CN102163044A - Variable-frequency controller of air compressor-refrigeration drier system - Google Patents
Variable-frequency controller of air compressor-refrigeration drier system Download PDFInfo
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- CN102163044A CN102163044A CN 201010600065 CN201010600065A CN102163044A CN 102163044 A CN102163044 A CN 102163044A CN 201010600065 CN201010600065 CN 201010600065 CN 201010600065 A CN201010600065 A CN 201010600065A CN 102163044 A CN102163044 A CN 102163044A
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Abstract
The invention provides a variable-frequency controller of an air compressor-refrigeration drier system, comprising a refrigeration compressor frequency converter, an air compressor frequency converter, a dew point temperature sensor, a pressure transducer and an energy-saving controller, wherein the dew point temperature sensor is used for detecting a cold medium temperature of the refrigeration drier; the pressure transducer is used for detecting the pressure of the air compressor; and the energy-saving controller is used for performing variable-frequency control to the compressor according to the dew point temperature and performing variable-frequency control to the air compressor according to the pressure. The refrigeration compressor frequency converter is connected with the refrigeration compressor of the refrigeration drier; the air compressor frequency converter is connected with a driving motor of the air compressor; the dew point temperature sensor and the pressure transducer are connected with the energy-saving controller; and the energy-saving controller is connected with the refrigeration compressor frequency converter and the air compressor frequency converter. The variable-frequency controller can effectively reduce the energy consumption and has good energy-saving effect and purification effect of the compressed air.
Description
Technical field
The present invention relates to air compressor-dryer field, especially a kind of air compressor machine-cooling driers system.
Background technology
Pressurized air is the most important industrial power source except electric power, all has extremely widely in machinery, electronics, petrochemical industry, automobile, weaving, chemical fibre, non-ferrous metal, electric power, coal, food, medicine and other fields and uses.Because the pressurized air of air compressor (hereinafter to be referred as air compressor machine) output contains oil, water, vapour and dust granule etc. inevitably, if do not carry out purified treatment, can make follow-up gas equipment and pipeline by corrosion, inferior, finally have a strong impact on the quality of product with the makings amount.Therefore, must dewater to pressurized air, oil removing, drying and purified treatment.Frozen compressed air dryer (hereinafter to be referred as cooling driers) is most important compressed air cleaning equipment, and cooling driers all will be used in the compressed-air actuated place of nearly all needs, as shown in Figure 1.Air compressor machine and cooling driers the two together, formed compressed air powered equipment system as power source.
As the patent No. is 200820205278.2, denomination of invention is the Chinese utility model patent of cooling driers controller, it discloses a kind of cooling driers controller, comprises electrical equipments compositions such as Programmable Logic Controller, analog-to-digital converting module, miniature man-machine interface, communication module, A.C. contactor and relay.It is main control system that this controller adopts Programmable Logic Controller; use miniature man-machine interface that operational factor is set; monitoring cooling driers, low-grade fever adsorption dry running status; stable performance; applied widely; can conveniently realize the automatic control and the dew point Energy Saving Control of combination type drying machines, system has refrigerant high pressure, refrigerant low pressure, overload of compressor, phase sequence, overtemperature alarm, infrabar warning to shut down function, can easily realize host computer communication.
But existing cooling driers is the many deficiencies of ubiquity technically, for example:
(1) energy consumption height.Air compressor machine-cooling driers system needs the industrial power-equipment of operation continuously, and the key that energy consumption is high mainly comes from two aspects: the one, and high-power highly energy-consuming is the air compressor machine of running continuously, and the 2nd, the refrigeration compressor in the cooling driers.When underloading or zero load appear in load end, because the power of air compressor driving motor is constant, air compressor machine will produce unnecessary pressurized air and a large amount of electric energy of waste, make energy consumption very high; Simultaneously, the refrigeration compressor in the cooling driers also is a firm power, and the power wastage when underloading or zero load is also quite serious.
In the prior art, more scheme is to select the driving power of air compressor machine is carried out variable frequency control, when for example using gas end underloading or zero load, can reduce the power operation by the Frequency Converter Control air compressor machine, when becoming big with gas end load, then increase the power operation, thereby realize energy-conservation effect by the Frequency Converter Control air compressor machine; But in whole air compressor machine-cooling driers system, the refrigeration compressor of cooling driers belongs to another energy consumption equipment, not to the Energy Saving Control of this energy consumption equipment, causes energy consumption higher in the prior art.
(2) give vent to anger dew point height, dew point instability cause air purification effect bad, make the pressurized air quality descend, thereby cause can't ensureing with the product quality of gas end.
Summary of the invention
In order to overcome the deficiency that energy consumption is higher, energy-saving effect is relatively poor, air purification effect is relatively poor of existing air compressor machine-cooling driers system, the invention provides a kind of frequency-converting control device that effectively cuts down the consumption of energy, has the air compressor machine-cooling driers system of good energy-saving effect and air purification effect.
The technical solution adopted for the present invention to solve the technical problems is:
The frequency-converting control device of a kind of air compressor machine-cooling driers system, comprise the refrigeration compressor frequency converter, the air compressor machine frequency converter, in order to detect the dew point temperature sensor of cooling driers refrigerant temperature, pressure unit and energy-saving controller in order to the gas-holder pressure that detects air compressor machine in order to carry out compressor variable frequency control according to dewpoint temperature and to carry out the air compressor machine variable frequency control according to pressure, described refrigeration compressor frequency converter is connected with the refrigeration compressor of described cooling driers, described air compressor machine frequency converter is connected with the drive motor of air compressor machine, described dew point temperature sensor, pressure unit is connected with described energy-saving controller, described energy-saving controller and described refrigeration compressor frequency converter, the air compressor machine frequency converter connects.
Further, described dew point temperature sensor is installed in the refrigerant channel of described cooling driers, but is not limited only to this position, also can be installed in other position that can survey dewpoint temperature.
Further again, described pressure unit is installed on the gas-holder of air compressor machine, but is not limited only to this position, also can be installed in other position of desirable barometric information.
Further, described energy-saving controller comprises:
The air compressor machine energy-saving control module compares in order to current pressure value and the preset standard force value that pressure unit is detected, if the current pressure value is higher than the normal pressure value, then sends the reduction power control signal to the air compressor machine frequency converter; If the current pressure value is lower than the normal pressure value, then send the increase power control signal to the air compressor machine frequency converter.
The cooling driers energy-saving control module compares in order to current temperature value and the preset standard temperature value that dew point temperature sensor is detected, if current temperature value is lower than the standard temperature value, then sends the reduction power control signal to the compressor variable frequency device; If current temperature value is higher than the standard temperature value, then send the increase power control signal to the compressor variable frequency device.
Described energy-saving controller is FPGA (Field Programmable Gate Array) control (PLC) chip.Certainly, energy-saving controller also can adopt other control chips, for example single-chip microcomputer etc.
In the described air compressor machine, the controlled range of drive motor frequency of operation is 10 ~ 60Hz.
In the described cooling driers, the controlled range of refrigeration compressor frequency of operation is 10 ~ 60Hz.
The detectable pressure limit of the gas-holder of described air compressor machine is 0 ~ 4.0MPa, and the current value of corresponding pressure unit is 4 ~ 44mA.
The detectable dewpoint temperature scope of described cooling driers refrigerant channel is-10 ℃ ~ 70 ℃, and the current value of corresponding temperature sensor is 4 ~ 20mA.
Technical conceive of the present invention is: one road signal of energy-saving controller input picks up from the dew point temperature sensor of refrigerant channel in cooling driers.If with gas end underloading or zero load, dewpoint temperature will descend, temperature sensor is sent to energy-saving controller with the signal that dew point descends.In energy-saving controller, through with the current signal contrast of the standard dew point of setting after, the frequency of operation of refrigeration compressor is controlled and changed to output by the refrigeration compressor frequency converter in the frequency conversion mode, also makes cooling driers be in the power match state automatically.
Because the compressor horsepower of cooling driers can be complementary with the output power load, has effectively avoided the waste of the constant power operation of prior art, has good energy-saving effect.
Energy-saving controller carries out FEEDBACK CONTROL according to dewpoint temperature, and in operational process, dewpoint temperature is relatively stable, has good control clean-up effect, has promoted the product quality of compression control, can effectively ensure the product quality of usefulness gas end.
On the other hand, another road sampled signal of energy-saving controller comes from the gas-holder of air compressor machine, converts the air pressure parameter to current signal by pressure unit (pressure transducer), feeds back to energy-saving controller.Energy-saving controller compares the current value (or pressure) of feedback with system standard value (pressure), output is by the frequency of operation of frequency converter with frequency conversion mode controlling and driving motor.If current value, then reduces the frequency (rotating speed) of (or increase) air compressor driving motor greater than (or less than) system calibrating value, thereby makes the energy consumption of electrical machinery of air compressor machine and the air mass flow of required processing mate automatically, further promote energy-saving effect.
The present invention adopts PLC variable frequency control mode, compares with the power frequency mode of routine, and the mode of PLC variable frequency control has clear superiority.In the power frequency mode, if with gas end underloading, when going out atmospheric pressure and reaching unloading pressure, air compressor machine will be closed gas admittance valve makes motor be in idling conditions, and simultaneously with unnecessary pressurized air emptying, this method of operation can cause very big electric energy and aerodynamic waste.And the mode that adopts the PLC variable frequency control is to realize the intelligent coupling of equipment energy consumption, a very effective method of saving the energy.Simultaneously, the PLC control technology have able to programme, powerful, easy to maintenance, reliability is high and outstanding advantage such as economical.
In addition,, the standby power frequency starter of a cover can be installed in addition in frequency conversion tank, promptly adopt the double startup device, so that just in case the frequency conversion mode breaks down, the still available power frequency of PLC starts air compressor machine for reliably.
The electric energy that adopts the PLC frequency conversion control technique and save depends on the variation of load weight and lasting time thereof.Because different user sides has the different gas situations of using, and therefore, can't accurately calculate amount of energy saving.If be in half cargo condition (this is the common situation of most of user) according to having 12 hours in 24 hours, then economize on electricity can reach 25%.According to flow 10m medium less than normal commonly used
3The air compressor machine of/min-cooling driers system estimation, the drive motor power of air compressor machine configuration is 55 ~ 60kW, the allocating power of the refrigeration compressor in the cooling driers is 2.25kw.Be simple meter, total allocating power of getting air compressor machine-cooling driers system is 60kW, and the power consumption of 1 year 365*24 is 52.56 ten thousand degree.Adopt after the PLC variable frequency control, economize on electricity 25%, the 13.14 ten thousand degree electricity that can economize on electricity, energy-saving and emission-reduction and economic benefit thereof are considerable.
Beneficial effect of the present invention mainly shows: effectively cut down the consumption of energy, have good energy-saving effect and air purification effect.
Description of drawings
Fig. 1 is the synoptic diagram of air compressor machine-cooling driers system.
Fig. 2 is the control synoptic diagram of the energy-saving control device of air compressor machine-cooling driers system.
Fig. 3 is the electric hookup of energy-saving control device.
Fig. 4 is the link of frequency converter.
Embodiment
Below in conjunction with accompanying drawing the present invention is further described.
With reference to Fig. 2～Fig. 4, the frequency-converting control device of a kind of air compressor machine-cooling driers system, comprise the refrigeration compressor frequency converter, the air compressor machine frequency converter, in order to detect the dew point temperature sensor of cooling driers refrigerant temperature, pressure unit and energy-saving controller in order to the gas-holder pressure that detects air compressor machine in order to carry out compressor variable frequency control according to dewpoint temperature and to carry out the air compressor machine variable frequency control according to pressure, described refrigeration compressor frequency converter is connected with the refrigeration compressor of described cooling driers, described air compressor machine frequency converter is connected with the drive motor of air compressor machine, described dew point temperature sensor, pressure unit is connected with described energy-saving controller, described energy-saving controller and described refrigeration compressor frequency converter, the air compressor machine frequency converter connects.
Described dew point temperature sensor is installed in the refrigerant channel of described cooling driers, but is not limited only to this position, also can be installed in other position that can survey dewpoint temperature.
Described pressure unit is installed on the gas-holder of air compressor machine, but is not limited only to this position, also can be installed in other position of desirable barometric information.
Described energy-saving controller comprises: the cooling driers energy-saving control module, compare in order to current temperature value and the preset standard temperature value that dew point temperature sensor is detected, if current temperature value is lower than the standard temperature value, then send the reduction power control signal to the compressor variable frequency device, if current temperature value is higher than the standard temperature value, then send the increase power control signal to the compressor variable frequency device; The air compressor machine energy-saving control module, compare in order to current pressure value and the preset standard force value that pressure unit is detected, if the current pressure value is higher than the normal pressure value, then send the reduction power control signal to the air compressor machine frequency converter, if the current pressure value is lower than the normal pressure value, then send the increase power control signal to the air compressor machine frequency converter.
Described energy-saving controller is the PLC chip.Certainly, energy-saving controller also can adopt other control chips, for example single-chip microcomputer etc.
In the described air compressor machine, the controlled range of drive motor frequency of operation is 10 ~ 60Hz.In the described cooling driers, the controlled range of refrigeration compressor frequency of operation is 10 ~ 60Hz.The detectable pressure limit of the gas-holder of described air compressor machine is 0 ~ 4.0MPa, and the current value of corresponding pressure unit is 4 ~ 44mA.The detectable dewpoint temperature scope of described cooling driers refrigerant channel is-10 ℃ ~ 70 ℃, and the current value of corresponding temperature sensor is 4 ~ 20mA.
Peripheral and inner electrical equipment wireline inspection can starting outfit after errorless with reference to Fig. 3 and Fig. 4 equipment.During device start, give the PLC starting-up signal by selecting button switch SB2, PLC to the start signal Processing after, KA1 starts A.C. contactor KM by the control auxiliary reclay.Judge A.C. contactor when the PLC internal arithmetic and start when errorless, enter converting operation for frequency converter enabling signal (STF) startup frequency converter by control auxiliary reclay KA4 again.When equipment broke down, PLC handled computing and passes to auxiliary reclay KA2 by output point the various fault-signals of input, came control fault pilot lamp HL2 and arrestment operation by control KA2.Because PLC itself carries out communication with display screen, so which kind of fault delivery of correspondence can be shown to display screen.When the equipment converting operation just often, (pressure limit of detection is 0 ~ 4.0MPa to air compressor machine by pressure transducer, corresponding current value is 4 ~ 44mA), (temperature range of detection is-10 ℃ ~ 70 ℃ to cooling driers by dew point temperature sensor (ST2), corresponding current value is 4 ~ 20mA), send pressure signal and temperature signal among the PLC A/D module respectively, CPU compares the standard value of value of feedback and setting, handle through sequential operation, with A/D module output signal end M0, the signal of I0, pass to frequency converter signal input port I+, I-, come the frequency of control of conversion device output by the frequency converter inter-process, make drive motor in the air compressor machine and the refrigeration compressor in the cooling driers (M) in the operation of 10 ~ 60Hz frequency separation, regulate air compressor machine the give vent to anger refrigeration work consumption of pressure flow and cooling driers and the Dynamic matching between the load.When equipment shuts down, give the PLC off signal by switch S B2.After PLC managed off signal, KA1 disconnected A.C. contactor KM by the control auxiliary reclay, controls auxiliary reclay KA5 simultaneously and comes control of conversion device off signal (MRS), disconnected the frequency converter operation.
Example 1:
The normal pressure of setting air compressor machine is P
s=0.7MPa, the corresponding calibrating gas current value of sending from pressure unit is I
G, s=11mA; The standard dewpoint temperature of setting cooling driers is T
s=5 ℃ (slightly better than 5 grades of national standards (＜7 ℃)), corresponding standard temperature electric current is I
T, s=7mA.If the gas current value of actual measurement is 10mA, less than I
G, s(11mA), illustrate that the gaseous tension of this moment is too low, load is overweight; Equally, if the dewpoint temperature of actual measurement is 10 ℃ (8mA), be higher than standard temperature T
s(5 ℃) illustrate refrigeration work consumption deficiency at this moment, and load is too heavy.More than in two factors, no matter be which factor, all can make PLC control of conversion device improve frequency.Too low for gaseous tension, can improve the frequency of air compressor driving motor, make system tolerance and gaseous tension increase, until normal pressure P
sFor cooling driers, can improve the frequency of operation of refrigeration compressor, make compressor horsepower increase, dewpoint temperature descends, until standard temperature T
s
Example 2:
The normal pressure of setting air compressor machine is P
s=0.7MPa, the corresponding calibrating gas current value of sending from pressure unit is I
G, s=11mA; The standard dewpoint temperature of setting cooling driers is T
s=5 ℃ (slightly better than 5 grades of national standards (＜7 ℃)), corresponding standard temperature electric current is I
T, s=7mA.If the gas current value of actual measurement is 11mA, with I
G, sIdentical, illustrate that the gaseous tension of this moment is normal; Equally, if the dewpoint temperature of actual measurement is 5 ℃ (7mA), with standard temperature T
sIdentical, illustrate that refrigeration work consumption is normal.At this moment, do not need PLC to do any action, frequency converter will be stabilized in current frequency operation.
Example 3:
The normal pressure of setting air compressor machine is P
s=0.7MPa, the corresponding calibrating gas current value of sending from pressure unit is I
G, s=11mA; The standard dewpoint temperature of setting cooling driers is T
s=5 ℃ (slightly better than 5 grades of national standards (＜7 ℃)), corresponding standard temperature electric current is I
T, s=7mA.If the gas current value of actual measurement is 12mA, greater than I
G, s(11mA), illustrate that the gaseous tension of this moment is too high, underload; Equally, if the dewpoint temperature of actual measurement is 0 ℃ (6mA), be lower than standard temperature T
s(5 ℃) illustrate that the refrigeration work consumption of this moment is too big, underload.Too high for gaseous tension, can reduce the frequency of air compressor driving motor, make system tolerance and gaseous tension reduce, until normal pressure P
sFor cooling driers, can reduce the frequency of operation of refrigeration compressor, make compressor horsepower reduce, dewpoint temperature rises, until standard temperature T
s
Among the above embodiment, the pressure parameter of PLC variable frequency control and the precision of temperature parameters depend on the setting of data bits and the precision of sensor self.The control accuracy of general pressure parameter can reach 0.0001MPa, and the precision of temperature can reach 0.001 ℃, and the control of precision size can be determined according to actual needs.
Claims (9)
1. the frequency-converting control device of air compressor machine-cooling driers system, it is characterized in that: described frequency-converting control device comprises the refrigeration compressor frequency converter, the air compressor machine frequency converter, in order to detect the dew point temperature sensor of cooling driers refrigerant temperature, pressure unit and energy-saving controller in order to the gas-holder pressure that detects air compressor machine in order to carry out compressor variable frequency control according to dewpoint temperature and to carry out the air compressor machine variable frequency control according to pressure, described refrigeration compressor frequency converter is connected with the refrigeration compressor of described cooling driers, described air compressor machine frequency converter is connected with the drive motor of air compressor machine, described dew point temperature sensor, pressure unit is connected with described energy-saving controller, described energy-saving controller and described refrigeration compressor frequency converter, the air compressor machine frequency converter connects.
2. the frequency-converting control device of air compressor machine as claimed in claim 1-cooling driers system is characterized in that: described dew point temperature sensor is installed in the refrigerant channel of described cooling driers.
3. the frequency-converting control device of air compressor machine as claimed in claim 1-cooling driers system is characterized in that: described pressure unit is installed on the gas-holder of air compressor machine.
4. as the frequency-converting control device of the described air compressor machine of one of claim 1 ~ 3-cooling driers system, it is characterized in that: described energy-saving controller comprises:
The cooling driers energy-saving control module, compare in order to current temperature value and the preset standard temperature value that dew point temperature sensor is detected, if current temperature value is lower than the standard temperature value, then send the reduction power control signal to the compressor variable frequency device, if current temperature value is higher than the standard temperature value, then send the increase power control signal to the compressor variable frequency device;
The air compressor machine energy-saving control module compares in order to current pressure value and the preset standard force value that pressure unit is detected, if the current pressure value is higher than the normal pressure value, then sends the reduction power control signal to the air compressor machine frequency converter; If the current pressure value is lower than the normal pressure value, then send the increase power control signal to the air compressor machine frequency converter.
5. as the frequency-converting control device of the described air compressor machine of one of claim 1 ~ 3-cooling driers system, it is characterized in that: described energy-saving controller is the FPGA (Field Programmable Gate Array) control chip.
6. as the frequency-converting control device of the described air compressor machine of one of claim 1 ~ 3-cooling driers system, it is characterized in that: in the described air compressor machine, the controlled range of drive motor frequency of operation is 10 ~ 60Hz.
7. as the frequency-converting control device of the described air compressor machine of one of claim 1 ~ 3-cooling driers system, it is characterized in that: in the described cooling driers, the controlled range of refrigeration compressor frequency of operation is 10 ~ 60Hz.
8. the frequency-converting control device of air compressor machine as claimed in claim 6-cooling driers system is characterized in that: the detectable pressure limit of the gas-holder of described air compressor machine is 0 ~ 4.0MPa, and the current value of corresponding pressure unit is 4 ~ 44mA.
9. the frequency-converting control device of air compressor machine as claimed in claim 7-cooling driers system is characterized in that: the detectable dewpoint temperature scope of described cooling driers refrigerant channel is-10 ℃ ~ 70 ℃, and the current value of corresponding temperature sensor is 4 ~ 20mA.
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| CN104819141A (en) * | 2015-04-01 | 2015-08-05 | 宁波杭州湾新区祥源动力供应有限公司 | Control method and system for air compression station |
| WO2016011816A1 (en) * | 2014-07-25 | 2016-01-28 | 株洲高新技术产业开发区壹星科技有限公司 | Heatless adsorption air dryer control method and device |
| CN106936363A (en) * | 2017-03-31 | 2017-07-07 | 上海源控自动化技术有限公司 | A kind of efficiency control device and energy efficiency controlling method |
| CN112275102A (en) * | 2020-10-20 | 2021-01-29 | 河北匠心智联软件技术有限公司 | AI frequency conversion precision control-based energy-saving control system and method for air dryer |
| CN113097974A (en) * | 2020-01-08 | 2021-07-09 | 上海松井机械有限公司 | Disintegrating machine |
| CN117846942A (en) * | 2024-03-08 | 2024-04-09 | 湖南捷工医疗科技有限公司 | Multifunctional automatic gas detection equipment |
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| CN113097974A (en) * | 2020-01-08 | 2021-07-09 | 上海松井机械有限公司 | Disintegrating machine |
| CN112275102A (en) * | 2020-10-20 | 2021-01-29 | 河北匠心智联软件技术有限公司 | AI frequency conversion precision control-based energy-saving control system and method for air dryer |
| CN117846942A (en) * | 2024-03-08 | 2024-04-09 | 湖南捷工医疗科技有限公司 | Multifunctional automatic gas detection equipment |
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