CN101514698A - Intelligent energy saving control system of air compressor - Google Patents
Intelligent energy saving control system of air compressor Download PDFInfo
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- CN101514698A CN101514698A CNA2009100248580A CN200910024858A CN101514698A CN 101514698 A CN101514698 A CN 101514698A CN A2009100248580 A CNA2009100248580 A CN A2009100248580A CN 200910024858 A CN200910024858 A CN 200910024858A CN 101514698 A CN101514698 A CN 101514698A
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Abstract
The invention relates to an intelligent energy saving control system of an air compressor. In the structure, an output end of a touch screen for setting pressure parameters is connected with a first input end of PLC, an output end of a pressure transmitter is connected with a second input end of PLC, an output end of PLC is connected with an input end of an inverter, an output end of the converter is connected with an input end of the air compressor, and an output end of the air compressor is connected with an input end of the pressure transmitter by a gasholder. The intelligent energy saving control system of the air compressor has the advantages that the energy saving performance is perfect, the electricity charge is saved by 20 percent above, and input capital can be recovered in about half a year; the operational cost is lowered, and the energy source cost is lowered by 44.3 percent; the pressure control precision is improved, the systematic pressure change of the pipe network can be kept within the range of +/-0.2bar, and the working condition quality is improved effectively; the service life of a compressor is prolonged; voices of the air compressor are lowered, and compared with an original system, the voices are lowered by about 3-7db; with high reliability, the supply pressure is stable and can be regulated at any time.
Description
Technical field
What the present invention relates to is a kind of intelligent energy saving control system of air compressor, belongs to air compressor control technique field.
Background technique
The control mode of air compressor mostly is switch suction port valve loading and unloading and regulates air pressure at present.Promptly when gas consumption reduced, air pressure increased, and when arriving upper limit pressure, closed inlet valve, made air compressor be in unloaded state, did not have gas to extrude, and at this moment air compressor is flogging a dead horse, and when air pressure was lower than threshold pression, the suction port valve was opened loading.This working method can be brought the air pressure shakiness, influences quality of product.The load of motor increases when air pressure is high, and power consumption increases.When air pressure is low, the air compressor unloading, motor is in unloaded state, flogs a dead horse, and also is to waste energy.And when air pressure was high, pipe leakage also was a kind of performance of power consumption.This working method can not satisfy development of modern industry.Needed air horsepower on the live axle of air compressor, with exhaust pressure, air compressor rotating speed direct relation is arranged, that is to say, in actual motion, because compressed-air actuated use is changing at any time, air compressor is without moving under the declared working condition of being everlasting, and the height of air compressor exhaust pressure then directly has influence on the size of actual axle power.Exhaust pressure is high more, and required air horsepower is also big more.For satisfying the requirement of variation at any time of gas consumption, gas must keep certain pressure in the gas holder, and present most of air compressors all adopt the regulative mode that cuts off air inlet to change the tolerance that drains into gas holder.Show as the variation of exhaust pressure for the supply-demand relationship of air compressor tolerance, the air compressor air displacement just in time satisfies when producing gas consumption and requiring, and gas storage pressure remains unchanged.If it is best certainly to keep this state, but in fact gas consumption changes at any time, and the design amount of redundancy is bigger, so the air compressor air displacement all is greater than gas consumption.If still constant speed running of air compressor, then the gas in the gas holder is cumulative, when the rising of jar internal pressure reaches setting pressure, generally adopts two kinds of ways:
1. air compressor off-load operation does not produce pressurized gas, and motor is in no-load running, and its power consumption still is the 30-60% of full load, and this part electric energy quilt wave is in vain destroyed.
2. stop compressor operation, as if like this electric energy that air compressor dallies or continuous emptying is wasted has been eliminated, but if the bigger gas holder of no volume, will bring the frequent starting of motor, the No Load Start electric current of air compressor approximately is 5-7 a times of rated current, bigger to electrical network and the impact of other consumer, also can be shortened the working life of air compressor.
Regulate suction valve by machinery type, air demand can't be regulated continuously, when gas consumption constantly changed, supply gas pressure produced fluctuation by a relatively large margin inevitably.Do not reach technological requirement with the gas precision.Add frequent adjusting suction valve, the wearing and tearing of meeting accelerating charge valve increase amount of maintenance and maintenance cost.
The frequent employing opens and closes bleed valve, and the serviceability of bleed valve can not get ensureing.
Summary of the invention
The present invention proposes a kind of intelligent energy saving control system of air compressor that utilizes constant pressure air feeding control, is intended to overcome the above-mentioned defective of existing in prior technology.
Technical solution of the present invention: its structure is the first input end that the output terminal of the touch screen of setting pressure parameter connects PLC, the output terminal of pressure transmitter connects second input end of PLC, the output terminal of PLC connects the input end of frequency variator, the output terminal of frequency variator connects the input end of air compressor, and the output terminal of air compressor connects the input end of pressure transmitter by gas holder.
Advantage of the present invention: (1) good energy saving property, save air compressor intelligent and energy saving system control compressor and compare with traditional compressor of controlling, energy conservation is of practical significance most.Coming the industry control of compressed and supplied machine according to the air quantity demand is economic operation conditions.It is about more than 20% to save the electricity charge, and be recyclable input half a year approximately; (2) operating cost reduces, and the operating cost of traditional compressor is formed by three: initial purchase cost, maintenance cost and energy cost.Wherein energy cost accounts for 77% of compressor operating cost greatly.Operating cost reduces by 44.3% by energy cost, adds that the impact to equipment reduces behind the varying frequency starting, safeguard and amount of maintenance is also followed reduction, so will reduce greatly; (3) improve pressure controling precision, frequency-changing control system has the accurate pressure control ability, and the tolerance that air pressure is exported and user's air system is required of compressor is complementary.The output tolerance of VFC compressor changes along with the change of motor speed.Because the precision of VFC motor speed improves, thus it the system pressure of pipe network is changed remain on ± the 0.2bar scope in, improved the quality of operating mode effectively; (4) working life of prolongation compressor, the air compressor intelligent and energy saving system is from the 0Hz starting compressor, and its starting time for acceleration can be adjusted, thus when reducing starting to the impact that electric component and mechanical part caused of compressor, the reliability of enhanced system prolongs the working life of compressor; (5) reduced the noise of air compressor, according to the working condition requirement of compressor, after frequency control of motor speed was transformed, motor rotation speed obviously slowed down, the noise when therefore having fallen compressor operation effectively.Noise and original system relatively descend about 3 to 7 decibels; The air compressor intelligent and energy saving system can be effectively be reduced to a minimum the peak value of starting current.Supply gas pressure is stable, and by pressure regulator, air compressor is remained under the force value of setting work, pressure stability reliability height, and also pressure can steplessly set, and adjustable at any time.Motor is realized soft start, and the working life of compressor and repair cycle all will be prolonged greatly.The air compressor air displacement is controlled by the rotating speed of air compressor, air valve plate opening and closing no longer repeatedly in the cylinder, and operating conditions such as valve seat, spring are improved greatly, have avoided high temperature, rapid the flowing and impact of pressurized gas, and maintenance load reduces.
Description of drawings
Accompanying drawing 1 is the energy-saving principle schematic representation of air compressor intelligent and energy saving system.
Accompanying drawing 2 is air compressor frequency-changing control system major loop figure.
Accompanying drawing 3 is air compressor frequency-changing control system secondary circuit figure.
Accompanying drawing 4 is transducer control circuit figure.
Accompanying drawing 5 is PLC control circuit figure.
Accompanying drawing 6 is pressure feedback circuit diagram.
Accompanying drawing 7 is air compressor main circuit diagrams.
Accompanying drawing 8 is the circuit diagram that increased auxiliary reclay KA5 contact, auxiliary reclay KA6 coil in former air compressor control secondary circuit.
Embodiment
Contrast accompanying drawing 3, its structure is to comprise contactor KM1 and KM2 normally-closed contact, throw over switch SA1, auxiliary reclay KA1 coil, auxiliary reclay KA5 coil, contactor KM2 coil, contactor KM1 coil, finish the power frequency of frequency-changing control system and the conversion between frequency conversion, the working state of indication frequency-changing control system realizes opening, stopping of frequency-changing control system.
Contrast accompanying drawing 6, its structure is made up of pressure transmitter.
Contrast accompanying drawing 7, its structure is to comprise A.C. contactor M normally opened contact, A.C. contactor D normally opened contact, A.C. contactor S normally opened contact, motor M1, wherein A.C. contactor M normally opened contact and motor M1 join, A.C. contactor D normally opened contact and A.C. contactor M normally opened contact, motor M1 join, and A.C. contactor S normally opened contact and motor M1 join.
Contrast accompanying drawing 8, its structure are that described auxiliary reclay KA5 contact, auxiliary reclay KA6 coil are connected on the Out let CN7 in the air compressor control circuit.
Described PLC storage is from the given signal of touch screen, for example require pressure to maintain about 0.7Kg, the digital quantity of analog amount correspondence is stored in the storage unit PLC with regard to inciting somebody to action therewith so, PLC gathers the analog amount that pressure transducer sends simultaneously, calculate (calculate by the program that is stored in the PLC the inside and finish) generation control signal with previously stored analog amount contrast after converting it into digital quantity, this control signal is received the Frequency Converter Control end, during force value that the force value that sends when pressure transmitter is set less than touch screen, PLC gives the frequency variator up-conversion signal, the operation frequency of frequency variator is raise, controlling rotating speed of motor this moment accelerates, the decrement of compressor strengthens, the gas storage pressure of gas holder the inside is raise, conform to the pressure of setting up to the pressure of gas holder.During force value that the force value that sends when pressure transmitter is set greater than touch screen, control procedure is then opposite.
Described pressure transmitter can detect the variation in pressure of 0.1MP, and this pressure transmitter is that the pressure linearity inside the gas holder is converted into current signal, passes to PLC.
Described frequency variator adopts Siemens standard frequency variator MM440, its input voltage is 380V～480V, and defeated Chu frequency is 0HZ～50HZ, as servo-drive, mainly be frequency, power supply be provided for the motor of air compressor at the control signal down conversion supply voltage of PLC.
Utilize frequency variator to regulate rotating speed by changing electric machine frequency, VFC is promptly controlled the air output of air compressor unit time by the rotating speed that changes motor, thereby reaches the pressure of pilot line, has remarkable energy saving effect.When the application frequency variator carries out constant pressure air feeding control, ductwork pressure as controlling object, change setting pressure electrical signal A into by touch screen setting pressure parameter P0 and send PLC to by its output terminal, pressure transmitter also changes the gas holder pressure P of air compressor into gas holder electric pressure signal B gives PLC, compare by setting pressure electrical signal A and gas holder electric pressure signal B, and carry out computing by set PID control mode according to the size of difference, produce control signal and send into frequency variator, because the frequency of rotating speed of motor and power supply is approximated to direct ratio, so change the motor of frequency of input voltage rear driving air compressor through frequency variator, the electric voltage frequency of motor changes and has also just changed rotating speed of motor, during force value that the force value that sends when pressure transmitter is set less than touch screen, PLC gives the frequency variator up-conversion signal, the operation frequency of frequency variator is raise, controlling rotating speed of motor this moment accelerates, the decrement of compressor strengthens, the gas storage pressure of gas holder the inside is raise, conform to the pressure of setting up to the pressure of gas holder.During force value that the force value that sends when pressure transmitter is set greater than touch screen, control procedure is then opposite.Thereby make actual pressure P all the time near setting pressure P0.Simultaneously, this scheme can increase power frequency and energy-conservation switching function, and keeps original control and protective system.
Air compressor energy-saving and frequency-variable system principle is as follows: go up pressure set points of input in man-machine interface (HMI),
Compare with the setting value of pressure by PLC by the gas holder force value that pressure transmitter records, obtain deviation, calculate and export to frequency variator analog amount control signal by PLC, the control frequency variator is adjusted the rotating speed of motor, make the gas holder variation in pressure, up to identical with the setting pressure value.
The air compressor intelligent and energy saving system adopts intelligent programmable software to be solidificated on the microprocessor; by electronic circuit load is detected in real time and follows the tracks of; control the angle of flow of thyristor in real time; centisecond is with interior optimum operating voltage of air compressor and the electric current of providing; the output power of air compressor is just mated with load in real time; and can lower copper loss, iron loss, and improve the air compressor starting, shut down performance, reach power savings.
In addition; the air compressor intelligent and energy saving system possesses soft start and relaxes the shutdown function, because frequency variator is to start operation from lower frequency, drive motor also is to start under lower frequency; so realized the soft start of motor, the infringement of having avoided direct-on-line starting that motor is caused.During shutdown; the output voltage frequency of frequency variator can drop to a low spot; form the process that a slope descends; the rotating speed of drive motor is also followed and is formed a process that relaxes reduction of speed; shut down thereby realize relaxing; can reduce air compressor owing to start and the impact of shutting down to power supply system, and protection air compressor and air-break switch etc.The air compressor intelligent and energy saving system could reduce the temperature rise and the noise of air compressor, improves working environment simultaneously!
Because air compressor can be produced under the needed minimum pressure in assurance and move, power input to machine descends greatly, is aided with pressure closed loop control, realizes the Dynamic matching of the supply gas pressure-rotating speed of air compressor, reduce the actual input power of motor, reached energy-conservation purpose.Be that rotating speed of motor is controlled by supply gas pressure, compressor needs great power, and motor is just exported great power, and needn't flog a dead horse, thereby obtains good energy-saving effect.Energy-conservation second aspect is that air compressor has stopped idle running, and there is not light running in motor.
The every index analysis of air compressor intelligent and energy saving system:
1) the motor frequency conversion running state keeps the gas holder outlet pressure stable, and the pressure surge scope is no more than ± 0.2bar.2) system has energy-conservation and power frequency two cover control loops; generally air compressor operates in the frequency conversion state under the driving of frequency variator; the situation that air compressor is shut down appears when preventing frequency converter failure; the bypath system that adds can be with the frequency variator bypass; make compressor operation under the power frequency state, the throw over switch that one of the two needs are contained on the cabinet face both can be realized.3) according to the industry control requirement of air compressor, system ensures the persevering torque roadability of electric tools.4) in order to prevent non sinusoidal wave interference air compressor controller, air compressor intelligent and energy saving system output terminal has installed the wave filter of frequency variator special use additional, filtering higher harmonics in the supply voltage, make through the voltage waveform after the frequency conversion gentlyer, suppressed electromagnetic interference effectively.5) under the narrow-minded situation of electricity consumption, when the air compressor intelligent and energy saving system is in low-frequency operation, ensure that the noise of motor windings temperature and motor is no more than the scope of permission.6) consider scaling problem after the system, the air compressor intelligent and energy saving system satisfies the requirement of the expansion of industry control in the future.7) install the input reactance device additional in this air compressor intelligent and energy saving system upper end, effectively suppressed of the interference of air compressor intelligent and energy saving system electrical network.
Native system also has converting operation and power frequency operation throw over switch, can select as required to switch.
Power frequency operation is opened energy-conservation cabinet air-break switch and original engine power supply switch, under outage state, places the power frequency position can pacify former startup method " power frequency-frequency conversion " throw over switch on the frequency conversion tank and starts air compressor.Can close the power supply of software cabinet (PLC) during power frequency operation.
Converting operation is opened energy-conservation cabinet air-break switch and original engine power supply switch, and checks and confirm that each cabinet heat radiation fan operation is in good condition.Under outage state, " power frequency-frequency conversion " throw over switch on the frequency conversion tank is placed " frequency conversion " position, air compressor enters the energy-saving and frequency-variable running state.After finishing the parameter setting on the man-machine interface, on former machine operation interface, start air compressor according to original startup method.
The air compressor intelligent and energy saving system can not produce the situation that product yield or performance quality descend.It can effectively reduce air compressor temperature rise and noise, prolongs air compressor maintenance period and working life, to reducing production costs and improving quality stability good action is arranged.Air compressor intelligent and energy saving system power supply incoming call needn't be through rectification, oscillation element, and self power consumption is low, has obviously improved the total efficiency of air compressor.Its micro computer processing system can accurately, quickly and reliably detect load and come intelligent energy-saving, and this technology has reached the top standard in the world.Although air compressor intelligent and energy saving system advanced technology, mature and reliable because it is simple in structure, compare with other economize on electricitys, its investment is cheap, and fractional energy savings is higher, more stable, and income is long-term, huge.
Claims (7)
1, intelligent energy saving control system of air compressor, it is characterized in that the output terminal of the touch screen of setting pressure parameter connects the first input end of PLC, the output terminal of pressure transmitter connects second input end of PLC, the output terminal of PLC connects the input end of frequency variator, the output terminal of frequency variator connects the input end of air compressor, and the output terminal of air compressor connects the pressure transmitter input end by gas holder.
2, intelligent energy saving control system of air compressor according to claim 1 is characterized in that the input reactance device in the described air compressor frequency-changing control system joins with frequency variator V/F is corresponding; The input end of input reactance device connects lightning arrester.
3, intelligent energy saving control system of air compressor according to claim 1, it is characterized in that second auxiliary reclay (KA2) normally opened contact, one end in the described air compressor frequency-changing control system secondary circuit joins with the control power source bus, the other end and green indicating lamp join; One end of first throw over switch (SA1) joins with the control power source bus, normally-closed contact one end of the other end of first throw over switch (SA1) and first contactor (KM1) joins, the normally-closed contact the other end of first contactor (KM1) and second contactor (KM2) coil, one end join, and second contactor (KM2) the coil the other end and zero line join; One end and first throw over switch (SA1) of second contactor (KM2) normally-closed contact join, the other end of second contactor (KM2) normally-closed contact and first contactor (KM1) coil and the 5th auxiliary reclay (KA5) coil one end join, and first contactor (KM1) coil and the 5th auxiliary reclay (KA5) the coil the other end and zero line join; Trouble shooting button one end joins with the control power source bus, the trouble shooting button the other end and the 3rd auxiliary reclay (KA3) normally opened contact one end join, the 3rd auxiliary reclay (KA3) the normally opened contact the other end and alarm bell one end join, and the alarm bell the other end and zero line join; Second throw over switch (SA2) end joins with the control power source bus, and second throw over switch (SA2) the other end and first contactor (KM1) normally opened contact, one end join; First contactor (KM1) the normally opened contact the other end and A.C. contactor normally opened contact one end join, the A.C. contactor normally opened contact the other end and the 3rd auxiliary reclay (KA3) normally-closed contact one end join, the 3rd auxiliary reclay (KA3) the normally-closed contact the other end and first auxiliary reclay (KA1) coil, one end join, and first auxiliary reclay (KA1) the coil the other end and zero line join.
4, intelligent energy saving control system of air compressor according to claim 1, it is characterized in that described transducer control circuit comprises frequency variator V/F, second auxiliary reclay (KA2) coil, the 3rd auxiliary reclay (KA3) coil, wherein the control end of frequency variator V/F joins with second auxiliary reclay (KA2) coil, the 3rd auxiliary reclay (KA3) coil.
5, intelligent energy saving control system of air compressor according to claim 1, the input end and first contactor (KM1), second contactor (KM2) normally opened contact, first auxiliary reclay (KA1), second auxiliary reclay (KA2), the 3rd auxiliary reclay (KA3), the 6th auxiliary reclay (KA6) normally opened contact that it is characterized in that the CPU in the described PLC control circuit join, and the output terminal of the 4th auxiliary reclay (KA4) coil and CPU joins.
6, intelligent energy saving control system of air compressor according to claim 1, it is characterized in that first A.C. contactor (M) normally opened contact one end and motor (M1) in the described air compressor main circuit join, first A.C. contactor (M) the normally opened contact the other end and second A.C. contactor (D) normally opened contact, one end join, second A.C. contactor (D) the normally opened contact the other end and first A.C. contactor (M) normally opened contact, one end join, first A.C. contactor (M) the normally opened contact the other end and motor (M1) join, and the 3rd A.C. contactor (S) normally opened contact and motor (M1) join.
7, intelligent energy saving control system of air compressor according to claim 1 is characterized in that the 5th auxiliary reclay (KA5) contact, the 6th auxiliary reclay (KA6) coil in the described air compressor control secondary circuit is connected on the Out let (CN7) in the air compressor control circuit.
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| CNA2009100248580A CN101514698A (en) | 2009-02-27 | 2009-02-27 | Intelligent energy saving control system of air compressor |
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Cited By (14)
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| CN102220961A (en) * | 2010-04-19 | 2011-10-19 | 深圳市汇川技术股份有限公司 | Air compressor energy-saving and pressure-stabilizing controlling system and air compressor |
| CN102644585A (en) * | 2012-04-25 | 2012-08-22 | 连云港杰瑞深软科技有限公司 | Air compressor hybrid control system and method |
| CN103362790A (en) * | 2012-04-01 | 2013-10-23 | 比亚迪股份有限公司 | Air compressor control system and control method thereof |
| CN103527461A (en) * | 2012-07-06 | 2014-01-22 | 博世力士乐(西安)电子传动与控制有限公司 | Operational control system of air compressor and operational control method of air compressor |
| CN104373330A (en) * | 2013-08-14 | 2015-02-25 | 青岛海普润机械有限公司 | Air compressor control device and method |
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| CN108980021A (en) * | 2018-07-27 | 2018-12-11 | 珠海市盛西源机电设备有限公司 | A kind of application method of frequency conversion energy-saving system on air compressor machine |
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| CN102220961A (en) * | 2010-04-19 | 2011-10-19 | 深圳市汇川技术股份有限公司 | Air compressor energy-saving and pressure-stabilizing controlling system and air compressor |
| CN103362790A (en) * | 2012-04-01 | 2013-10-23 | 比亚迪股份有限公司 | Air compressor control system and control method thereof |
| CN102644585A (en) * | 2012-04-25 | 2012-08-22 | 连云港杰瑞深软科技有限公司 | Air compressor hybrid control system and method |
| CN102644585B (en) * | 2012-04-25 | 2014-12-10 | 连云港杰瑞深软科技有限公司 | Air compressor hybrid control system and method |
| CN103527461A (en) * | 2012-07-06 | 2014-01-22 | 博世力士乐(西安)电子传动与控制有限公司 | Operational control system of air compressor and operational control method of air compressor |
| CN104373330A (en) * | 2013-08-14 | 2015-02-25 | 青岛海普润机械有限公司 | Air compressor control device and method |
| CN105004018A (en) * | 2015-06-19 | 2015-10-28 | 中山顺富节能科技有限公司 | an air conditioner |
| CN105201805A (en) * | 2015-10-16 | 2015-12-30 | 宝钢发展有限公司 | Air compressor set intelligent control system and method based on user informatization allocation |
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| CN107013443B (en) * | 2016-01-28 | 2019-03-22 | Abb技术有限公司 | Load/unload control method and equipment for compressor assembly |
| CN108980021A (en) * | 2018-07-27 | 2018-12-11 | 珠海市盛西源机电设备有限公司 | A kind of application method of frequency conversion energy-saving system on air compressor machine |
| CN110735781A (en) * | 2019-11-11 | 2020-01-31 | 宁夏实德新型建材有限公司 | Control system and method for air compressor components |
| CN110735781B (en) * | 2019-11-11 | 2021-08-31 | 宁夏实德新型建材有限公司 | Control system and method for air compressor assembly |
| CN111120277A (en) * | 2019-12-30 | 2020-05-08 | 中山路得斯空调有限公司 | Linkage operation method and system for air compressor unit |
| CN111120277B (en) * | 2019-12-30 | 2022-07-29 | 广东路得斯环境科技有限公司 | Linkage operation method and system for air compressor unit |
| CN113153719A (en) * | 2021-06-02 | 2021-07-23 | 中车青岛四方车辆研究所有限公司 | Air supply control method and system for railway vehicle and railway vehicle |
| CN113685341A (en) * | 2021-08-24 | 2021-11-23 | 广东鑫钻节能科技股份有限公司 | Operation protection system of intelligent air compression station |
| CN117231486A (en) * | 2023-10-26 | 2023-12-15 | 上海瑞气气体科技有限公司 | Variable frequency control method, system and logic controller of air compressor |
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