CN105240302A - Intelligent and energy-saving all-in-one machine for air compressor drive and methods thereof - Google Patents

Intelligent and energy-saving all-in-one machine for air compressor drive and methods thereof Download PDF

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Publication number
CN105240302A
CN105240302A CN201510627280.3A CN201510627280A CN105240302A CN 105240302 A CN105240302 A CN 105240302A CN 201510627280 A CN201510627280 A CN 201510627280A CN 105240302 A CN105240302 A CN 105240302A
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China
Prior art keywords
air compressor
module
temperature
energy
blower fan
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CN201510627280.3A
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Chinese (zh)
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CN105240302B (en
Inventor
卞光辉
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ANCHORWILL TECHNOLOGY Co Ltd
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ANCHORWILL TECHNOLOGY Co Ltd
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Priority to CN201510627280.3A priority Critical patent/CN105240302B/en
Publication of CN105240302A publication Critical patent/CN105240302A/en
Priority to PCT/CN2016/096815 priority patent/WO2017054596A1/en
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06Control using electricity
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04CROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C28/00Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04CROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C28/00Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
    • F04C28/06Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids specially adapted for stopping, starting, idling or no-load operation

Abstract

The invention provides an intelligent and energy-saving all-in-one machine for an air compressor drive and methods thereof. The intelligent and energy-saving all-in-one machine and the methods include a soft-starting all-in-one machine with multiple soft-starting functions and a starting method of the soft-starting all-in-one machine, a self-adaptive energy conservation method based on air compressor load characteristics, an intelligent air compressor control device capable of achieving remote monitoring, an air compressor energy consumption monitoring and management system and a monitoring method of the system. The defects that in the prior art, existing soft-starters do not have the functions of controlling fans, and are large in starting current, high in impact on a power grid and prone to making the power grid unstable, operation safety of other electric equipment is threatened simultaneously, electric energy waste is caused due to long-term work, a device for remotely monitoring an air compressor do not exist, thus monitoring efficiency is affected, and a system and method for monitoring energy consumption of the air compressor do not exist are avoided.

Description

Air compressor drives intelligent power saving integrated machine and method thereof
Technical field
The invention belongs to air compressor technical field, be specifically related to a kind of air compressor and drive intelligent power saving integrated machine and method thereof.
Background technique
Intelligent soft start machine is used widely.Soft Starter is a kind of novel motor control assembly integrating soft start, soft stop, light-load energy saving and multifunction protection, is also called SoftStarter.It not only realizes actuating motor level and smooth without impacting in whole starting process, and can regulate the parameter in starting process according to the characteristic of motor load, as cut-off current, starting time etc.In addition, it also has multiple to electric motor protecting function, and this just fundamentally solves many drawbacks of traditional decompression starting equipment.
But existing soft start machine is not but for the controlling functions of blower fan.
Use power frequency to drive air compressor host and oil cooling blower fan, pressurized gas is stored in gas holder, comes controlled loading and unloading by the gas pressure of signal piping; Use larger gas holder, thus cause whole air compressor floor space larger;
When the air pressure of pipeline reaches desired value, the control mode of compression and decompression also will make its pressure continue to rise to unloading pressure, needs main frame continuous service to pressurize during this period of time, even if after unloading, main frame is also still in no-load running state, and waste electric energy;
Mair motor adopts Y-△ (star-triangle) to start, and inrush current is large, impacts large to electrical network, easily causes electrical network unstable, threatens the security of operation of other consumer simultaneously;
Drive compressor oil air cooler with power frequency, long-term work is also the waste of electric energy.
Air compressor is the basic product of the modernization of industry, and that often says electrically and in automation just has entirely pneumatic implication; And air compressor is just to provide source of the gas power, it is the main body in the dynamo-electric bleed air source device of nucleus equipment of pneumatic system, it is the device mechanical energy of former dynamic (normally motor) being converted to gas pressure energy, is compressed-air actuated pressure generator.
Also not having now the device of the air compressor of remote monitoring, thus have impact on monitoring efficiency, is exactly there is not monitoring system for the energy consumption of air compressor and method in addition.
Summary of the invention
Object of the present invention provides a kind of air compressor to drive intelligent power saving integrated machine and method thereof, comprise the soft start integrated machine of many soft start functions and starting method thereof, based on air compressor load characteristic adaptive power-economizing method, can the air compressor intelligent controlling device of remote monitoring, air compressor energy consumption monitoring management system and monitoring method thereof.The existing soft start machine avoiding prior art but not large for the controlling functions of blower fan, inrush current, electrical network impacted great Yi cause electrical network unstable, threaten the security of operation of other consumer and long-term work to cause the waste of electric energy, also there is no the device of the air compressor of remote monitoring thus have impact on monitoring efficiency, not for the monitoring system of the energy consumption of air compressor and the defect of method simultaneously.
In order to overcome deficiency of the prior art, the invention provides the solution that a kind of air compressor drives intelligent power saving integrated machine and method thereof, specific as follows:
A kind of air compressor drives intelligent power saving integrated machine, comprise power module, described power module is connected with MCU micro-control module, communication module, host driven module, No. 1 Logic control module, No. 2 Logic control modules, No. 1 blower fan driver module and No. 2 blower fan driver modules, and the described same communication module of MCU micro-control module, host driven module, No. 1 Logic control module, No. 2 Logic control modules, No. 1 blower fan driver module and No. 2 blower fan driver modules are connected;
Also comprising can the air compressor intelligent controlling device of remote monitoring, wherein containing user terminal, described user terminal is connected with cloud platform, described cloud platform is connected with Ethernet by telecommunications network, and described Ethernet is connected with I/O interface, driver module and the terminal with man-machine interface; Described telecommunications network comprises optical fiber, wired, wireless 3G or 4G communication network;
Also comprise air compressor energy consumption monitoring management system, wherein containing the current transformer be connected in the main circuit loop of air compressor and voltage acquisition module, also comprise the pressure acquisition analog amount terminal be arranged on air compressor.
Described host driven module adopts controllable silicon reverse parallel connection structure to realize driving, and is controlled by MCU micro-control module.
Described blower fan driver module adopts controllable silicon reverse parallel connection structure, and shared MCU micro-control module realizes logic and independently controls; Allow blower fan drive and logic control separately thus.
Described air compressor drives the method for intelligent power saving integrated machine for first driving intelligent power saving integrated machine to power on loading to air compressor, if temperature is greater than setting value lower limit 1, automatic detection motor temperature, head temperature and delivery temperature, then No. 1 blower fan is started, if temperature is greater than setting value lower limit 2 just start No. 2 blower fans;
And air compressor power on after load operating, running time T 1, detects user pressure p, uses fuzzy algorithmic approach to calculate use gas variable quantity △ P=K △ p/ △ T, and wherein △ p is pressure variety, and △ T is time variation amount, after gas consumption is stable, enters energy saver mode;
The unloaded delay time T=K1 intra coeff [((PCC) power temperature-ambient temperature) K2+ (head temperature-ambient temperature) K3+ (motor temperature-ambient temperature) K4] of energy saver mode, wherein said K1 is the first intra coeff, K2 is the second intra coeff, K3 is the 3rd intra coeff, and K4 is the 4th intra coeff;
Like this by the difference of Integrated comparative power temperature, head temperature, motor temperature and ambient temperature, be multiplied by different COEFFICIENT K 2 ~ K4 separately, summation, and be comprehensively multiplied by COEFFICIENT K 1, provide the unloaded delay time T of energy saver mode;
Be in unloading to run as air compressor is current, and meet when not entering load operating state in unloaded delay time T, then the zero load that system enters in unloaded delay time T is shut down, i.e. energy-conservation shutdown, as client uses gas again, air pressure when meeting on-load pressure, air compressor transfers load operating to;
According to the current transformer be connected in the main circuit loop of air compressor, voltage acquisition module and the pressure acquisition analog amount terminal that is arranged on air compressor, Real-time Collection electric current, voltage and force value, and pass through obtain air compressor energy consumption power P, T is the cycle of ac signal, u (t) is the instantaneous voltage of moment t, i (t) is the transient current of moment t, then the value of electricity W is obtained by W=η Pt*cos φ, wherein η is efficiency value, and cos φ is motor power factor, obtains gas consumption additionally by force value.
Described on-load pressure is the on-load pressure of function code setting; Described method energy Non-follow control or automatically control.
Soft start machine of the present invention achieves the controlling functions for blower fan; The method that air compressor is special, use interval according to pressure, intelligent recognition, shuts down energy-conservation, to greatest extent saving power; How soft integrated, main frame, blower fan all adopt soft, and independently control, energy-saving and cost-reducing, protection motor; The change of monitoring gas consumption, and the Expenditure Levels of electric energy, and calculates compared with electricity under non-energy saver mode, can very clear power savings; Compact structure designs, and level of integration is more spent.
Of the present invention can the advantage of air compressor intelligent controlling device of remote monitoring as follows:
1, based on Ethernet and optical fiber/wire/wireless 3G/4G;
2, can telemonitoring compressor operation and energy consumption service condition;
3, mobile phone remote can be realized control.
The invention also achieves the monitoring system for the energy consumption of air compressor and method.
Accompanying drawing explanation
Fig. 1 is the structural drawing of integrated machine of the present invention.
Fig. 2 is the partial process view of method of the present invention.
Fig. 3 is the flow chart of the adaptive power-economizing method based on air compressor load characteristic of the present invention.
Fig. 4 is the coordinate diagram of the star-triangular methods of prior art.
Fig. 5 is the coordinate diagram of frequency variator method of the present invention.
Fig. 6 is the coordinate diagram of the embodiment of the adaptive power-economizing method based on air compressor load characteristic of the present invention.
Fig. 7 be of the present invention can the structural representation of air compressor intelligent controlling device of remote monitoring.
Fig. 8 is the structural representation of the monitoring system of the energy consumption for air compressor of the present invention
Embodiment
Below in conjunction with accompanying drawing, summary of the invention is described further:
Shown in Fig. 1-Fig. 8, air compressor drives intelligent power saving integrated machine, comprise power module, described power module is connected with MCU micro-control module, communication module, host driven module, No. 1 Logic control module, No. 2 Logic control modules, No. 1 blower fan driver module and No. 2 blower fan driver modules, and the described same communication module of MCU micro-control module, host driven module, No. 1 Logic control module, No. 2 Logic control modules, No. 1 blower fan driver module and No. 2 blower fan driver modules are connected; Also comprising can the air compressor intelligent controlling device of remote monitoring, wherein containing user terminal, described user terminal is connected with cloud platform, described cloud platform is connected with Ethernet by telecommunications network, and described Ethernet is connected with I/O interface, driver module and the terminal with man-machine interface; Described telecommunications network comprises optical fiber, wired, wireless 3G or 4G communication network passes through telecommunications network, just can on long-range user terminal, send various control command to send instruction to I/O interface or driver module, only need I/O interface or driver module to access air compressor thus and just can realize corresponding monitoring.
Described host driven module adopts controllable silicon reverse parallel connection structure to realize driving, and is controlled by MCU micro-control module.
Described blower fan driver module adopts controllable silicon reverse parallel connection structure, and shared MCU micro-control module realizes logic and independently controls; Allow blower fan drive and logic control separately thus.
Described air compressor drives the method for intelligent power saving integrated machine for first driving intelligent power saving integrated machine to power on loading to air compressor, if temperature is greater than setting value lower limit 1, automatic detection motor temperature, head temperature and delivery temperature, then No. 1 blower fan is started, if temperature is greater than setting value lower limit 2 just start No. 2 blower fans;
And air compressor power on after load operating, running time T 1, detects user pressure p, uses fuzzy algorithmic approach to calculate use gas variable quantity △ P=K △ p/ △ T, and wherein △ p is pressure variety, and △ T is time variation amount, after gas consumption is stable, enters energy saver mode;
The unloaded delay time T=K1 intra coeff [((PCC) power temperature-ambient temperature) K2+ (head temperature-ambient temperature) K3+ (motor temperature-ambient temperature) K4] of energy saver mode, wherein said K1 is the first intra coeff, K2 is the second intra coeff, K3 is the 3rd intra coeff, and K4 is the 4th intra coeff;
Like this by the difference of Integrated comparative power temperature, head temperature, motor temperature and ambient temperature, be multiplied by different COEFFICIENT K 2 ~ K4 separately, summation, and be comprehensively multiplied by COEFFICIENT K 1, provide the unloaded delay time T of energy saver mode;
Be in unloading to run as air compressor is current, and meet when not entering load operating state in unloaded delay time T, then the zero load that system enters in unloaded delay time T is shut down; i.e. energy-conservation shutdown; as client uses gas again, air pressure when meeting on-load pressure, air compressor transfers load operating to.For 45KW power air compressor, suppose that client's gas consumption is 0.8MPa, detecting air compressor after N minute enters stable for gaseity, detection power assembly, head, motor, environment equitemperature, record motor, (PCC) power, head equitemperature starts a temperature rise and loads once gas T service time, calculate, under 30 DEG C of ambient temperatures, motor stopping state temperature is reduced to prestart temperature and is needed 40s, (PCC) power outage state temperature is reduced to prestart temperature and is needed 25s, as T < 40+10s, air compressor is not then allowed to stop, as T > 40+10s, then energy-conservation shutdown after permission air compressor 10s.As air pressure just " during on-load pressure " sets lower than < function code, air compressor transfers starting to.This embodiment is obviously better to the technique effect of Fig. 4 and Fig. 5 as shown in Figure 6.
Described on-load pressure is the on-load pressure of function code setting; Described method energy Non-follow control or automatically control.
Also comprise, air compressor energy consumption monitoring management system, wherein containing the current transformer be connected in the main circuit loop of air compressor and voltage acquisition module, also comprise the pressure acquisition analog amount terminal be arranged on air compressor.
The monitoring method of described air compressor energy consumption monitoring management system is according to the current transformer be connected in the main circuit loop of air compressor, voltage acquisition module and the pressure acquisition analog amount terminal that is arranged on air compressor, Real-time Collection electric current, voltage and force value, and pass through obtain air compressor energy consumption power P, T is the cycle of ac signal, u (t) is the instantaneous voltage of moment t, i (t) is the transient current of moment t, then the value of electricity W is obtained by W=η Pt*cos φ, wherein η is efficiency value, and cos φ is motor power factor, obtains gas consumption additionally by force value.
In a word, the present invention has following features:
1. in conjunction with tailor-made algorithm;
2. integrated following functions is in one;
3. air-blower control, charge valve control, fuel tap control, detect internal pressure, external exhaust gas pressure, testing environment temperature, motor temperature, head temperature, delivery temperature;
4. the soft start of integrated multipath blower fan drives, and drive and the control separately of multichannel blower fan.
The above, it is only preferred embodiment of the present invention, not any pro forma restriction is done to the present invention, although the present invention discloses as above with preferred embodiment, but and be not used to limit the present invention, any those skilled in the art, do not departing within the scope of technical solution of the present invention, make a little change when the technology contents of above-mentioned announcement can be utilized or be modified to the Equivalent embodiments of equivalent variations, in every case be do not depart from technical solution of the present invention content, according to technical spirit of the present invention, within the spirit and principles in the present invention, to any simple amendment that above embodiment does, equivalent replacement and improvement etc., within the protection domain all still belonging to technical solution of the present invention.

Claims (5)

1. an air compressor drives intelligent power saving integrated machine, it is characterized in that comprising power module, described power module is connected with MCU micro-control module, communication module, host driven module, No. 1 Logic control module, No. 2 Logic control modules, No. 1 blower fan driver module and No. 2 blower fan driver modules, and the described same communication module of MCU micro-control module, host driven module, No. 1 Logic control module, No. 2 Logic control modules, No. 1 blower fan driver module and No. 2 blower fan driver modules are connected;
Also comprising can the air compressor intelligent controlling device of remote monitoring, wherein containing user terminal, described user terminal is connected with cloud platform, described cloud platform is connected with Ethernet by telecommunications network, and described Ethernet is connected with I/O interface, driver module and the terminal with man-machine interface; Described telecommunications network comprises optical fiber, wired, wireless 3G or 4G communication network;
Also comprise air compressor energy consumption monitoring management system, wherein containing the current transformer be connected in the main circuit loop of air compressor and voltage acquisition module, also comprise the pressure acquisition analog amount terminal be arranged on air compressor.
2. air compressor according to claim 1 drives intelligent power saving integrated machine, it is characterized in that described host driven module adopts controllable silicon reverse parallel connection structure to realize driving, is controlled by MCU micro-control module.
3. air compressor according to claim 1 drives intelligent power saving integrated machine, and it is characterized in that described blower fan driver module adopts controllable silicon reverse parallel connection structure, shared MCU micro-control module realizes logic and independently controls; Allow blower fan drive and logic control separately thus.
4. air compressor according to claim 1 drives the method for intelligent power saving integrated machine, it is characterized in that described air compressor drives the method for intelligent power saving integrated machine for first driving intelligent power saving integrated machine to power on loading to air compressor, if temperature is greater than setting value lower limit 1, automatic detection motor temperature, head temperature and delivery temperature, then No. 1 blower fan is started, if temperature is greater than setting value lower limit 2 just start No. 2 blower fans;
And air compressor power on after load operating, running time T 1, detects user pressure p, uses fuzzy algorithmic approach to calculate use gas variation delta P=K Δ p/ Δ T, and wherein Δ p is pressure variety, and Δ T is time variation amount, after gas consumption is stable, enters energy saver mode;
The unloaded delay time T=K1 intra coeff [((PCC) power temperature-ambient temperature) K2+ (head temperature-ambient temperature) K3+ (motor temperature-ambient temperature) K4] of energy saver mode, wherein said K1 is the first intra coeff, K2 is the second intra coeff, K3 is the 3rd intra coeff, and K4 is the 4th intra coeff;
Like this by the difference of Integrated comparative power temperature, head temperature, motor temperature and ambient temperature, be multiplied by different COEFFICIENT K 2 ~ K4 separately, summation, and be comprehensively multiplied by COEFFICIENT K 1, provide the unloaded delay time T of energy saver mode;
Be in unloading to run as air compressor is current, and meet when not entering load operating state in unloaded delay time T, then the zero load that system enters in unloaded delay time T is shut down, i.e. energy-conservation shutdown, as client uses gas again, air pressure when meeting on-load pressure, air compressor transfers load operating to;
According to the current transformer be connected in the main circuit loop of air compressor, voltage acquisition module and the pressure acquisition analog amount terminal that is arranged on air compressor, Real-time Collection electric current, voltage and force value, and pass through obtain air compressor energy consumption power P, T is the cycle of ac signal, u (t) is the instantaneous voltage of moment t, i (t) is the transient current of moment t, then the value of electricity W is obtained by W=η Pt*cos Φ, wherein η is efficiency value, and cos Φ is motor power factor, obtains gas consumption additionally by force value.
5. air compressor according to claim 4 drives the method for intelligent power saving integrated machine, it is characterized in that described method energy Non-follow control or automatically controls; Described on-load pressure is the on-load pressure of function code setting.
CN201510627280.3A 2015-09-28 2015-09-28 Air compressor machine drives intelligent power saving all-in-one machine and its method Active CN105240302B (en)

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PCT/CN2016/096815 WO2017054596A1 (en) 2015-09-28 2016-08-26 All-in-one machine for air compressor driving and intelligent energy conservation and method thereof

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WO2017054596A1 (en) * 2015-09-28 2017-04-06 苏州艾克威尔科技有限公司 All-in-one machine for air compressor driving and intelligent energy conservation and method thereof
WO2018086283A1 (en) * 2016-11-10 2018-05-17 湖北创全电气有限公司 Starlike/triangular seamless joint intelligent control system for air compressor energy-saving operation

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CN112906306A (en) * 2021-03-24 2021-06-04 青岛洪锦智慧能源技术有限公司 Prediction method for energy consumption of air compressor unit of air compression station
CN113050573B (en) * 2021-03-26 2022-09-13 山东莱钢永锋钢铁有限公司 Production rhythm-based energy-saving method for air compressor
CN114483557A (en) * 2022-02-10 2022-05-13 宁波中科绿色电力有限公司 Air compression system and method
CN114645844B (en) * 2022-05-23 2022-07-19 蘑菇物联技术(深圳)有限公司 Method, computing device and computer medium for determining flow state of air compression station

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