Background information:
Micro pump usually refers to a gas delivery device that is small in size and has a gaseous working medium. It is mainly used for gas sampling, gas circulation, vacuum adsorption, vacuum pressure maintaining, pumping, pumping, pressurization and other purposes. With its advantages of portability, maintenance-free, and pollution-free, it is widely used in many industries such as medical, scientific research, environmental protection, chemical industry, and instrumentation.
The first category is civilian grade products. This type of micro pump is mainly equipped for cheap civilian products, such as aquarium air pumps, sphygmomanometer air pumps, car air pumps, etc. The technology of this type of micro pump has initially matured, with large output and low price, and can meet the needs of daily use.
The second category is industrial grade products. This type of product mainly uses high-end micro pumps, which are used in industrial instrumentation, medical equipment, sampling analysis, military equipment, etc. The parameters such as pressure, vacuum, and flow are relatively high, and particularly require stable parameters and high reliability. There are many air pumps on the internet, ranging from a dozen yuan to a thousand yuan, with a wide variety of styles, a mixed bag, and uneven quality. Customers can choose according to their own circumstances when purchasing products. The following is a brief analysis and comparison of civilian-grade and industrial-grade air pumps from five aspects.
Material and assembly process:
The micro pump is mainly composed of two parts: a motor and a micro pump body. The motor includes a casing and a stator and a rotor arranged in the casing. The pump body includes a bottom cover, a diaphragm compression component and a pump head component, and an intake and exhaust check valve [umbrella valve is not the industry standard General] etc. The quality of the materials of core components such as motors and diaphragms directly determines the quality of the pump, and the accuracy of the assembly process also determines the life of the pump. Material The reason why the civilian-grade air micro pump is low in price is directly related to the raw materials it purchases.
The motor uses materials such as silicon steel sheets, scrap copper enameled wire, varnish as insulating paint, etc. In layman’s terms, a motor is considered qualified if it can rotate. The core elements of its design and production are low material cost, longevity and Big compromises have been made in terms of security. Take our products as an example for industrial-grade air pumps.
The motors are all high-quality brushless motors produced by Japan Nidec, with exquisite materials and exquisite workmanship. The ethylene propylene diene rubber (EPDM) used in the diaphragm assembly has an excellent bending life under the temperature difference of -20℃-100℃, and is also resistant to low acid and alkali corrosion. Therefore, under some customers’ special working conditions, our company’s air pumps can still maintain stability and long life.
The fineness of the assembly process will also have an impact on the micro pump. The tightness of the bearings and connecting rods, the direction of riveting, the angle of the motor, the tightness of the rubber bowl and umbrella valve, etc. have strict requirements, so various factors are comprehensively determined. improve micro pump performance. Therefore, for civilian-grade products, unified specifications are required, and quality inspection specifications are relatively simplified. The tightness of assembly of various components is far from the industrial-grade level. Therefore, the noise and reliability are far from industrial products.
Support temperature range:
The ambient temperature range and medium temperature range used are also one of the important indicators of the quality of the air pump. Civilian air pumps can operate normally at normal temperatures (about 10°C-40°C), but customers are widely distributed.
Many northern customers have outdoor ambient temperatures of 0°C or even below. In such harsh environments, most civilian air pumps cannot start. Let alone working properly. Similarly, in the summer in the south, outdoor temperatures of 30°C are common, and sometimes can even reach 40°C. The air pump working under load at high ambient temperatures will aggravate the aging of the motor and other circuit components, and the service life cannot be guaranteed.
The temperature range supported by industrial-grade products and the allowed medium temperature range are much greater than those of civilian-grade products. Most of our company’s air pumps can realize customization of ambient temperature and medium temperature. The customization range is -15℃–100℃, which can meet the needs of absolutely the needs of most customers. For example, for customers in the chromatography industry, when the flame ionization detector (FID) is working, the ambient temperature can reach 90°C, and our company’s D35L series air pump can still operate stably and reliably.
Continuous working time and service life:
Continuous working time and service life are important parameters to measure the air pump. Ordinary civilian-grade air pumps, are clearly marked for intermittent operation and cannot work continuously for more than 4 hours; the suction or exhaust ports cannot be blocked, otherwise the motor will be easily burned out; at the same time, this type of air micro pump The service life is also very short, often only 200-400 hours.
However, many scenarios in customer industry require continuous long-term work, or even 24-hour uninterrupted high-load work. Under such high-intensity working conditions, civilian-grade air pumps often The lifespan is very short, and it will be damaged in half a month or a month. Frequent replacement and maintenance will inevitably increase the cost.
Compared with civilian-grade air pumps, industrial-grade air pumps have great differences in continuous working time and lifespan. The continuous working time of industrial-grade air pumps can reach more than 8 hours or even longer. Take our company’s air pump as an example. The air pump can operate at full load 24 hours a day without manual maintenance. It is more user-friendly.
Under special circumstances, even if there is an air extraction port or the exhaust port is blocked, it can still work normally without being suffocated. The pump is damaged, and for ordinary civilian-grade products, after the air nozzle is blocked by foreign matter, the motor is very likely to burn out due to overload in a short period of time. This is an important point that distinguishes civilian-grade and industrial-grade air pumps.
Speed adjustment function, remote control:
Multi-functional integration is also a significant difference between civilian air pumps and industrial-grade air pumps. Ordinary civilian-grade air pumps do not have functions such as speed regulation and speed feedback. This type of air pump generally has a simple circuit connection. It can start when the power is turned on and stop when the power is turned off. It is suitable for daily use and cannot be used in complex and precise working conditions. However, the use of air pumps in industry is very different.
Different customers use different working conditions and require different parameters during use, such as PLC or other host computers to control the speed, remote control start and stop, etc., which requires The air pump can meet the needs of users to meet their special working conditions. The high versions of our company’s air pumps with different flow rates all support the speed adjustment function, mainly in the following three ways, pwm speed adjustment, frequency speed adjustment, and touch speed adjustment. According to different usage methods, targeted selection can be made, which is especially suitable for customers in the automatic control industry.
Air tightness and gas leakage:
Civilian air micro pumps are generally used to transmit air and do not involve the transmission of toxic, harmful or special chemical composition gases. Therefore, air tightness is generally not optimized during design, nor are parameters such as gas leakage rate optimized. Therefore, the working pressure When working at high or even normal pressure, the air micro pump does not maintain a sealed state.
For example, civilian air pumps often inhale 1L of gas and only spit out 0.9L of gas. However, industrial-grade air pumps transmit complex components and the working environment is also complicated. If there is no good Poor air tightness will cause gas leakage in the air path and even cause personal injury, so the air micro pump needs to have very good air tightness;
Micro pump Electromagnetic interference:
Civilian air micro pumps mostly use brushed motors. Due to the commutation of the brushes during operation, strong electromagnetic interference is easily generated, causing interference to surrounding circuit components. In order to meet the electromagnetic compatibility requirements of precision instruments such as medical devices, our industrial-grade micro pumps are driven by low-interference brushless motors and have passed EU CE and EMC certification to meet the requirements of industrial-grade customers.