determine a position of the electric inlet valve;   calculate a change in position of the electric inlet valve based on the pressure difference; and   control the motor to adjust the position of the electric inlet valve based on the calculated change in position.   
     
     
         12 . The power system as defined in  claim 7 , wherein the sensor is a pressure sensor. 
     
     
         13 . An engine driven power system comprising:
 a power supply;   an air compressor comprising an electric inlet valve; and   a controller configured to:
 receive an input corresponding to one or more parameters associated with the power supply or the air compressor; and 
 generate one or more electrical control signals to regulate an output of the power supply and to regulate airflow of the air compressor in response to the input. 
   
     
     
         14 . The system as defined in  claim 13 , wherein the input corresponds to a single input that provides a plurality of parameter settings for the power supply and the air compressor. 
     
     
         15 . The system as defined in  claim 14 , wherein the input corresponds to a gouging or plasma cutting operation. 
     
     
         16 . The system as defined in  claim 13 , further comprising a sensor to measure a pressure at an inlet or an outlet of the air compressor. 
     
     
         17 . The system as defined in  claim 16  wherein the controller is further configured to:
 receive a signal corresponding to a measured pressure level of the air compressor from the sensor; 
 compare the selected pressure level to the measured pressure level; and 
 calculate a pressure difference based on the comparison. 
 
     
     
         18 . The system as defined in  claim 16 , wherein the controller is further configured to:
 determine a position of the electric inlet valve; and   calculate a change in position of the electric inlet valve based on the pressure difference.   
     
     
         19 . The system as defined in  claim 18 , wherein the electrically powered mechanism is a motor, the controller further configured to control the motor to adjust the position of the electric inlet valve based the calculated change in position. 
     
     
         20 . The system as defined in  claim 18 , wherein the controller is further configured to:
 command the air compressor to shut off; and   control the motor to maintain the electric inlet valve in a closed position to prevent oil mist and/or fumes from evacuating the compressor case as the air compressor cools down.