Abstract:
In a soft start device for pneumatic systems comprising a primary inlet where compressed air can be supplied at primary pressure, wherein the primary inlet is, via a valve circuit, connected to at least one secondary outlet which can be coupled to a load and where compressed air can be discharged at secondary pressure, the secondary pressure being lower than or equal to the primary pressure, wherein a main valve is installed between the primary inlet and the secondary outlet, a restrictor device being installed in the bypass, wherein the main valve and the restrictor device together with further directional valves of the valve circuit are interconnected such and the valve circuit can be switched into a standard switching position for venting such that the secondary outlet is vented, the valves of the valve circuit are interconnected such that several further switching positions for venting are possible.

Description:
This application claims priority based on an International Application filed under the Patent Cooperation Treaty, PCT/EP2008/001164, filed Feb. 15, 2008. 
     BACKGROUND OF THE INVENTION 
     The invention relates to a soft start device for pneumatic systems and to a method for the operation of a soft start device. The soft start device comprises:
         a primary inlet where compressed air can be supplied at primary pressure,   wherein the primary inlet is, via a valve circuit, connected to at least one secondary outlet which can be coupled to a load and where compressed air can be discharged at secondary pressure, the secondary pressure being lower than or equal to the primary pressure,   wherein a main valve of the type 2/2 nc (normally closed) which can be bypassed by means of a bypass is installed between the primary inlet and the secondary outlet, a restrictor device being installed in the bypass,   wherein the main valve and the restrictor device together with further directional valves of the valve circuit are interconnected such that, in a soft start process while the main valve is initially closed, compressed air is applied to the secondary outlet at a secondary pressure which is lower than primary pressure and increases gradually, until from a defined ratio between secondary and primary pressure the main valve is switched into its open position, so that compressed air arrives at the secondary outlet at primary pressure, and so that   the valve circuit can be placed in a standard switching position for venting, so that the secondary outlet is vented.       

     Soft start devices are used in pneumatic systems to supply compressed air to functional units sensitive to pressure surges, such as service units etc., in conditions where the pressure gradually increases from a relatively low secondary pressure to the higher primary or operating pressure. In this way, pressure surges at harmfully high primary pressure are avoided. Functional units sensitive to pressure surges include filter units or double-acting pneumatic cylinders. In the case of double-acting pneumatic cylinders, the piston may be in an intermediate position in the “pressure-less” state of the cylinder, so that the piston, if subjected to the full pressure surge, could suddenly move into one of its end position, which may result in damage to the piston or to the end stop of the cylinder. The unintended piston movement could moreover damage a downstream functional unit, which may once again result in a hazardous situation. Such dangerous movement could result in personal injury in particular. This is prevented by a soft start, causing the piston to move into its end position relatively slowly. 
     A soft start device is for example disclosed in EP 0 758 063 B1, which describes a starting valve in the form of a seating valve, the valve being vented via a fast venting device. The starting valve comprises a housing wherein a single flow path runs from the inlet to the outlet, the seating valve acting as a restrictor being disposed in the flow path. 
     In pneumatic systems, certain safety aspects have to be observed. These are for example categorised in the standard EN 954-1 and in the follow-up standard DIN EN ISO 13849-1. To fulfil the requirements of category 3 of EN 954-1, the pneumatic device is subject to so-called “single fault safety” in safety-relevant functions. This means that the system must be capable of venting even if a single fault is present. 
     A soft start device of the type referred to above which offers “single fault safety” is disclosed in EP 645 755 A2. If one of the valves malfunctions, the secondary outlet can nevertheless be vented. This being so, this soft start device fulfils the requirements of EN 954-1, category 3. 
     The follow-up standard DIN ISO 13849, however, requires a higher test quality for category 3 and in particular for category 4. It demands in particular that a test or diagnostic mode of the valves should be run prior to the soft start process, in order to eliminate faults in the initiation of the soft start process. 
     SUMMARY OF THE INVENTION 
     The invention is therefore based on the problem of creating a soft start device and a method for the operation of a soft start device of the type referred to above, by means of which a diagnostic mode can be executed before the starting process is initiated. 
     This problem is solved by a soft start device with the features of the independent claim  1 . Further developments of the invention are described in the dependent claims. 
     The soft start device according to the invention is characterised in that
         the inlet of the main valve, which is designed as a fifth directional valve of the type 2/2-nc, is connected to the primary inlet and the outlet is connected to the inlet of a fourth directional valve of the type 3/2-nc and, parallel thereto, to the output-side of the restrictor device, the fifth directional valve being on the control side coupled to the output-side of the restrictor device and in addition to an outlet of a sixth directional valve of the type 4/2-nc,   the inlet of the first directional valve of the type 3/2-nc is connected to the primary inlet and the outlet is connected to the control side of the sixth directional valve, wherein the first directional valve can be vented via a venting port and actively switched via control-side switching means,   the inlet of the third directional valve of the type 3/2-nc is connected to the primary inlet and the outlet of the third directional valve is coupled to the control side of a fourth directional valve of the type 3/2-nc, wherein the third directional valve can be vented via a venting port and actively switched via control-side switching means,   the outlet of the fourth directional valve is connected to the secondary outlet and, parallel thereto, to an inlet of the sixth directional valve, wherein the fourth directional valve can be vented via a venting port, and   the sixth directional valve can be switched between a normal position and a functional position, wherein in the normal position a first inlet is connected to the secondary outlet and, parallel thereto, to the outlet of the fourth directional valve, while the respective first venting port is open to the atmosphere, and a second inlet is coupled to the control side of the fifth directional valve while a respective second venting port is open to the atmosphere, and wherein, in the functional position, the inlet is connected to the outlet of the fourth directional valve and, parallel thereto, to the secondary outlet, while the respective outlet is coupled to the control side of the fifth directional valve.       

     The first and third directional valves are therefore connected in parallel, the first directional valve controlling the sixth directional valve and the third directional valve controlling the fourth directional valve. This permits the execution of a test or diagnostic mode wherein the switching states of the fourth and sixth directional valves are checked independently. As the fourth and sixth directional valves are not actively switchable, it is advantageous that the switching states of these valves can be checked before the soft start process is initiated. After long stoppages, in particular, a so-called “slip-stick” effect may develop in these valves, so that these valves may not be switched into their open or functional position even if compressed air is applied to their control side. It is therefore possible to initiate a fault finding process before the start. The diagnostic mode ensures that none of the valves malfunctions in the soft start process. 
     In a particularly preferred manner, the directional valves which are not actively switchable are held in their nc-position by control springs and in addition by the application of compressed air, in order to make them independent of upstream pressure. As an alternative, these directional valves could be held in their nc-position without the additional application of compressed air, for example by using a control spring with a correspondingly higher spring force. 
     The restrictor device may comprise an adjustable throttle valve and in addition a fixed restrictor in the form of a restrictor bypass surrounding the adjustable throttle valve. This prevents the total blocking of the flow path if the throttle valve is completely closed. 
     In a particularly preferred way, a sensor device comprising a plurality of sensors is provided for detecting the current switching states of the valves, in particular of those which are not actively switchable. The sensors may for example be designed as reed switches, but other types of sensors can be used. A control unit coupled to the switching means of the first and third directional valves is expediently provided. This allows for a signal transmission from the sensors to the control unit and, depending on an evaluation result, from the control unit to the switching means. 
     The invention further includes a method for the operation of a soft start device with the features of the independent claim  11 . 
     The method according to the invention, by means of which a test or diagnostic mode can be executed, comprises the following steps:
         the switching of the first directional valve into its open position, whereby compressed air is applied to the control side of the sixth directional valve,   the determination of the switching state of the sixth directional valve by means of the respective sensor,   the detection of the result of the switching state enquiry wherein, if a switching operation of the sixth directional valve has been detected, a switching operation of the third directional valve or the soft start process is initiated,   the switching of the third directional valve into its open position after or alternatively before the switching of the first directional valve, wherein the first directional valve is in its nc-position while the third directional valve is switched, wherein compressed air is applied to the control side of the fourth directional valve by switching the third directional valve,   the determination of the switching state of the fourth directional valve by means of the respective sensor,   the detection of the result of the switching state enquiry wherein, if a switching operation of the fourth directional valve has been detected, a switching operation of the first directional valve or the soft start process is initiated.       

     As mentioned above, the first and third directional valves are connected in parallel, so that pressure can be applied to the sixth directional valve independently of the fourth directional valve. The first directional valve is expediently switched first, with the result that compressed air is applied to the control side of the sixth directional valve. The switching state of the sixth directional valve is then checked by means of the sensor. If a switching operation has taken place, the strand between primary inlet, first directional valve and sixth directional valve is free of faults, and the process can be followed by a diagnosis of the other strand containing the third and fourth directional valves. The first directional valve is once again in its nc-position. If a switching operation of the fourth directional valve is detected as the third directional valve is switched, this strand too is free of faults. The soft start process can now be initiated. It is of course possible to test the third directional valve first, followed by the strand of the third and fourth directional valves, and then the first directional valve and the strand of the first and sixth directional valves. 
     In a further development of the invention, signals corresponding to the result of the switching state enquiry are transmitted from the respective sensor to the control unit, the switching means assigned to the first and third directional valves being actuated or not depending on the result. If no fault is detected, the soft start process can be initiated automatically. If however a fault is found in one of the strands, the soft start process is not initiated. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A preferred embodiment of the invention is illustrated in the drawing and explained in greater detail below. Of the drawing, 
         FIG. 1  shows a valve circuit including pneumatically pressurised strands (bold lines) of a preferred embodiment of the soft start device according to the invention in its neutral position prior to the soft start process, 
         FIG. 2  shows the valve circuit according to  FIG. 1  in the diagnostic mode after the first directional valve has been switched, 
         FIG. 3  shows the valve circuit according to  FIG. 1  in the diagnostic mode after the third directional valve has been switched, while the first directional valve is in its nc-position. 
         FIG. 4  shows the valve circuit according to  FIG. 1  after the first and third directional valves have been switched, the soft start process having been initiated, 
         FIG. 5  shows the valve circuit according to  FIG. 1  after the soft start process, 
         FIG. 6  shows the valve circuit according to  FIG. 1  during the venting process in a standard switching position for venting, 
         FIG. 7  shows the valve circuit according to  FIG. 1  during the venting process, the first directional valve malfunctioning, 
         FIG. 8  shows the valve circuit according to  FIG. 1  during the venting process, the third directional valve malfunctioning, 
         FIG. 9  shows the valve circuit according to  FIG. 1  during the venting process, the fifth directional valve malfunctioning, 
         FIG. 10  shows the valve circuit according to  FIG. 1  during the venting process, the fourth directional valve malfunctioning, and 
         FIG. 11  shows the valve circuit according to  FIG. 1  during the venting process, the sixth directional valve malfunctioning. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIGS. 1 to 11  show a preferred embodiment of the soft start device  11  according to the invention. The components of the valve circuit can be accommodated together in a valve assembly. A primary inlet P 1  is provided to supply compressed air at primary pressure. Via a main flow path  12 , the primary inlet P 1  is connected to a secondary outlet P 2 , where compressed air is discharged at secondary pressure to the loads. 
     As  FIG. 1  shows by way of example, the valve circuit of the preferred embodiment has the following structure: 
     A fifth directional valve WV 5  of the type 2/2-nc is provided, the inlet E 5  of which is connected to the primary inlet P 1  and the outlet A 5  of which is connected to the inlet E 4  of a fourth directional valve WV 4  of the type 3/2-nc and, parallel thereto, to the output-side of a restrictor device  13 , the control side of the fifth directional valve WV 5  being coupled to the output side of the restrictor device  13  and in addition to an outlet A 6  of a sixth directional valve WV 6  of the type 4/2-nc, if the sixth directional valve WV 6  is in its functional position as described below. The fifth directional valve WV 5  is held in its nc-position by a control spring  14  and in addition by the application of compressed air via a coupling with the primary inlet P 1 . A sensor for detecting its current switching position is further assigned to the fifth directional valve WV 5 . 
     Connected in parallel with the fifth directional valve WV 5 , a first directional valve WV 1  is provided, its inlet E 1  being connected to the primary inlet P 1  and its outlet A 1  being connected to the control side S 6  of a sixth directional valve WV 6 , wherein the first directional valve WV 1  can be vented via a venting port R 1  and actively switched via switching means  16  provided on the control side. The first directional valve WV 1  is further held in its nc-position by a control spring  14 . 
     Connected in parallel to the first directional valve WV 1 , a third directional valve WV 3  is provided, its inlet E 3  being coupled to the primary inlet P 1  and its outlet A 3  being coupled to the control side S 4  of a fourth directional valve WV 4  of the type 3/2-nc, wherein the third directional valve WV 3  can be vented via a venting port R 3  and actively switched via switching means  16  provided on the control side. 
     The fourth directional valve WV 4  selected by means of the third directional valve WV 3  has its outlet A 4  connected to the secondary outlet P 2  and, parallel thereto, to an inlet E 6  of a sixth directional valve WV 6 , the fourth directional valve WV 4  being ventable via a venting port R 4 . The fourth directional valve WV 4  is held in its nc-position by a control spring  14  and additionally by coupling to the output side of the restrictor device  13  and, parallel thereto, by coupling to the outlet A 5  of the fifth directional valve WV 5 . In addition, a sensor  15  is provided to detect the current switching state of the fourth directional valve WV 4 . 
     Finally, the sixth directional valve WV 6  selected via the first directional valve WV 1  is switchable between a normal position and a functional position; in the normal position, a first inlet E 6  is connected to the secondary outlet P 2  and, parallel thereto, to the outlet A 4  of the fourth directional valve WV 4 , while the first venting port R 6  is open to the atmosphere. In the normal position of the sixth directional valve WV 6 , a second inlet E 6 * is further coupled to the control side S 5  of the fifth directional valve WV 5 , while a corresponding second venting port R 6 * is open to the atmosphere. In the functional position of the sixth directional valve WV 6 , on the other hand, its inlet E 6  is connected to the outlet A 4  of the fourth directional valve WV 4  and, parallel thereto, to the secondary outlet P 2 , while the corresponding outlet A 6  is coupled to the control side S 5  of the fifth directional valve WV 5 . 
       FIG. 1  shows a switching position in which all 3/2- or 2/2-type directional valves are in their nc-position and the sixth directional valve WV 6  of the type 4/2-nc is in its normal position. This position could also be referred to as neutral position before the soft start process. In this state, compressed air from the primary inlet P 1  is applied at primary pressure to the inlet E 1  of the closed first directional valve WV 1  and, parallel thereto, to the inlet E 5  of the closed fifth directional valve WV 5  and, parallel thereto, to the inlet E 3  of the third directional valve WV 3 . Parallel thereto, compressed air is applied to the counter-control side of the fifth directional valve WV 5  to support the control spring  14 . Compressed air finally flows into the bypass  17 , reaching the restrictor device  13  and flowing from there to the inlet E 4  of the fourth directional valve WV 4 , the outlet A 5  of the closed fifth directional valve WV 5  and the control side of S 5  of the fifth directional valve WV 5 . The restrictor device  13  provided is an adjustable throttle valve and in addition a fixed restrictor in the form of a restrictor bypass surrounding the adjustable throttle valve. This prevents the complete blocking of the flow path if the throttle valve is closed. On the contrary, an amount of compressed air can always reach the respective ports of the fourth and fifth directional valves WV 4  and WV 5  via the restrictor bypass, which has a relatively small cross-section. Finally, compressed air is applied at primary pressure to the counter-control side of the fourth directional valve WV 4 , thereby supporting to force of the control spring  14 . 
       FIG. 2  shows the test mode, in which initially only the first directional valve WV 1  has been switched into its open position, allowing compressed air at primary pressure to reach the control side S 6  of the sixth directional valve WV 6 . In the test or diagnostic mode, a switching state enquiry of this sixth directional valve WV 6  is executed by means of the sensor  15  assigned to the sixth directional valve WV 6 . The sensor  15  detects the switching state of the sixth directional valve WV 6  and transmits signals corresponding thereto to a control unit  20 . If the sixth directional valve WV 6  is in its functional position as shown in  FIG. 2 , the possibility of a malfunction of the sixth directional valve WV 6  can be eliminated. Such a malfunction may occur after long stoppages, for example as a result of the “slip-stick” effect mentioned earlier. If the sixth directional valve WV 6  switches, the strand comprising the primary inlet P 1 , the first directional valve WV 1  and the sixth directional valve WV 6  is free of faults. The control unit  20  now switches the first directional valve WV 1  back into its nc-position. If it is found, however, that the sixth directional valve WV 6  has not been switched into its functional position as required, the process is aborted, i.e. a continuation of the process will only be possible after the fault has been rectified. 
       FIG. 3  also shows the test mode, in which, after it has been established that the strand comprising the primary the inlet P 1 , the first directional valve WV 1  and the sixth directional valve WV 6  is free of faults, the third directional valve WV 3  is switched into its open position. The third directional valve WV 3  is switched into its open position to allow compressed air at primary pressure to reach the control side S 4  of the fourth directional valve WV 4 . Here, too, a switching state enquiry of the fourth directional valve WV 4  is executed by means of the respective sensor  15 . The signals corresponding to this switching state are once again transmitted to the control unit  20 . If the fourth directional valve WV 4  has reached its open position shown in  FIG. 3  as required, the strand comprising the primary inlet P 1 , the third directional valve WV 3  and the fourth directional valve WV 4  is free of faults. If it is found, however, that the fourth directional valve WV 4  has not been switched into its open position as required, the process is once again aborted until the fault has been rectified. If the fourth directional valve WV 4  has been switched into its open position as required and the sensor  15  has transmitted corresponding signals about the detected switching state to the control unit  20 , the control unit  20  selects the switching means  16  assigned to the first directional valve WV 1 , thereby automatically initiating the soft start process shown in  FIG. 4 . 
     As mentioned above,  FIG. 4  shows a switching position at the initiation of the soft start process. The first directional valve WV 1  and the third directional valve WV 3  have been switched into their open positions as required. Although compressed air at primary pressure has collected in front of the inlet E 4  of the fourth directional valve WV 4  in its blocked state, this compressed air, which is initially held between the output-side of the restrictor device  13  and the inlet E 4  of the fourth directional valve WV 4 , is discharged as the fourth directional valve WV 4  is opened and reaches the primary outlet P 2 . Compressed air at primary pressure is, however, not able to flow on immediately, because the restrictor device  13  restricts the oncoming compressed air from primary to secondary pressure. As a result, compressed air reaches the fourth directional valve WV 4  at secondary pressure and flows from there to the primary outlet P 2 . At the same time, compressed air at secondary pressure flows to the inlet E 6  of the sixth directional valve WV 6  and from there via the outlet A 6  to the control side S 5  of the fifth directional valve WV 5 . At the same time, there is a direct connection from the output side of the restrictor device  13  to the control side S 5  of the fifth dc WV 5 , so that compressed air at secondary pressure is applied twice to the control side of the fifth directional valve WV 5 . The pressure at the secondary outlet P 2  now increases gradually until, from a defined ratio between secondary and primary pressure, the fifth directional valve WV 5  is caused to switch into its open position. This ratio between secondary and primary pressure may lie in the range between &gt;0 and 1, in particular between 0.4 and 0.6. Particularly preferred is a switching into open position if the secondary pressure P 2  is approximately equal to 0.5 of the primary pressure P 1 . 
       FIG. 5  shows the switching position after the soft start process. The fifth directional valve WV 5  has been opened by the pressure applied to its control side S 5 , allowing compressed air to flow directly from the primary inlet P 1  via the main flow path  12 , passing through the fourth directional valve WV 4 , to the secondary outlet P 2  and from there to the loads. 
       FIG. 6  shows a standard switching position for venting the secondary outlet P 2 . The first and third directional valves WV 1  and WV 3  have been switched back into their nc-positions as required, so that the compressed air applied to the control side S 4  of the fourth directional valve WV 4  escapes via the venting port R 3 , while the compressed air applied to the control side S 6  of the sixth directional valve WV 6  escapes via the venting port R 1 . As a result, the fourth directional valve WV 4  is returned into an nc-position, while the sixth directional valve WV 6  is returned into its normal position. Compressed air from the secondary outlet P 2  can now escape via the venting port R 4  of the fourth directional valve WV 4  and in addition via the venting port R 6  of the sixth directional valve WV 6 . The venting ports R 4  and R 6  are preferably combined to form a common central venting port  18  open to the atmosphere. The central venting port  18  may be provided with a silencer  19  to attenuate the sound of the escaping compressed air. 
     If the soft start process is aborted and venting is required, the standard switching position for venting will be established, i.e. compressed air from the secondary outlet P 2  escapes via the venting ports R 4  and R 6  of the fourth and sixth directional valves WV 4  and WV 6  respectively. 
       FIG. 7  shows a switching position for venting in which the first directional valve WV 1  malfunctions, i.e. does not return into its nc-position. This leaves the path E 1 -A 1  open, and compressed air is still applied to the control side S 6  of the sixth directional valve WV 6 , holding it in its functional position. This means that the venting port R 6  of the sixth directional valve WV 6  is blocked. Venting is nevertheless possible, because the third directional valve WV 3  has returned into its nc-position as required, allowing the compressed air applied to the control side S 4  of the fourth directional valve WV 4  to escape via the venting port R 3 , which causes the fourth directional valve WV 4  to return into its nc-position. Compressed air from the secondary outlet P 2  can now escape into the venting port R 4 . In addition, the control side S 5  of the fifth directional valve WV 5  is vented via A 6 -E 6  and the venting port R 4 , so that the fifth directional valve WV 5  returns into its nc-position. 
       FIG. 8  shows a switching position for venting in which the third directional valve WV 3  malfunctions, i.e. does not return into its nc-position. This leaves the path E 3 -A 3  open, and compressed air is still applied to the control side S 4  of the fourth directional valve WV 4 , holding it in its open position. This means that the venting port R 4  of the fourth directional valve WV 4  is blocked. Venting is nevertheless possible, because the first directional valve WV 1  has returned into its nc-position as required, allowing the compressed air applied to the control side S 6  of the sixth directional valve WV 6  to escape via the venting port R 1 , which causes the sixth directional valve WV 6  to return into its normal position. Compressed air from the secondary outlet P 2  can now escape via the venting port R 6 . In addition, the control side S 5  of the fifth directional valve WV 5  is vented to the atmosphere via A 6 -E 6 , so that the fifth directional valve WV 5  returns into its nc-position. 
       FIG. 9  shows a switching position for venting in which the fifth directional valve WV 5  malfunctions, i.e. does not return into its nc-position. This leaves the main flow path  12  via E 5 -A 5  open, allowing compressed air from the primary inlet P 1  to flow. Venting is nevertheless possible, because the two directional valves WV 1  and WV 3  have returned into their nc-positions, venting both the control side S 4  of the fourth directional valve WV 4  and the control side S 6  of the sixth directional valve WV 6 , so that the fourth and sixth directional valves WV 4  and WV 6  have returned into the nc-position or normal position respectively. This once again allows the venting of the compressed air from the secondary outlet P 2  via the venting ports R 4  and R 6 . 
       FIG. 10  shows a switching position for venting in which the fourth directional valve WV 4  malfunctions, i.e. does not return into its nc-position. This blocks the venting port R 4 . Venting is nevertheless possible, because the first and third directional valves WV 1  and WV 3  have returned into their nc-positions as required, venting in particular the control side S 6  of the sixth directional valve WV 6 , causing it to return into its normal position, so that compressed air applied to the control side S 5  of the fifth directional valve WV 5  is vented via E 6 * and R 6 * and the fifth directional valve WV 5  also returns into its nc-position. Compressed air from the secondary outlet P 2  can now escape via the venting port R 6 . 
       FIG. 11  finally shows a switching position for venting in which the sixth directional valve WV 6  malfunctions, i.e. does not return into its normal position. This blocks the venting port R 6 . However, the first and third directional valves WV 1  and WV 3  have returned into their nc-positions as required, so that the control side S 4  of the fourth directional valve WV 4  is vented, returning this valve into its nc-position, so that compressed air from the secondary outlet P 2  can escape via the venting port R 4 . In addition, the control side R 5  is vented via A 6 -E 6  and the venting port R 4 , causing the fifth directional valve WV 5  to return into its nc-position.