Thursday, August 15

What Is a Flow Controller & Do I Need One?

There are a few different kinds of flow controllers that all operate under the same principle for your compressed air systems. Let’s dig into some of the specifics about flow controllers and their applications.

Flow Controller Overview

What is A Flow Controller?

Flow controllers are configurable tools that allow the user to change the volume of air within your compressed air system to optimize the user’s compressed air usage. They are essentially pressure regulators that provide quick response time to meet the plant’s demand by maintaining stable system pressure.

Flow controllers are separate pieces of equipment that can be installed to an existing or new system. These pieces of equipment are generally placed immediately after an air storage receiver or air storage tank so that it can draw from already pressurized air that is ready for use and control the amount of this air that leaves the supply side and enters the demand side. A flow controller may reduce the number of compressors needed to operate to meet demand. They also can save energy and reduce air leak losses.

Types of Flow Controllers

Motorized Flow Control Valves: These valves are constructed of two ceramic discs that rotate around each other to allow for maximum air flow when the two discs align. When these discs are out of alignment, air flow becomes restricted.

Proportional Flow Control Valves: These valves utilize a spool with a microprocessor that can accurately and precisely control the air flow.

Banjo Flow Controllers: These flow controllers are managed manually by using a screwdriver slot or knurled nut to make adjustments.

How Do Flow Controllers Work?

Flow controllers operate just how they sound: they control the air flow traveling through them. They do this by adjusting the size of the opening of the flow controller, only allowing a certain amount of air to pass through passed on what the demand is requiring. The smaller the opening, the lower the air flow and conversely, the larger the opening, the greater the air flow. Flow controllers also possess the power to close the opening all together, allowing no air to pass through.

Choosing the Right Air Flow Controller

Connection Type: air flow controllers can be push-in units or threaded
Control Method: will the user need remote or manual adjustment capabilities?
Surrounding Environment: environmental factors like temperature and humidity can impact your flow controller choice
Configuration Needs: Do you need a unidirectional or bidirectional valve? If you need a unidirectional valve, you will also need to decide if you need to control in-flow or exhaust cycles.
Flow Rates Required: The range of minimum and maximum flow rates required for your demand will also dictate the necessary port size of your controller.
Material: While composite fittings are most common for many compressed air applications, more heavy-duty, rugged environments and applications may require a heavier metal material.

ZORN'S PROMISE

Zorn is the Midwest leader of custom, engineered compressed air and vacuum solutions. We provide the best customer experience by understanding your applications and needs and offering an unparalleled commitment to customer satisfaction.

Our comprehensive product and service solutions keep you running 24/7.

Reliable equipment
Trusted brands
Seamless, easy installation
Post-sales support
Local, 24/7 service

Our compressed air experts look forward to meeting you to discuss your equipment and support needs. Please contact us directly at (262) 695-7000 with any questions or to schedule service for your system moving forward.

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