Air compressor is a kind of general dynamic machinery that is widely used in many industries such as oil, chemical industry, mine, metallurgy, machinery, electronics, weaving, building.At present, compressor generally all makes to drive power source by exchanging constant speed motor, and, general AC motor and control gear thereof be its operating mode of randomly changing initiatively all, so, account for air compressor and these power consumptions of water pump " rich and influential family " of China 1/3rd for power consumption, how to reduce power consumption and become the key subjects that people more and more are concerned about.Now, small-sized air compressor can be taked gap work, and large-scale compressor changes the operation needs that satisfy actual conditions because of the working state of should not frequent starting just taking to change each pipeline valve group or the adjusting by peripheral system.Like this, power savings is very not remarkable on the one hand, on the other hand, and the peripheral control system device bulky complex of air compressor.Investment is high, easy break-down.For example: the various direct reading type of on the main position of compressor gas, water, each pipeline of oil, installing or pressure gauge, thermometer, the flowmeter of electric contact type, be to be used for detecting compressor operating air inlets at different levels, the pressure of exhaust, temperature, the flow of cooling water, the pressure of lubricant oil, temperature so that change its output operating mode at any time.But these instrument are because of the influence of machine vibration and pressurized gas pulsation by compression, and reliability reduces, working life is short, and operator must often make an inspection tour these instrument, to monitor and to adjust compressor and operation of motor, in addition, the noise of compressor also endangers health of operators.Therefore, how reducing the power consumption of compressor, alleviate labor intensity of operating personnel simultaneously, reduce acquiring cost of device and improving its functional reliability of peripheral control equipment, has been numerous users' an urgent demand.
The objective of the invention is to design a kind of industrial compressors that can make according to predetermined criteria, regulate the working condition of compressor automatically, make compressor and whole machine set system all be in the compressor of the numerically-controlled variable working condition of work under the optimum performance state.
Hardware configuration of the present invention is as shown in Figure 1: it is made up of compressor 1, Wechselstrommotor 2 and driving-controlling device thereof.Its characteristics are that with the driving-controlling device of the air compressor 1 coaxial Wechselstrommotor that connects 2 are all parameter sensings by compressor and Wechselstrommotor, detector group 3, the power converter 4 and their controller 5 of Wechselstrommotor are formed, each parameter sensing wherein, detector set is installed in corresponding site responsive near the needs of compressor and motor and that detect respectively, its output then links to each other with the controller 5 that is placed in nearby by cable 6, the output of controller 5 is then received from 50HZ city electrical network 7 input and the power converter 4 of output as the driving power of Wechselstrommotor, just compressor, motor, sensing, control is synthesized the new type compressor of a numerically controlled variable working condition at random with five parts of frequency conversion.The load module 9 that mates with sensor, detector group 3 is arranged in controller 5, and they all are inserted in the slot of industrial control interface RTU8, and take this to be connected with microcomputer 10.Store each process parameter, protection limit value etc. the data and the program of air compressor normal operation in the microcomputer; production plant can be according to the prior program curing of the needs of domestic consumer in chip; some user such as needs are adjusted change operation or some process parameters voluntarily, are protected limit value; then can utilize input keyboard 11 modifications; then, again amended data and procedure stores in the read write memory chip.The peripheral unit display device 12 of microcomputer configuration is to be used for showing in real time each process parameter numerical value of compressor and every program and the data of being revised.For example one-level exhaust pressure and temperature, secondary exhaust pressure and temperature, lubricating oil pressure, temperature and cooling water flow etc. also show operating current, input voltage and the frequency thereof etc. of Wechselstrommotor.Printer 13 is to be used in real time or the operation conditions (form) of each constituent elements of the whole machine set system of time printing compressor.
Hardware configuration of the present invention is series equipment-comprise sensor, input matching module, industrial control interface, the control computer etc.-as the core of the control gear of numerically-controlled variable working condition compressor, form the measuring instrument and the control apparatus of intellectuality, digitizing, automation based on electromechanical integration technology.It can be gentle according to the demand of operating load, water, oil, machine situation change the Wechselstrommotor frequency of input voltage automatically, make it in 50HZ is adjusted to the scope of 0-60HZ, to change, reach saving power, alleviate labor intensity of operating staff, reduce peripheral adjustment control apparatus, reduce the equipment investment expense and increase the multinomial economic benefit of functional reliability thereby change motor speed (being frequency control of motor speed).
The principle logic block flow chart of the software control process when Fig. 2 is a working state of the present invention.At first be to import each parameter limit value and be stored into related memory cell (parameter setting) with keyboard, restart the compressor bank setting in motion, just arrive measured value storage unit (parametric measurement) to the data storage that each parameter sensors, detector are sent here this moment, usually each parameter is wanted 8 above data of continuous acquisition at least, by data processing module a plurality of data of each parameter are asked arithmetic mean value, mean value and the setting value with each measured value of parameters compares again.If compressor motion is normal, then turn back to continuous sensitivity, detect the state of each parameter, give display device corresponding data simultaneously and show and printing record.If do not meet with setting value, then this parameter elder generation compares with alarming value, as surpassing, then sends guard sign on the one hand, compares with the limit protection value more on the one hand, and as still surpassing, then protection mechanism action shutdown is waited to repair.Report to the police or the limit protection value if be provided with to reach, just detected state is higher than or is lower than former setup parameter again.As higher, then power supply frequency is reduced, reduce the rotating speed of motor, thereby reduce the Operational Limits of compressor; Otherwise it is then on the low side as status parameter.The software of this device is made up of a plurality of module, and the sensitivity of each process parameter handles, more all needs wherein several modules to finish jointly, and design is because easy and saving capacity like this, and is convenient to modification and increases new function.
The present invention is compressor, power, sensing, processing and five part integrators of frequency conversion, can realize according to the motion state oneself of the whole machine set system of compressor itself regulating, i.e. variable working condition and compressor is under the optimum state turn round at random.When for example load becomes big, can improve the frequency of input voltage of AC motor, change operating mode, up to satisfying the state requirement of setting with the rotating speed that improves compressor.Vice versa.Adopt this device, significantly saving power reaches power saving more than 30%.And, peripheral adjustment control apparatus adopts the series equipment of electromechanical integration and simplifies greatly, has fundamentally improved the defective that compressor detection, control instrument exist, both cost savings, improve compressor operating efficient and working life again, alleviated labor intensity of operating personnel greatly.Entire work process needn't personnel get involved, as long as set process parameter in advance, gets in touch just to have only startup, stop and resetting three kinds between people and the device and has operated.The present invention also has certain versatility, hardware configuration is not only applicable to compressor is carried out the digital control of variable working condition at random, also applicable to the control of other similar products (as water pump, blower fan etc.) or technology, certainly, the configuration of sensitivity, monitor, hardware and softwares such as kind all need be made necessary corresponding modifications and changes.In a word, the present invention is the control gear that AC motor frequency modulation variable-speed operation proposes an electromechanical integration, and China's conventional equipment energy consumption is big for changing, and the backward situation that economic benefit is low can play very useful effect.
