Abstract:
A zoned fluid control system in a valve manifold system has a plurality of manifold blocks connected together and a plurality of control valves mounted to the manifold blocks with the control valves being electrically actuated and pilot pressure operated. The plurality of manifold blocks forms at least first and second separate pilot pressure passages of a respective first zone and second zone not connected to each other for supplying a respective first set and second set of control valves with independently controlled pilot pressure. A pilot supply valve selectively supplies pilot pressure and shuts off pilot pressure to the second pilot pressure passage without affecting the pilot pressure to the first pilot pressure passage thereby disabling the second set of control valves as a separate zone independent from the first set of control valves.

Description:
TECHNICAL FIELD 
       [0001]    The field of this invention relates to pneumatic solenoid valve control systems with a manifold assembly. 
       BACKGROUND OF THE DISCLOSURE 
       [0002]    Industrial automation has been greatly improved by using manifold assemblies that direct pneumatic pressure to control many control devices. The manifold assemblies incorporate electrical actuated solenoid valves that control the direction of pneumatic flow for actuating these control devices. These manifold assemblies are commonly assembled in modular form from a plurality of manifold blocks. The manifold assembly has a common pilot pressure passage and main pressure passages that are connected to the solenoid valves which in turn control the flow of main pressure to a respective control device. The solenoid actuated control valve has a main valve or spool and a solenoid actuated pilot valve that provides pilot pressure to the main valve. Pilot pressure to actuate a main valve is well known. If the pilot pressure connected to the solenoid actuated valves is independently supplied from the main pressure, the actuation of the main valve in the solenoid can take place only when both pilot pressure is supplied to the valve and electrical actuation of the solenoid valve occurs. 
         [0003]    These manifolds can incorporate many manifold blocks with many valve stations and solenoid valves which in turn control many control devices. It is often desired to shut down one or more of the control devices without shutting down all the control devices connected to the manifold assembly. A shutdown may be due to routine maintenance of the device or for repairing unexpected malfunction of or damage to the device. Previous efforts to control individual valve stations were accomplished by shutting off the electrical power to an individual solenoid that controls the downstream device. The application of zoned power has also been used to control the electrical power to a group of devices in a particular zone such that only that zone may be turned off without turning off other zones of power. However, these zones of power have introduced complications to the modular assembly by increasing the number of different parts. 
         [0004]    Manifold assemblies need to accommodate guidelines for different levels of industrial architecture that have recently been proposed or implemented. One guideline level calls for moving the solenoid valve to a mid-position to prevent pneumatic flow to the device when the device is inactivated. Another guideline level of architecture calls for detection of any movement of the device during shutdown and also provides further warning signals of the motion during shutdown. A further level or architecture calls for providing a spring loaded brake that will prevent the device from further motion when air is released for actuating the spring loaded brake. 
         [0005]    Manifold assemblies commonly have a sandwich block interposed between a manifold block and the solenoid actuated valve. These sandwich blocks have been used to provide shut off valves for the main pressure, introduction of separate main pressure to a single valve station or to provide and isolate the exhaust of a single valve station from the manifold. 
         [0006]    What is now desired is to provide redundancy to the architecture to further prevent inadvertent actuation of the solenoid by selectively eliminating and exhausting pilot pressure for the solenoid actuated valve. Further what is desired is both a pilot pressure system and an electrical circuit system that provides zones in the manifold assembly without the need for a great increase in inventory parts. What is further desired is a manifold assembly that can introduce a separate pilot pressure to a zone of solenoid actuated valves via a sandwich block interposed between the manifold block and the solenoid actuated valve. 
       SUMMARY OF THE DISCLOSURE 
       [0007]    In accordance with one aspect of the invention a valve manifold assembly has a plurality of manifold blocks connected together with valve stations on one surface of each manifold block. The valve manifold assembly includes a first pilot pressure supply operably connectable to a first set of control valves electrically actuated and a first set of control valves mounted to a first set of valve stations on the manifold blocks. A first pilot pressure passage is operably connectable to the first pilot pressure supply for supplying pilot pressure to the first set of valve stations. 
         [0008]    A second pilot pressure supply is operably connectable to a second set of control valves that are electrically actuated. The second set of control valves is mounted to a second set of valve stations on the manifold blocks. A second pilot pressure passage is operably connectable to an actuable pilot supply valve for selectively supplying zoned pilot pressure to the second set of valve stations such that the second set of control valves may be deactuated if pilot pressure is shut off thereto while the first set of control valves remain connected to pilot pressure. 
         [0009]    Preferably, the first pilot pressure passage is separated from the second pilot pressure passage by a closure within one of the manifold blocks. The closure is preferably within the one manifold block that has at least two valve stations with one station being part of the first set of valve stations and at least a second valve station being part of the second set of valve stations. In one embodiment, the closure is a seal member press fitted into a pilot bore separating the first pilot passage from the second pilot passage. 
         [0010]    It is desirable that a sandwich block is interposed between one of the manifold blocks and one of the control valves. The sandwich block has an exterior connector to be connectable to a pilot supply leading from the pilot supply valve. The sandwich block also has a port in fluid connection to the exterior connector for introducing pilot pressure from the pilot supply valve to the one control valve. It is desirable that the sandwich block has a passage from the port to the manifold block to introduce pilot pressure to the second pilot pressure passage. In one embodiment, the first set of control valves is electrically actuated from a first electrical power supply and the second set of control valves is electrically actuated from a second electrical power supply. 
         [0011]    According to another aspect of the invention, a sandwich block is constructed to be interposed between a manifold block and a control valve that is solenoid actuated and pilot pressure operated. The sandwich block has an inlet for receiving pilot pressure from a pilot supply valve external from the manifold block. The inlet has a passage to an outlet operably connectable to the control valve such that the pilot supply valve can selectively supply pilot pressure to the control valve. 
         [0012]    In accordance with another aspect of the invention, a zoned fluid control system in a valve manifold system has a plurality of manifold blocks connected together and a plurality of control valves mounted to the manifold blocks with the control valves being electrically actuated and pilot pressure operated. The plurality of manifold blocks forms at least first and second separate pilot pressure passages of a respective first zone and second zone not connected to each other for supplying a respective first set and second set of control valves with independently controlled pilot pressure. A pilot supply valve selectively supplies pilot pressure and shuts off pilot pressure to the second pilot pressure passage without affecting the pilot pressure to the first pilot pressure passage thereby disabling the second set of control valves as a separate zone independent from the first set of control valves. 
         [0013]    Preferably, an electrical control circuit independently supplies electrical power to the first set and second set of control valves such that in order for the second set of control valves to be actuated, the electrical control circuit needs to supply electrical power to the second set and the pilot supply valve must be open to supply pilot pressure to the second separate pilot pressure passage in the separate zone. Preferably, the first and second pilot pressure passages are aligned through the manifold block. It is also desirable that a manifold block at the beginning of a zone has an external fitting to be connected to an electrical power supply and a respective sandwich block is interposed between the manifold block and a control valve mounted thereon for supplying pilot pressure from the pilot supply valve to the second separate pilot pressure passage of the second zone. 
         [0014]    In accordance with another aspect of the invention, a valve manifold block for zoned fluid control has a first zone and second zone between connected valve manifold blocks. The manifold block has a plurality of fluid pathways therethrough, and ports forming a first and second valve station and controlled by respective first and second control valves operably mounted thereto. A circuit board passage passes through the manifold block from a first side to a second side. A pilot passage inlet port and a pilot passage outlet port are on respective first and second sides. The pilot passage inlet port is part of the first zone and not in operable communication with the pilot passage outlet port which is part of the second zone. A circuit board is received in the circuit board passage and has a first edge in proximity with the first side and with a plurality of first electrical contacts, and a second edge in proximity with the second side with a plurality of second mating electrical contacts to connect to respective first electrical connector in another printed circuit board in another downstream valve manifold block. 
         [0015]    The circuit board has a common voltage connector contact at said first edge and leads to a first jumper terminal on the circuit board that receives electrical power from a first zone. The valve manifold block has an external electrical connector for connecting a zoned power source to a second jumper terminal on the circuit board, a zoned common voltage connector contact at the second edge, and in electrical connection with the second valve station to drive said second control valve. 
         [0016]    The first and second jumper terminals are selectively placed in contact with a common jumper terminal that is in electrical connection with the first control valve such that the first control valve can be powered by either electrical power from said first zone from the common voltage connector at the first edge or from the second zoned power source from the zoned common voltage connector from the external connector. 
         [0017]    It is preferred that the first and second jumper terminals are arranged with the common jumper terminal on a three pin header with a two pole shunt being selectively positioned on said common line with either of said first or second jumper terminal. 
         [0018]    In accordance with another aspect of the invention, a manifold block for a valve manifold assembly has a least one valve station for mounting a control valve thereon and a circuit board mounted in a duct through the manifold. The circuit board has a first circuit at an edge for supplying a first source of electrical power; and a second circuit for supplying a second source of electrical power. An electrical connector supplying a second source of electrical power to the second circuit is mounted at a side of said block. The circuit board has a jumper station thereon for selectively controlling whether the first circuit or the second circuit supplies electrical power to the at least one valve station in the manifold block. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    Reference now is made to the accompanying drawings in which: 
           [0020]      FIG. 1  is a perspective and partially schematic overview of one arrangement according to one embodiment of the invention; 
           [0021]      FIG. 2  is a partially exploded view of a zoned power manifold block; 
           [0022]      FIG. 3  is a cross sectional view of the zoned power manifold block shown in  FIG. 2 ; 
           [0023]      FIG. 4  is an enlarged perspective view of a sandwich block shown in  FIG. 1 ; 
           [0024]      FIG. 5  is a cross sectional view along  5 - 5 —shown in  FIG. 4 ; 
           [0025]      FIG. 6  is a cross sectional view similar to  FIG. 5  showing a sandwich block configured to supply a single valve station; 
           [0026]      FIG. 7  is an enlarged view of the circuit board shown in  FIG. 2  with a shunt shown in a first position; 
           [0027]      FIG. 8  is a view similar to  FIG. 7  with the shunt shown in the second position; 
           [0028]      FIG. 9  is a schematic view of a first face of the circuit board shown in  FIG. 7  illustrating the trace lines; 
           [0029]      FIG. 10  is a schematic view of a second face of the circuit board shown in  FIG. 7  illustrating the trace lines; 
           [0030]      FIG. 11  is a schematic end view of the first and second edges of the circuit board for a double solenoid valve unit as shown in  FIG. 1  illustrating the terminals connections to respective circuits in the circuit board and the connection to the shunt in a first position and second position (in phantom); 
           [0031]      FIG. 12  is a perspective view of manifold block illustrating a second embodiment according to the invention; 
           [0032]      FIG. 13  is a top perspective view of the supply station cover as shown in  FIG. 10  with the external pilot supply port; 
           [0033]      FIG. 14  is a fragmentary bottom perspective view of the supply station cover shown in  FIG. 13 ; 
           [0034]      FIG. 15  an enlarged schematic view of the first face of the circuit board for the manifold shown in  FIG. 10 ; 
           [0035]      FIG. 16  is an enlarged schematic view of the second face of the circuit board shown in  FIG. 15 ; and 
           [0036]      FIG. 17  is a schematic end view of the first and second edges of the circuit board as shown in  FIG. 15  illustrating the terminals connections to respective circuits in the circuit board and the connection to the shunt in a first position and second position (in phantom). 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0037]    Referring now to  FIGS. 1-3 , a fluid control system  10  is modular in nature and depending on the application has a plurality of valve manifold blocks  12  interconnected together. The manifold blocks  12  may be in different zones  14 ,  16 , and  18  for example with a modified manifold block  20  at the start of the second zone  14 , third zone  18 , and any sequential zone. As illustrated in  FIG. 2 , each manifold block  20  has two valve stations  26  and  28  that mount two control valves  30 . Each manifold block  20  has an electrical connector  22  for introducing a zoned electrical power supply for the respective zone. Each of the zoned electrical power supply can be independently turned off. 
         [0038]    As shown in  FIGS. 2 and 3 , the manifold block  20  at the beginning of each zone  16  and  18  has the respective valve stations  26  and  28  with a respective pilot pressure port  32  and  34  that is connected to a pilot chamber in a respective solenoid actuated valve pilot pressure chamber (not shown) of a standard control valve  30  that is electrically actuated and pilot operated. For example, electric actuation of a solenoid opens an internal pilot valve in the control valve  30  that then supplies pilot pressure to one side of a spool valve which moves the spool valve. The spool valve controls the flow between different ports  36  at a respective valve station  26 ,  28  in the manifold block  20 . These ports  36  are in connection with transverse ducts  42  that align with similar transverse ducts in other manifold blocks. Some of these ports  36  may also be in communication to terminals  44  that are connected to downstream devices (not shown) to both supply main pressure to the devices and to allow the main device to exhaust pneumatic pressure back through the manifold block. 
         [0039]    As shown in  FIGS. 2 and 3 , the manifold block  20  has pilot pressure port  32  connected to a transverse first pilot passage  46  connected to previous manifold blocks  12  in a previous zone. Similarly pilot pressure port  34  is connected to a transverse second pilot passage  48  that in turn is connected to downstream manifold blocks  12  in the next zone. A plug  50  in the form of a ball is press fitted to separate and seal pilot passage  46  from pilot passage  48 . 
         [0040]    As shown in  FIG. 1 , a pilot sandwich block  52  is interposed between a block  20  and a control valve  30  at a valve station  28 . The pilot sandwich block  52  as shown in  FIGS. 4 and 5  has an external pilot port  54  that is operably connected to a pilot supply valve  56  that provides independent pilot pressure to the second valve station  28 . The pilot supply valve  56  is conventional in structure and can be independently actuated to an “on” or open position to supply pilot pressure and an “off” e.g. exhaust position. The pilot sandwich block  52  has its port  54  connected to a pilot supply outlet  38  that leads to the control valve  30  at valve station  28 . As shown in  FIG. 5 , the pilot sandwich block  52  also has a through duct  58  that is connected to lower port  39  that seats on and is operably connected to pilot port  34  on the valve station  28  that leads to the second pilot passage  48  in the manifold to supply the rest of the second zone. The remaining ports  59  operably connect the ports  36  on station  28  to the control valve in a desired fashion. 
         [0041]    Referring now to  FIG. 6 , if it is desired to have the pilot pressure feed only the control valve  30  on the single station  28 , the sandwich block  52  is modified such that the through duct  58  is eliminated. In this fashion the external pilot pressure only feeds the single valve station  28  and is separated from either the first pilot passage  46  or the second pilot passage  48  in the manifold block. The lower port  39  is a blind hole and seals off port  34 . 
         [0042]    Referring now to  FIGS. 7-11 , an electrical circuit board  60  for the manifold block  20  is described. The circuit board  60  has a first edge  62  and second edge  64  with trace contacts  66  on both faces  63  and  65  of the board. As shown in  FIG. 11 , the terms labeled A or B e.g. A 1 -A 19  and B 1 -B 19  refer to the positions of the contacts and conductive lines on the respective sides A, B of the circuit board  60  at each edge  62  and  64 . The terms labeled with the V as prefix e.g. V 1 , V 2 , etc. refer to the downstream valve number that the circuit operates counting from the shown circuit board  60 . On the present circuit board  60 , only the first four valve numbers V 1 -V 4  are connected to the valves on the manifold block  20 . The remaining set  69  of valve lines V 5 -V 32  have the traces  68  that are merely stepped down from the trace contacts  66  at the first edge  62  to the trace contacts  66  at the second edge  64 . For example V 5  at position A 5  at the first edge  62  drops to position A 4  at the second edge  64  to be connected to a V 1  contact at position A 4  of a sequential board. Top contact positions A 19 , B 19 , A 18 , and B 18  at edge  64  are not connected to any conductive lines on the board. In this particular shown circuit board  60 , V 31  indicates that the valve manifold using that circuit board is limited to a maximum of thirty-one solenoid valves. Other layouts for the circuit board lines are possible to provide for less or more solenoid valves. 
         [0043]    Each circuit board has pin connector sets  72  and  73  mounted thereon. The contacts A 4  and B 4  corresponding to V 1  and V 2  are operably connected to pin connector set  72  via circuit traces  75  and  77 . The pin connector set  72  is connected to the control valve  30  at the first station  26 . Pin connector sets  72  and  73  are also connected to protective earth line PE connected to contact A 2  through traces  79 . Pins connector set  72  is connected to a middle contact  76  at jumper station  70  through circuit trace  81 . In addition, one of the trace contacts B 3  connected on the first edge  62  labeled Vcom is also connected to a contact  88  at a jumper station  70  on the circuit board through circuit trace  83 . 
         [0044]    The electrical connector  22  is also connected to the circuit board  60  at contact  86 . The contact  86  leads through circuit trace  85  to the contact  84  at jumper station  70 , and pin connector set  73  pin. Pin connector set  73  is connected to control valve  30  at valve station  28 . In this manner, the electrical connector  22  powers the control valve  30  at the second station  28  in the second zone. The pin connector set  73  finishes the circuit by connecting the connector  22  via circuit trace  87  to an outgoing Zcom contact trace A 3  and B 3  at the second edge  64  to power subsequent manifold blocks  12 . 
         [0045]    A shunt  82  is connectable to the jumper station  70  at a first position as shown in  FIG. 7  or a second position as shown in  FIG. 8 . As shown in  FIG. 7 , the shunt  82  bridges contact  84  with contact  76 . Thus, the power from the electrical connector  22  passes to pin set  72  as well as powering pin set  73 . In this position valve station  26  and valve station  28  are both powered by the electrical connector  22  and can be said to be in the same electrical zone or powered by the same electrical supply. The contact  88  is open and in effect Vcomn through its trace  83  is not connected to anything in this configuration. 
         [0046]    If it is desired to have valve station  26  in a previous zone i.e. powered by a different electrical supply, and thus, valve station  28  becomes the first station in a sequential zone, shunt  82  is moved to the position shown in  FIG. 8  and also  FIG. 11  in phantom. In this position, the Vcomn terminal A 3  through trace  83  connects from contact  86  to contact  76  and powers pin set  72 . Thus, valve station  26  is powered by Vcomm from contact  88  while the second valve station  28  remains powered by the external electrical connector  22  via circuit path  85  to pin connector  73 . The electrical connector  22  is still operably connected through circuit path  87  to the Zomm contact at the second edge which can provide power to downstream electrical circuit boards in manifolds  12 . Valve station  26  now receives separate electrical power and a separate pilot pressure than valve station  28 . The downstream manifolds  12  are thus in zone  2  and also receive the zoned electrical power and zoned pilot pressure until another zone is started. 
         [0047]    When a zone of the valve manifold needs to be deactuated, i.e. valve station  28  needs to be turned off, the electrical power through electrical connector  22  can be turned off in addition to the external pilot supply valve  56  being turned off. Thus, zone  2  can be turned off while the remaining zones  1  and  3  can remain actuated. As now becomes apparent, each zone can be independently turned on or off. For example, zone  2  can be off while both zones  1  and  3  can remain on. The control valves  30  in each zone will not work unless both the pilot pressure from pilot supply valve  56  is supplied and electrical power from the electrical connector  22  is supplied. Thus, by having both the electrical power and pilot pressure deactuated in a turned off zone, a redundancy is introduced to assure that the zone remains off. 
         [0048]    Referring now to  FIGS. 12-17 , a modified manifold block  120  includes four valve stations of which only valve station  127  and  128  are shown. A pilot pressure cover plate  152  is mounted over a first valve station and has an external pilot port  154  for connection to a pilot supply valve (not shown) and a passage  155  that leads to a pilot inlet  141  that leads to the transverse pilot duct  142  through the manifold block. A cover plate  157  is mounted over a second valve station to seal the v and a modified circuit board  160  is shown. 
         [0049]    The manifold block  120  has an external electrical connector  122  and various ports  140  at the respective valve stations. Shown valve stations  126  and  128  can mount control valves  30 . A pilot plug  150  in the form of ball is press fitted into the end of the transverse pilot duct  142  to form the beginning of the valve zone and prevent communication from a previous manifold block and its pilot duct  142 . An electrical connector  122  is similarly mounted as previously described electrical connector  22 . 
         [0050]    Control circuit board  160  is similarly stepped as circuit board  60  in order to serve the two valve stations  126  and  128  with dual solenoid valves. The comparable traces and contacts and jumper will carry the same numerals as the ones previously described for circuit board  60  and only the differences between the boards  60  and  160  will be explained in detail. 
         [0051]    The Vcomn power at contact end A 3  and B 3  at edge  64  is connected to jumper station  70  at contact  84  through trace  183 . Middle common contact  76  of jumper station  70  is connected to both sets of pins  72  and  73  through traces  185  and to Zcomn contact B 3  and A 3  at edge  62  through trace  187 . Electrical connector  122  is connected to terminal  186  and through trace  189  is connected to jumper station  70  at contact  88 . 
         [0052]    As shown in  FIG. 17 , when it is desired to have the electrical powered supplied by electrical connector  122 , the shunt  82  is moved to the right position and connects contact  88  with contact  76  at jumper station  70 . In this fashion, both pin sets  72  and  73  receive the power from the electrical connector  122  through terminal  186 . If on the other hand, when it is desired to have both stations  126  and  128  receive power from the Vcomn lines, the shunt  82  is positioned to the phantom position shown on the left. Both pins sets  72  and  73  now receive power via the Vcomn contacts A 3  and B 3  at edge  62 . In this fashion, a circuit board  160  provides a choice as to electrical power sources that feed the valve stations  126  and  128  in block manifold  120 . 
         [0053]    Other variations and modifications are possible without departing from the scope and spirit of the present invention as defined by the appended claims.