Vacuum generators are widely used in the industrial field. Therefore, it is very important to understand what a vacuum generator is. And how does a vacuum generator work? Only by mastering the basic knowledge of vacuum generators. And how does a vacuum generator work in practical applications? Which can we better apply this technology in complex and changing industrial environments.
What is a vacuum generator?
The vacuum generator is a new type of efficient, clean, economical and small vacuum component that uses a positive pressure gas source to generate negative pressure. This makes it easy and convenient to obtain negative pressure where compressed air is available, or where both positive and negative pressure are required in a pneumatic system. Vacuum generators are widely used in the fields of machinery, electronics, packaging, printing, plastics and robotics in industrial automation.
How does a vacuum generator work？
How does a vacuum generator work? It is mainly based on the principles of fluid mechanics, especially Bernoulli’s theorem and the Venturi effect. When compressed air passes through the nozzle of the vacuum generator, the airflow is accelerated and a suction flow is generated due to the constricted cross section of the nozzle. This entrainment flow causes the air around the nozzle outlet to be continuously sucked away, thereby reducing the pressure in the adsorption chamber to below atmospheric pressure, forming a certain degree of vacuum.
Specifically, how does a vacuum generator work? The process can be divided into the following stages:
- Compressed air: Compressed air is introduced into the vacuum generator.
- Venturi nozzle: The compressed air is accelerated through a constricted cross-section, called the Venturi nozzle. This increases the dynamic pressure and decreases the static air pressure.
- Vacuum: Once the air has passed the Venturi nozzle, it expands and creates a vacuum.
- Air is sucked in: Air is “sucked” into the vacuum generator through the vacuum connection.
- Exhaust air: The compressed air and the air that was sucked in escape from the vacuum generator through the exhaust air.
Various ways of working with vacuum generators
How does a vacuum generator work? After understanding the vacuum ejector, it is also very important to understand how the vacuum ejector works. Vacuum generators can work in a variety of ways, including:
1. Pneumatic vacuum generators:
Use the Venturi principle to generate a vacuum. By accelerating the compressed air through the nozzle, the static pressure is reduced according to the Bernoulli principle, forming the required vacuum environment. Its fast and stable vacuum generation capability makes it shine in small precision parts assembly lines and can accurately pick up tiny electronic components.
2. Vacuum ejectors:
Use high-pressure air flow to generate negative pressure. The high-speed jet of air forms a complex flow field in a specific space, causing the surrounding air pressure to drop sharply. This working mode makes it suitable for industrial scenarios with large-area or large-flow air extraction, such as dust cleaning in construction, where the dust is sucked into the collection device through negative pressure.
3. Vacuum blowers:
Can generate high levels of suction and are often used for material handling, pneumatic conveying, and vacuum packaging. Relying on the high-speed rotation of the internal impeller to drive the air to flow quickly, forming a low-pressure area and generating strong suction. In material handling, both bulk and powdery materials can be moved easily. Provides continuous power in pneumatic conveying systems to ensure smooth transportation of boring boredom. In vacuum packaging, the air in the package is quickly extracted to complete efficient packaging and ensure product freshness and quality.
How does a vacuum generator work diagram?
How does a vacuum generator work?If you want to have a comprehensive understanding, the most important thing is to understand the schematic diagram.How does a vacuum generator work diagram? This is especially important in industrial environments. The diagram of how the vacuum generator works can help us understand the working principle of the vacuum generator more intuitively, and thus be more adept at it in practical applications.
Below is a diagram of one of the series of vacuum ejectors listed by HANUMAN. How does a vacuum generator work diagram of ZK series?
Key components of vacuum generator
The key components of the vacuum generator mainly include nozzle, diffusion chamber, valve, vacuum pump (or air source), connecting pipes and (pneumatic) diaphragm.
- Nozzle: Converts high-pressure gas into high-speed jets and reduces static pressure based on the principles of fluid mechanics.
- Diffusion chamber: It receives the high-speed jet generated by the nozzle, collides and mixes with the surrounding air to form a negative pressure area, which is the basis for the generation of vacuum.
- Valve: Controls the direction and speed of gas flow, ensures that high-pressure gas enters the nozzle smoothly, and adjusts the pressure of the vacuum system.
- Vacuum pump (or gas source): Provides a continuous supply of high-pressure gas to maintain the high-speed jet of the nozzle and the negative pressure of the diffusion chamber.
- Connecting pipeline: Connecting various components into a complete vacuum system requires good air tightness to maintain system stability.
- Diaphragm (pneumatic type): Moves downward under the action of compressed air, reducing the pressure in the rear exhaust chamber and intake chamber, forming a vacuum.
How do the key components work together to create a vacuum?
These key components work together to create a vacuum: the high-speed jet generated by the nozzle enters the diffusion chamber, collides and mixes with the surrounding air to form a negative pressure area. And as high-speed jets continue to be generated, the negative pressure area continues to expand, forming a stable vacuum environment. The valve controls the direction and speed of gas flow to ensure that high-pressure gas enters the nozzle smoothly to produce a high-speed jet. While the vacuum pump (or gas source) continuously supplies high-pressure gas to maintain the nozzle jet and the negative pressure in the diffusion chamber.
In a pneumatic vacuum generator, diaphragm movement is the key. When compressed air flows through the air inlet, the diaphragm moves downward to reduce the pressure in the rear exhaust chamber and the air inlet chamber. Its continued movement can extract more gas to deepen the vacuum. The connecting pipes tightly connect the components to form a complete vacuum system. Its air tightness is extremely critical to maintaining the stability of the system. Once a leak occurs, the vacuum degree will drop or even the system will fail.
The main application areas of vacuum generators
1. Robotic arm grasping systems:
The vacuum generator provides stable suction for the robot arm to grasp. In industrial production, the suction cup at the end of the robotic arm can grab workpiece of different shapes and materials. For example, in automobile manufacturing, it can grasp large components such as body shells and dashboards, as well as small parts such as screws, efficiently and without damaging the workpiece, ensuring grasping accuracy and stability.
2. Packaging machinery:
In the field of food packaging, the air in the packaging bag can be quickly extracted. Such as vacuum packaging of meat, vegetables, etc., which reduces oxygen content and prolongs shelf life, while making the packaging compact for easy transportation and storage. For electronic product packaging, it can prevent damage during transportation and play a buffering role.
3. Material handling systems:
It plays a significant role in logistics and factory material handling. For thin and light materials, such as transporting paper in paper mills and transporting plastic films in logistics warehouses, the suction cup can firmly adsorb and achieve efficient transport and neat stacking. In automated warehouses, handling robots use their suction power to accurately pick up and place goods, improving handling efficiency and accuracy.
4. Medical equipment:
During dental treatment, it provides suction for the saliva suction device to remove saliva and blood from the patient’s mouth and keep the treatment area clean. In in vitro diagnostic equipment, it is used to collect and process samples such as blood to ensure the smooth progress of the testing process.
5. Precision component processing in electronic manufacturing:
During the lithography process of chip manufacturing, the chip is kept in a fixed position during exposure to ensure manufacturing accuracy. During the circuit board assembly process, tiny electronic components such as resistors and capacitors can be accurately picked up and placed accurately, which is crucial to the quality and performance of electronic products.
How to choose a suitable vacuum generator?
1. Suction:
Different application scenarios have different suction requirements. For example, when a robotic arm grabs heavy steel parts, strong suction is required, which requires the vacuum generator to have a high vacuum degree and a large suction volume. When handling thin electronic components, a small amount of suction is sufficient to avoid damaging the components. The appropriate suction force is determined according to the weight, material and shape of the object being adsorbed, and can be selected by checking parameters such as the vacuum degree of the vacuum generator.
2. Speed:
Packaging machinery and other equipment have high requirements for vacuuming speed. Like food vacuum packaging, the pumping has to be done in a short period of time. The pumping speed depends on the nozzle and diffuser design. An efficient nozzle can accelerate the compressed air to produce a strong jet, and a good diffuser can make the air extraction smoother, thereby increasing the speed.
3. Compressed air consumption:
For long-running scenarios such as material handling, compressed air consumption is a key cost. Such as if automated handling is used in logistics warehouses, large-scale use will increase costs. Comparing the air flow parameter selection, the energy-saving vacuum generator can reduce the air flow while ensuring the performance by optimizing the structure.
4. Maintenance requirements:
The vacuum generators in the medical equipment field need to be easy to maintain and clean, and they need to have strong anti-pollution capabilities in harsh industrial environments. The simple structure makes it easier to disassemble and repair, and the durability of key components can reduce maintenance. High quality products such as valves and nozzles require low maintenance frequency.
Methods to optimize vacuum generator performance:
- Match application requirements: Select a vacuum generator model that matches the design requirements to avoid energy waste caused by over-design.
- System optimization: Reduce gas leakage and energy consumption by optimizing vacuum system layout and pipeline design.
- Intelligent control: Adopt intelligent control system to adjust the operating status of vacuum generator according to actual needs and realize refined management of energy consumption.
- Regular maintenance: Keep the vacuum generator in good condition, regularly check and replace worn parts to ensure its efficient and stable operation.
Maintenance and troubleshooting of vacuum generator
Daily maintenance recommendations:
- External cleaning: Wipe the surface of the vacuum generator regularly with a soft cloth and detergent, and avoid scratching it with hard objects.
- Vacuum channel cleaning: Flush the vacuum channel with detergent to ensure there is no residue, then flush it with clear gas.
- Check the vacuum pump: Check the vacuum pump regularly to see if all parts are in good condition and replace worn parts in time.
- Calibration accuracy: Regularly calibrate measuring instruments to ensure accurate measurements.
- Replace consumables: Replace vacuum pump oil, seals, etc. according to the manual requirements to keep the equipment stable.
- Check parts: Check main parts regularly and replace them in time if there are any problems.
Common faults and solutions:
- Suction pipe blowback: increase the blowback device to prevent the gas from blowing back.
- Powder spraying phenomenon: Clean the vacuum generator and filter to ensure good sealing.
- Suction cannot be stopped: Check the piston seal and reinstall it to ensure it is reset.
- Insufficient vacuum: Check the performance of the vacuum pump, clean the vacuum channel, and replace sealing parts.
- Excessive noise: Check the internal parts of the vacuum pump, replace worn parts, and increase lubrication.
Daily maintenance is the key to ensuring the normal operation of the positive air generator. Timely troubleshooting can extend the service life of the equipment. During the maintenance process, the operating procedures should be strictly followed.
Any questions about vacuum generators, such as: How does a vacuum generator work? What vacuum generators does HANUMAN have? How to maintain a vacuum generator? You can consult HANUMAN.
HANUMAN has a professional team to answer your questions and provide technical guidance! HANUMAN welcomes your consultation!
