CN101725515A - Air compressor energy-saving control method - Google Patents
Air compressor energy-saving control method Download PDFInfo
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- CN101725515A CN101725515A CN200910112770A CN200910112770A CN101725515A CN 101725515 A CN101725515 A CN 101725515A CN 200910112770 A CN200910112770 A CN 200910112770A CN 200910112770 A CN200910112770 A CN 200910112770A CN 101725515 A CN101725515 A CN 101725515A
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Abstract
The invention mainly discloses an air compressor energy-saving control method. A a frequency conversion starting mode and a power frequency starting mode are set for a motor of an air compressor; and the selection of the two modes are realized by a control circuit which is formed by a contactor. Frequency conversion starting is driven by a transducer; and control signals of the transducer for the motor are determined according to a pressure transmitter on an air reservoir of the air compressor. At the same time, in the method, a distributed control system DCS is adopted; the pressure transmitter is a data acquiring station of the DCS; the transducer is a controlled object of the DCS; and a remote computer or an industrial computer is used as an operator station or an engineer station of the DCS. The method has the characteristics of energy conservation, high control accuracy, low energy consumption and excellent performance.
Description
Technical field
The present invention relates to the field of energy-saving technology of air compressor (abbreviation air compressor), special relevant with a kind of air compressor energy-saving control method.
Background technique
Total head was moved after the main motor method of operation of existing air compressor mostly was star-angle decompression starting greatly.Unit operation is in suction valve open and close control mode, closes valve during the upper pressure limit of gas holder, drives valve during the low pressure limit of gas holder, and efficient is low, and running current is big, and equipment energy consumption is big.
The site operation personnel is a conservation of power, has to take artificial start, shutdown, and so not only labor intensity is big, and controls not prompt enoughly, and unit starting is frequent.The unit frequent starting increases load, and inrush current is big, starts the energy consumption height, impacts big to equipment and electrical network.
Simultaneously, solenoid valve acts frequently, the spoilage height.Power factor is low, and reactive loss is big.When supply gas pressure is on the low side, can not satisfy technological requirement; When supply gas pressure is higher, the power consumption height.But certainly will want supply gas pressure higher for satisfying technological requirement, thereby cause air feed cost height, energy consumption height.Again because the running speed height, and air intake valve opens and closes frequently, causes the machine room noise big.
Also have, general air compressor has power frequency or a kind of working state of frequency conversion, and working method is single like this, and when the damage of frequency variator or power frequency branch road takes place when, just can't proper functioning.
Given this, the inventor designs a kind of air compressor energy-saving control method, and this case produces thus.
Summary of the invention
Main purpose of the present invention is to provide a kind of air compressor energy-saving control method, has power frequency/frequency conversion switching function, overcomes the solenoid valve frequent movement, avoids manual control switch's motor to cause controlling untimely, cuts down the consumption of energy.
Another object of the present invention is to eliminate harmonic wave and the noise that frequency variator brings, improve power factor.
To achieve these goals, the technical solution adopted in the present invention is:
Air compressor energy-saving control method, the motor of air compressor are provided with variable frequency starting and power frequency starts dual mode, and the selection of this dual mode is realized by the control circuit that contactor forms; Variable frequency starting is driven by frequency variator, and frequency variator is decided according to the pressure transmitter on the gas holder of air compressor the control signal of motor; Simultaneously, adopt DCS (DistributedControl System distributed control system among the present invention, claim Distributed Control System again), pressure transmitter is exactly the data acquisition station of DCS, frequency variator is the controlling object of DCS, and remote computer or industrial computer are as operator station or the engineer station of DCS.
The present invention can also be further perfect:
Described variable frequency starting and power frequency startup all have on-site manual and DCS telecontrol dual mode.
During variable frequency starting, by reactor and wave filter harmonic carcellation and noise interference.In addition, can also suppress prominent next high pressure by piezoresistance ground connection.
After adopting such scheme, the present invention has two kinds of working methods of frequency conversion/power frequency, and gas holder pressure as the data capture object, is done control adjustment through DCS to frequency variator, thereby realizes the energy-conservation purpose of air compressor.Like this, the start-stop air compressor reduces the amount of labour manually, and control simultaneously in time improves precision, cuts down the consumption of energy.The present invention adapts to the variation of load behavior automatically, and dynamic adjustments reaches the real equilibrium of supply and demand in good time, has good energy-saving effect, and power saving rate can reach 20%～30%, and makes whole system reach optimum Working.
Again, the present invention possesses perfect protective function, and the assurance equipment safety operation reduces noise and to the electrical network impact, reduces equipment attrition, improves power factor, reliably switches the working life of prolonged mechanical parts.
Description of drawings
Fig. 1 is the main loop circuit figure of motor of the present invention;
Fig. 2 is the circuit diagram of control circuit of the present invention;
Fig. 3 is a system construction drawing of the present invention.
Embodiment
The present invention provides power frequency to start and two kinds of working methods of variable frequency starting to motor, by control circuit its dual mode is switched.Wherein in the frequency conversion working method, the force value in the sampling gas holder is dynamically adjusted the output of frequency variator, realizes energy-conservation purpose.Whole system adopts DCS (distributed control system claims Distributed Control System again), with the flexible monitoring management of air compressor.
In conjunction with Fig. 1, Fig. 2 and Fig. 3 realization of the present invention is done further and to be elaborated.
Motor major loop of the present invention is that power frequency in parallel starts branch road 1 and variable frequency starting branch road 2 after air-break switch QF, is connected to control circuit 3 between air-break switch QF and the N two ends, and control circuit 3 is mainly realized by contactor.
Wherein variable frequency starting branch road 2 comprises contactor master normally opened contact KM1-1, input AC reactor LA1, input noise wave filter LC1, frequency variator 21, contactor master normally opened contact KM2-1, output AC reactor LA2, the output noise wave filter LC2 of series connection successively, is connected to the motor of air compressor afterwards.
In the present embodiment, also be connected to piezoresistance V at variable frequency starting branch road 2 and suppress prominent next high pressure.
Power frequency starts branch road 1 and directly is connected to motor by contactor master normally opened contact KM3-1 and thermorelay FR exactly after air-break switch QF.
Among the present invention, pressure transmitter 20 is housed on the gas holder of air compressor, pressure transmitter 20 is selected Rosemount 3051 pressure transmitters for use, and this pressure transmitter adopts two-wire system connection, these two lines be power line be again signaling line.During work, the isolation diaphragm of high and low pressure side and filling liquid pass to filling liquid with pressure process, and then filling liquid transfers the pressure on the pressure-sensitive diaphragm of center sensor.The maximum displacement of pressure-sensitive diaphragm is 0.004 inch (0.1 millimeter), and displacement amount is directly proportional with pressure.The capacitor plate of both sides detects the position of pressure-sensitive diaphragm.The difference of electric capacity is converted into the DC current output signal of 4～20mA between pressure-sensitive diaphragm and the capacitor plate.
As shown in Figure 3, DCS of the present invention mainly comprises DCS control centre 4, data acquisition station, controlling object one, controlling object two.Wherein data acquisition station is exactly a pressure transmitter 20, and controlling object one is a frequency variator 21, and controlling object two is a control circuit 3, and these three parts all are connected on the bus of DCS control centre 4.DCS control centre 4 connects long-range operator station 41, operator station 42 and engineer station 43 by Ethernet, realizes telecontrol.
Power frequency hand push button SB1, DCS VFC normally-closed contact K1-2, contactor shop that power frequency control branch road 31 has series connection successively help normally-closed contact KM2-2, thermorelay FR, contactor coil KM3.Be parallel with the contactor shop simultaneously at the two ends of power frequency hand push button SB1 and help normally opened contact KM3-2 and DCS power frequency control normally opened contact K1-1.Power frequency tutorial light HL1 is connected across DCS VFC normally-closed contact K1-2, the contactor shop helps the two ends after normally-closed contact KM2-2, thermorelay FR and the contactor coil KM3 series connection.
VFC branch road 32 is in series with frequency conversion hand switch SB2, DCS VFC normally-closed contact K2-2 successively, the contactor shop helps normally closed switch KM3-3, contactor coil KM2.Be parallel with the contactor shop at the two ends of frequency conversion hand switch SB2 and help normally opened contact KM2-4 and DCS VFC normally opened contact K2-1.Be connected across the two ends of contactor coil KM2 after the contactor shop helps normally opened contact KM2-3 and contactor coil KM1 connects, the tutorial light of frequency conversion simultaneously HL2 is connected across DCS VFC normally-closed contact K2-2, the contactor shop helps the two ends after normally-closed contact KM3-3 and the contactor coil KM2 series connection.
In addition, go up in the present embodiment, also be in series with fus FU before the knob ST.
During real work of the present invention, can on-site manual control, but also DCS control centre 4 controls.After closing, air-break switch QF inserts three phase mains, on-the-spot knob ST opens, and then prerun tutorial light HL3 is bright, and the prerun tutorial light in operator station 41 or the operator station 42 is also bright, illustrate that power frequency/frequency conversion can start operation, but power frequency/frequency conversion can not start operation simultaneously.
When frequency variator 21 just often, adopt frequency-conversion starting motor.If select the on-site manual mode, at first, press the button SB2, contactor coil KM2 gets electric, the auxiliary normally opened contact KM2-4 closure of corresponding contactor master normally opened contact KM2-1 and contactor, like this, make contactor coil KM1 also, its corresponding contactor master normally opened contact KM1-1 is also closed, and at this moment, variable frequency starting branch road 2 is connected.On VFC branch road 32, contactor coil KM1, KM2 have two electrical paths, and after unclamping start button SB2, contactor coil KM1, KM2 still can help the contact energising and keep attracting state by its shop like this, and HL2 is bright for the tutorial light of frequency conversion simultaneously.
If during with 4 controls of DCS control centre, then click start button in operator station 41 or operator station 42, signal is delivered to DCS control centre 4 through Ethernet, makes DCS VFC normally opened contact K2-1 closure.So just can DCS telecontrol variable frequency starting, thus drive motor.
In the frequency conversion working method, frequency variator 21 setup pressure value, pressure transmitter 20 is converted to electrical signal to the pressure of the gas holder that collect and sends DCS control centre 4 to, the pressure that collects and the force value of setting compares and carry out the pid control law computing.When the force value of setting when the pressure ratio that collects was big, then output frequency value reduced the air compressor motor rotating speed; The force value of setting when the pressure ratio that collects hour, then output frequency value increases the air compressor motor rotating speed; When the pressure that collects equated with setting pressure, output frequency stopped motor automatically, saved electric energy.
In case frequency variator 21 faults, then also select the power frequency operation mode, if select on-site manual to start power frequency control branch road 31, then press the button SB1, contactor coil KM3 gets electric, its contactor master normally opened contact KM3-1 closure, power frequency control branch road is connected, electric motor starting, the auxiliary normally opened contact KM3-2 of contactor is also closed simultaneously, and contactor coil KM3 has two electrical paths.After unclamping start button SB1, contactor coil KM3 still can help the contact energising and keep attracting state by its shop like this, and HL1 is bright for the power frequency tutorial light.
If start with DCS telecontrol power frequency, then in operator's website 41 or 42, click start button, signal is delivered to DCS control centre 4 through Ethernet, makes DCS power frequency control normally opened contact K1-1 closure, and the same power frequency of motor starts.In like manner, click stop button, DCS power frequency control normally-closed contact K1-2 is disconnected, motor stops.
Further specify, fus FU is used for protecting control circuit, in order to avoid overcurrent burns out control means, guarantees that the frequency conversion loop disconnects.Thermorelay FR is overtemperature protection, because during power frequency operation, motor is overheated easily, so will carry out overtemperature protection to the power frequency loop.
In sum, the present invention has following advantage:
1, saving power, the present invention is by pressure transmitter 20, gather the air compressor air storage tank force value, pressure is changed into electrical signal give DCS control centre 4, after DCS control centre 4 carries out the pid control algorithm computing, rotating speed and output power that the output control signal regulates air compressor motor for frequency variator 21, automatically regulate the air compressor air demand according to actual demand, and keep-up pressure constant, reaching purpose of energy saving, general power saving rate can reach 20%～30%.
2, the present invention adopts DCS, can monitor the runnability of air compressors in the operator station 41 or 42 in control room, the automaticity height.In addition, in the time of with energy-saving and frequency-variable, also adopt input output reactor, input output wave filter to eliminate harmonic wave and the noise that frequency variator 21 causes, the quality of power supply of guaranteeing to power reaches standard, avoids waste electric energy in energy-conservation.
3, improve pressure controling precision, DCS control centre 4 has pid control algorithm, makes it have the accurate pressure control ability.The tolerance that air pressure is exported and user's air system is required of air compressor is complementary.The output tolerance of VFC air compressor changes along with the change of motor speed.Because the precision of VFC motor speed improves,, improved the quality of product effectively so it can make gas holder pressure keep constant.
4, improve the ride quality of air compressor comprehensively, frequency variator 21 is from the OHz starting electrical machinery, and its startup time for acceleration can be adjusted, thereby reduces the impact that when starting air compressor electric component and mechanical part is caused, the reliability of enhanced system prolongs the working life of air compressor.In addition, the current fluctuation when VFC can reduce unit starting, this fluctuating current can influence the electricity consumption of electrical network and miscellaneous equipment, and frequency variator 21 can be effectively be reduced to a minimum the peak value of inrush current.According to the working condition requirement of air compressor, after frequency control of motor speed was transformed, motor rotation speed obviously slowed down, thus the noise when having reduced compressor operation effectively.On-site measurement shows, noise and original system about 3～7dB that relatively descends.
Claims (4)
1. air compressor energy-saving control method is characterized in that: the motor of air compressor is provided with variable frequency starting and power frequency starts dual mode, and the selection of this dual mode is realized by the control circuit that contactor forms; Variable frequency starting is driven by frequency variator, and frequency variator is decided according to the pressure transmitter on the gas holder of air compressor the control signal of motor; Simultaneously, adopt DCS (Distributed Control System distributed control system among the present invention, claim Distributed Control System again), pressure transmitter is exactly the data acquisition station of DCS, frequency variator is the controlling object of DCS, and remote computer or industrial computer are as operator station or the engineer station of DCS.
2. air compressor energy-saving control method as claimed in claim 1 is characterized in that: described variable frequency starting and power frequency startup all have on-site manual and DCS telecontrol dual mode.
3. air compressor energy-saving control method as claimed in claim 1 or 2 is characterized in that: during variable frequency starting, by reactor and wave filter harmonic carcellation and noise interference.
4. air compressor energy-saving control method as claimed in claim 3 is characterized in that: during variable frequency starting, eliminate impacting with high pressure by piezoresistance.
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| Application Number | Priority Date | Filing Date | Title |
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| CN 200910112770 CN101725515B (en) | 2009-11-12 | 2009-11-12 | Air compressor energy-saving control method |
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| CN 200910112770 CN101725515B (en) | 2009-11-12 | 2009-11-12 | Air compressor energy-saving control method |
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| CN101725515A true CN101725515A (en) | 2010-06-09 |
| CN101725515B CN101725515B (en) | 2013-08-07 |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN102003377A (en) * | 2010-11-23 | 2011-04-06 | 北京时代科仪新能源科技有限公司 | Control device and method for air compressor |
| CN103334913A (en) * | 2013-07-25 | 2013-10-02 | 河南省通信电缆有限公司 | Control system of air compressor |
| CN103696953A (en) * | 2013-12-31 | 2014-04-02 | 大唐贵州发耳发电有限公司 | Air compressor control device |
| CN105008194A (en) * | 2013-02-14 | 2015-10-28 | 克诺尔轨道车辆系统有限公司 | Air supply system with electronic converter |
| CN105422455A (en) * | 2015-12-31 | 2016-03-23 | 天津市金星空气压缩机制造股份有限公司 | Energy-saving control cabinet of screw air compressor |
| CN106593816A (en) * | 2017-02-06 | 2017-04-26 | 荣成市固废综合处理与应用产业园有限公司 | Variable frequency one-drive-two compressed air system for air compressor |
| CN110278137A (en) * | 2019-06-12 | 2019-09-24 | 山西大学 | A kind of upper-level control system and field level telecommunication system and method |
| CN110608160A (en) * | 2019-09-05 | 2019-12-24 | 上海泾铎科技有限公司 | Control method and device for main motor of air compressor set |
Families Citing this family (1)
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| CN105790646A (en) * | 2016-03-16 | 2016-07-20 | 甘肃酒钢集团宏兴钢铁股份有限公司 | Device for one-drive-two control of three-phase AC asynchronous motors |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6053703A (en) * | 1995-06-19 | 2000-04-25 | Ebara Corporation | Control method for displacement-type fluid machine, and apparatus thereof |
| CN2755864Y (en) * | 2004-10-14 | 2006-02-01 | 华北油田科达开发有限公司 | Controller with variable-frequency and power frequency synchronous switch |
| CN201083194Y (en) * | 2007-09-13 | 2008-07-09 | 宝山钢铁股份有限公司 | Air compressor frequency conversion energy-saving device |
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2009
- 2009-11-12 CN CN 200910112770 patent/CN101725515B/en active Active
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102003377A (en) * | 2010-11-23 | 2011-04-06 | 北京时代科仪新能源科技有限公司 | Control device and method for air compressor |
| CN105008194A (en) * | 2013-02-14 | 2015-10-28 | 克诺尔轨道车辆系统有限公司 | Air supply system with electronic converter |
| CN105008194B (en) * | 2013-02-14 | 2017-08-29 | 克诺尔轨道车辆系统有限公司 | Air supply device with electronic inverter |
| US11300117B2 (en) | 2013-02-14 | 2022-04-12 | Knorr-Bremse Systeme für Schienenfahrzeuge GmbH | Air supply system with electronic converter |
| CN103334913A (en) * | 2013-07-25 | 2013-10-02 | 河南省通信电缆有限公司 | Control system of air compressor |
| CN103334913B (en) * | 2013-07-25 | 2016-05-18 | 河南省通信电缆有限公司 | A kind of control system of air compressor |
| CN103696953A (en) * | 2013-12-31 | 2014-04-02 | 大唐贵州发耳发电有限公司 | Air compressor control device |
| CN105422455A (en) * | 2015-12-31 | 2016-03-23 | 天津市金星空气压缩机制造股份有限公司 | Energy-saving control cabinet of screw air compressor |
| CN106593816A (en) * | 2017-02-06 | 2017-04-26 | 荣成市固废综合处理与应用产业园有限公司 | Variable frequency one-drive-two compressed air system for air compressor |
| CN110278137A (en) * | 2019-06-12 | 2019-09-24 | 山西大学 | A kind of upper-level control system and field level telecommunication system and method |
| CN110608160A (en) * | 2019-09-05 | 2019-12-24 | 上海泾铎科技有限公司 | Control method and device for main motor of air compressor set |
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| Publication number | Publication date |
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| CN101725515B (en) | 2013-08-07 |
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