IT201800006517A1 - INTELLIGENT EXHAUST SYSTEM, INTELLIGENT EXHAUST METHOD AND PNEUMATIC SYSTEM INCLUDING THE INTELLIGENT EXHAUST SYSTEM - Google Patents

Description

DESCRIPTION

of the patent for industrial invention entitled:

"INTELLIGENT EXHAUST SYSTEM, INTELLIGENT EXHAUST METHOD AND PNEUMATIC SYSTEM INCLUDING THE INTELLIGENT EXHAUST SYSTEM"

The present invention relates to a discharge system for discharging condensate of a pneumatic system, a pneumatic system comprising the discharge system and a relative discharge method.

Pneumatic systems for the production and treatment of compressed air are known. As is known, pneumatic systems need drainage systems to discharge the moisture that condenses in the system itself.

In particular, to evacuate condensate and / or other liquids from the ducts of a pneumatic system, the use of condensate discharge devices is known, suitably coupled to various compressed air treatment modules included in the pneumatic system.

For example, the use of condensate discharge devices with a maximum level sensor is known, including an accumulation chamber, in which, due to the effect of gravity, condensate forms in the duct to which the device is connected. The level reached by the condensate is typically detected by a maximum level sensor, which causes the automatic opening of a drain solenoid valve once the accumulation chamber is full.

Discharge devices are also known in which the maximum level sensor is of the capacitive type; in this case, in particular, the maximum level sensor detects the dielectric variation between two plates arranged in the accumulation chamber, due to the variation of the condensate level between the plates, and sends an electrical command signal to a control unit , which commands the opening of the drain solenoid valve when this electrical signal reaches a predetermined threshold.

Discharge devices of the known type with capacitive sensor have drawbacks in use, as they require specific calibration based on the liquid to be discharged and, therefore, the specific application of the exhaust system in which they are installed.

In fact, the electrical signal at the level sensor output varies substantially linearly as a function of the level reached by the liquid between the plates, with a proportionality coefficient that depends on the electrical conductivity of the liquid itself. In other words, with the same height occupied between the plates by different liquids, without modifying the calibration, the sensor emits different output signals.

For example, the condensate that forms in pneumatic compressed air treatment systems is substantially composed of water in which metal particles are dissolved or suspended, therefore it has a relatively high electrical conductivity, while oil generally has a relatively high electrical conductivity. low. Consequently, in applications where it is necessary to drain oil, instead of condensate, the drain devices require a setting such as to make the drain device more sensitive, i.e. a setting such as to open the drain solenoid valve at a lower threshold. low for the electrical control signal.

On the other hand, the drain devices configured to discharge condensate, therefore calibrated in such a way as to have a higher threshold, face the risk of non-intervention and, therefore, of overflowing from the accumulation chamber, as the output signal of the level sensor may never reach the threshold set by calibration even if the oil completely fills the space between the plates.

In addition, the actual condensate drain times depend, on the one hand, on the passage section of the drain solenoid valve and, on the other, on the operating pressure in the pneumatic system to which the drain device is connected; however, in the known solutions described above, the opening time of the drain solenoid valve is fixed a priori to a fixed value which is oversized enough to be able to use the same drain device for a wide range of operating pressures that can occur in various pneumatic systems.

By doing so, however, the condensate discharge generally ends before the discharge solenoid valve closes, with a consequent waste of electrical power and a leakage and waste of compressed air from the pneumatic system during the final part of the solenoid valve opening time. where all the condensate has already been discharged. To try to remedy this latter drawback, it is known to also provide a minimum level sensor, also of the capacitive type, to also control the closure of the drain solenoid valve. However, this solution involves relatively high costs and relatively complex control systems.

Discharge devices are known which have a lower cost and complexity than level sensor discharge devices. In particular, timed discharge devices are known, in which the opening and closing times of the solenoid valve are predetermined and can be set by an operator. In other words, the timer drain devices are configured to open and close the drain solenoid valve at regular intervals.

A disadvantage of the known timer discharge devices is that the discharge solenoid valve can be opened even in periods of time in which there is no condensate to discharge, resulting in a waste of compressed air and / or electrical power. , since the power consumption of the drain device when the solenoid valve is closed is less than at least one order of magnitude compared to the power consumption when the solenoid valve is open.

To obviate this latter drawback, timer discharge devices with condensation sensor are known, in which there are waiting periods of predetermined duration in which the discharge solenoid valve is closed, interspersed with periods of activity, of duration preset, in which the drain solenoid valve is open on condition that the condensation sensor detects the presence of condensation. In this way, the consumption of compressed air and / or electrical power is limited compared to timer discharge devices without a condensation sensor, without reaching the costs of maximum level sensor discharge devices. In any case, apart from the presence or absence of the condensation sensor, the duration of the waiting intervals is predetermined in the timer drain devices.

A disadvantage common to all the aforementioned discharge devices of the known type consists in the fact that, in any case, the condensate discharge devices in a pneumatic system operate in a timely manner and are not interconnected with each other; consequently they are unable to recognize anomalies or systematic changes in parameters relating to the operation of the pneumatic system and are unable to transmit them to third parties.

The object of the present invention is to provide an unloading system, an unloading method and a pneumatic system, suitable for overcoming the drawbacks of the known art.

According to the present invention, an unloading system, an unloading method and a pneumatic system are realized, as defined in the attached claims.

For a better understanding of the present invention, preferred embodiments are now described, purely by way of non-limiting example, with reference to the attached drawings, in which:

Figure 1 schematically illustrates a pneumatic system comprising an exhaust system according to an embodiment of the present invention;

Figures 2A-2D show a time course of respective control signals of a portion of the exhaust system of Figure 1 during an unloading cycle;

figure 3 schematically illustrates, by means of a block diagram, an unloading method implemented by the unloading system of figure 1;

Figure 4 schematically illustrates, by means of a block diagram, a control method implemented by the exhaust system of Figure 1; And

Figure 5 schematically illustrates, by means of a block diagram, a data analysis and processing method implemented by the unloading system of Figure 1.

Figure 1 schematically illustrates a pneumatic system 1 comprising an exhaust system 2 according to an embodiment of the present invention. In particular, the pneumatic plant 1 is a compressed air production and treatment plant.

In particular, in a per se known way, the pneumatic system 1 comprises a compressor 4, an aftercooler 6, a tank 8, a prefilter 10, a dryer 12 and a filter 14. Respective pneumatic ducts 16a-16f fluidically couple the compressor 4 to the aftercooler 6, the aftercooler 6 to the tank 8, the tank 8 to the prefilter 10, the prefilter 10 to the dryer 12, the dryer 12 to the filter 14 and the filter 14 to an outlet of the pneumatic system 1 suitable for supplying compressed air outlet suitably treated and ready for use.

In other embodiments, the pneumatic system 1 could comprise a single filtering stage upstream or downstream of the dryer 12, so that one between the prefilter 10 and the filter 14 could be absent. Furthermore, in other embodiments, the aftercooler 6 could be integrated into the compressor 4.

In detail, the compressor 4 produces and injects compressed air into the pneumatic duct 16a. In particular, the compressor 4 draws in air with characteristics that depend on the climatic conditions of the place where the pneumatic system 1 is installed (such as for example atmospheric pressure, atmospheric temperature and relative atmospheric humidity), and compresses it until it reaches the desired pressure. As known for physics, and in particular by applying, with appropriate approximations, the law of perfect gases to the air sucked in by compressor 4, an increase in pressure at a constant volume leads to an increase in temperature in a directly proportional way. Consequently, the compressed air at the outlet of compressor 4 has a temperature higher than the atmospheric temperature, for example 30 ° C, depending on the type of compressor used.

In addition, the air sucked in by compressor 4 contains a quantity of water vapor dependent on the atmospheric humidity of the place where the system is installed. It is preferable that the amount of water vapor is reduced as much as possible before the compressed air reaches the outlet of the pneumatic system 1, as it is preferable to supply the pneumatic system with 1 dry compressed air free of contaminants.

Relative humidity is defined as the ratio between the quantity of water vapor contained in a volume of air, also defined as absolute humidity, and the maximum quantity of water vapor that can be contained in said volume of air at the same pressure level, defined also as saturation humidity.

As is known, an increase in temperature leads to an increase in saturation humidity, and consequently a decrease in relative humidity. In other words, the increase in air temperature, due to the compression operation performed by compressor 4, leads to an increase in the capacity of the air to absorb water.

However, usually, the amount of water contained in the air sucked in by the compressor 4 is such that the saturation humidity is still reached inside the compressor 4, resulting in a condensation of excess water vapor.

The condensate thus produced is collected and discharged as described below by a first discharge device 18a, operatively coupled to the compressor 4.

The compressed air from the compressor 4 is therefore injected into the pneumatic duct 16a and received by the aftercooler 6, which reduces its temperature up to a value depending on the specifications of the aftercooler, for example 20 ° C. The decrease in the compressed air temperature inside the aftercooler 6 leads to an increase in relative humidity. In particular, the temperature is lowered below the dew point ("dew point") of the compressed air, so as to condense at least part of the water vapor originally sucked in by the compressor 4 and not discharged by the first discharge device 18a. The condensate thus produced is collected and discharged as described below by a second discharge device 18b, operatively coupled to the aftercooler 6.

The compressed air treated by the aftercooler 6 is then introduced into the pneumatic duct 16b and received by the tank 8. Once the tank 8 is reached, the compressed air could still contain water vapor, for example if the aftercooler 6 has not lowered the temperature of the compressed air to a value sufficient to completely condense the water vapor and / or for a non-ideal calibration of the second exhaust device 18b, or for other reasons, including for example malfunctions of the aftercooler 6 and / or of the second discharge device 18b. A third discharge device 18c is operatively coupled to the tank 8 and is configured to collect and discharge the condensate generated by any residual water vapor in the compressed air passing through the tank 8.

Then, the compressed air comes out of the tank 8 and reaches the prefilter 10 passing through the pneumatic duct 16c. The prefilter 10 is configured to obstruct the passage of oil, water and / or particulate matter towards subsequent stages of the pneumatic system 1. For example, the prefilter 10 includes a coalescing filter. A fourth discharge device 18d is operatively coupled to the prefilter 10 and is configured to collect and discharge the condensate generated by any residual water vapor in the compressed air passing through the prefilter 10.

Then, the compressed air comes out of the prefilter 10 and reaches the dryer 12 passing through the pneumatic duct 16d. The dryer 12 is configured to further reduce the temperature of the compressed air, and consequently the water vapor it may contain. For example, the compressed air temperature inside the dryer 12 is lowered to a value corresponding to the type of dryer chosen, for example 4 ° C. The dryer 12 is for example a chemical dryer or a membrane dryer. A fifth discharge device 18e is operatively coupled to the dryer 12 and is configured to collect and discharge the condensate generated from any residual water vapor in the compressed air passing through the dryer 12.

Then, the compressed air comes out of the dryer 12 and reaches the filter 14 passing through the pneumatic duct 16e. Similarly to the prefilter 10, the filter 14 is configured to further obstruct the passage of oil, water and / or particulates towards the outlet of the pneumatic system 1. A sixth discharge device 18f is operatively coupled to the filter 14 and is configured to collect and drain the condensate generated by any residual water vapor in the compressed air passing through the filter 14.

Each of the first, second, third, fourth, fifth and sixth discharge devices 18a-18f is for example a timer discharge device provided with a sensor for the presence of condensation. As described in detail below, each discharge device 18a-18f includes a control unit that checks at regular intervals whether condensate to be discharged has accumulated, and if so opens a respective discharge solenoid valve. In other embodiments, the discharge devices could be of different types, for example they could be timer discharge devices without condensation sensor or level sensor discharge devices.

A hydraulic pipe 20 is configured to convey the condensate discharged from the discharge devices 18a-18f towards a water / oil separator 22. In particular, the water / oil separator 22 is configured to remove oil, if present, from the condensate discharged from the devices 18a-18f, in order to allow purified condensate to be disposed of in compliance with environmental standards that may be in force in the place where the pneumatic system is installed 1. For example, the oil can be a lubricant of the compressor 4. The water / water separator oil 22 can also be configured to remove further contaminants present in the condensate, such as for example hydrocarbons, dust and particulates, rust, abrasions or remains of sealants. The water / oil separator 22 is for example a gravity separator.

According to an aspect of the present invention, in addition to the unloading devices 18a-18f, the unloading system 2 comprises a controller 24, a bus 26 and a data analysis module 28. In particular, the bus 26 is configured to allow bidirectional communication between the discharge devices 18a-18f and the controller 24. For example, the bus 26 is a token bus. Optionally, the bus 26 also allows a bidirectional communication between the water / oil separator 22 and the controller 24. Optionally, the bus 26 also allows the distribution of electrical power to supply the discharge devices 18a-18f. Furthermore, the controller 24 is also in bidirectional communication with the data analysis module 28, for example through a wireless communication channel. The data analysis module 28 is for example a remote module part of a cloud infrastructure ("cloud infrastructure"), not shown in figure 1. For example, the cloud infrastructure can include a database, diagnostic systems, alarm and event management systems and control panels for operators or administrators of the pneumatic system 1.

In particular, as better detailed below, the controller 24 receives from each discharge device 18a-18f diagnostic signals of the real-time operation of each discharge device 18a-18f, and sends said diagnostic signals to the data analysis module 28. In particular, said diagnostic signals comprise data indicative of the discharge time duration of the respective discharge device 18a-18f. The data analysis module 28 analyzes said diagnostic signals together with climatic information on the geographical position in which the pneumatic system 1 is installed, so as to process and send to the controller 24 new control parameters for each unloading device 18a-18f suitable to optimize its operation. In particular, said control parameters comprise a waiting time between consecutive unloading periods.

According to an aspect of the present invention, each discharge device 18a-18f is associated with an identification code, stored by the controller 24 and / or by the data analysis module 28 so as to identify and distinguish each discharge device 18a-18f and the related data. diagnostics from the other exhaust devices 18a-18f and the respective diagnostic data.

Furthermore, after the first installation of the unloading devices 18a-18f in the pneumatic system 1, the data analysis module 28 receives information on the positioning of each unloading device 18a-18f and in particular on its ordering in series in the pneumatic system 1 and on the respective compressed air treatment module to which it is operatively coupled. For example, in the case of Figure 1, the data analysis module 28 stores or receives from the database of the cloud infrastructure data indicative of the fact that the first discharge device 18a is operatively coupled to a compressor, the second discharge device 18b it is operatively coupled to an aftercooler arranged downstream of the first discharge device 18a, the third discharge device 18c is operatively coupled to a tank arranged downstream of the second discharge device 18c, and so on.

Consequently, as better described below, it is possible to carry out an accurate diagnosis of the operation of the pneumatic system 1 and in particular of the exhaust devices 18a-18f and of the compressed air treatment modules to which they are operatively coupled, without increasing the complexity of exhaust devices 18a-18f.

Optionally, the functions of the data analysis module 28 can be implemented by the controller 24, so as to allow correct operation of the discharge system 2 even in the event of communication problems between the controller 24 and the data analysis module 28 or in the event of malfunctions of the data analysis module 28 By way of non-limiting example, Figures 2A-2D show a possible time course of respective control signals of any unloading device between the unloading devices 18a-18f of the exhaust system intelligent system of the hydraulic system 1 of Figure 1, during a discharge cycle of said discharge device, and using a common time scale. In particular, for simplicity of description, reference will be made hereinafter to the first discharge device 18a. It is clear that the same considerations apply to the other discharge devices 18b-18f.

In particular, an activation signal ENABLE, the time course of which is shown in Figure 2A, controls a state of activity of the unloading device 18a. In particular, when the ENABLE activation signal has a logic value "0", the drain device is in a low power consumption "standby" state, while when the ENABLE activation signal has a logic value "1" , the drain device is in an active state, configured to drain condensate if present. As said, in this embodiment the discharge device 18a is a timer discharge device with a sensor for the presence of condensation; consequently, in a per se known manner, the activation signal ENABLE is generated locally by the timer of the unloading device 18a. In particular, therefore, the ENABLE activation signal alternately has a logic value “0” for a waiting time interval ΔtOFF and a logic value “1” for a time interval of activity ΔtON.

In addition, a signal of the presence of WATER condensation, the time course of which is shown in Figure 2B, takes on a different value depending on the presence or absence of condensation inside the discharge device 18a. In particular, the WATER condensate presence signal has a logic value "1" if the condensation sensor of the discharge device 18a detects condensation inside the discharge device 18a, otherwise it has a logical value "0". For example, the signal of presence of condensation WATER is an output signal of the presence of condensation sensor.

In addition, a HOLD maintenance signal, the time course of which is shown in figure 2C, contributes to the control of the opening state of the discharge solenoid valve of the discharge device 18a. In particular, the HOLD signal has a transition from the logic value "0" to the logic value "1" whenever the signal of the presence of condensation WATER has a transition from the logic value "1" to the logic value "0", that is every time which reaches the end of a condensation detection by the discharge device 18a. After this transition, the HOLD signal remains stable at the logic value “1” for a holding time interval ∆tHOLD, at the end of which it returns to the logic value “0”. The drain solenoid valve can be closed only in correspondence with a transition of the HOLD maintenance signal from the logic value "1" to the logic value "0". Consequently, the hold signal HOLD has the function of delaying the closing of the solenoid valve by a time ∆tHOLD, in order to prevent it from being closed immediately after it stops detecting condensation, and therefore to prevent inefficiencies in the event of false recognitions. of the end of the unloading.

Furthermore, a control signal VALVE of the solenoid valve, whose time course is shown in figure 2D, commands the solenoid valve so that it is open if the control signal VALVE has a logic value "1" and is closed if the control signal VALVE has a logical value of “0”.

The HOLD maintenance signal and the VALVE command signal are generated by the control unit of the unloading device 18a on the basis of the ENABLE and WATER signals received at the input.

According to an aspect of the present invention, the duration of the time interval in which the command signal VALVE has a logic value "1" during a discharge cycle corresponds to the duration of the discharge time ∆tDRAIN, which is comprised, as mentioned, between the diagnostic signals sent by the unloading device 18a to the controller 24.

With reference jointly to Figures 2A-2D, a possible unloading cycle of any one of the unloading devices 18a-18f of the intelligent unloading system is described below by way of non-limiting example; for example, without loss of generality, reference will be made hereinafter to the unloading device 18a.

In a first instant in time t1, the ENABLE activation signal has a logical value "0", the signal of the presence of condensation WATER has a logical value "0", the holding signal HOLD has a logical value "0" and the command signal VALVE of the solenoid valve has a logic value of “0”. In this initial configuration, the solenoid valve is closed and there is no condensation accumulated in the discharge device 18a; in any case, the discharge device 18a is in a waiting state since the first time instant t1 is included in a waiting time interval ∆tOFF, so that, as mentioned, the discharge solenoid valve is closed regardless of the presence or less condensation.

In a second time instant t2, subsequent to the first time instant t1, the signal of the presence of condensation WATER changes its logical state, passing from the logical value "0" to the logical value "1". In other words, at the time instant t2 the condensation sensor of the discharge device 18a begins to detect condensation to be discharged. However, at the time instant t2 the drain device 18a is still in the waiting state (ENABLE = "0"), therefore the drain solenoid valve remains closed (VALVE = "0").

In a third time instant t3, subsequent to the second time instant t2, the activation signal ENABLE changes its logical state, passing from the logical value "0" to the logical value "1". In other words, at the time instant t3 a waiting time interval ∆tOFF ends and a time interval of activity ∆tON of the unloading device 18a begins. Consequently, at the time instant t3 the discharge device 18a begins to be enabled (ENABLE = "1") to check if there is condensate to be discharged and if so open the discharge solenoid valve; in this example, at the time instant t3 there is condensate to be discharged (WATER = "1"), consequently, the drain solenoid valve is opened (VALVE = "0") and the condensate begins to discharge.

In a fourth time instant t4, following the third time instant t3, the signal of the presence of condensation WATER changes its logical state, passing from the logical value "1" to the logical value "0". In other words, at the time instant t4 the condensation sensor stops detecting condensation as there is no more condensation to detect. Consequently, at the instant t4 the HOLD maintenance signal passes from the logical value "0" to the logical value "1".

In a fifth time instant t5, subsequent to the fourth time instant t4 and such that t5 - t4 = ∆tHOLD, the signal of the presence of condensation WATER changes its logical state, passing from the logical value "1" to the logical value "0". In other words, at the time instant t5 the maintenance time interval ∆tHOLD has passed after the end of the detection of the presence of condensation, so it is possible to close the drain solenoid valve. Consequently, at the instant t5 the valve command signal VALVE of the solenoid valve goes from the logic value "1" to the logic value "0". Consequently, the drain solenoid valve was opened for a drain time duration ∆tDRAIN = t5 - t3.

After the fifth time instant t5, the drain device 18a is still in a state of activity (ENABLE = "1"), consequently the control unit continues to monitor the presence of condensation based on the value of the signal for the presence of condensation WATER.

In this example, the condensation sensor does not detect further condensation to be discharged until the end of the current activity time interval ∆tON, i.e. up to a sixth time interval t6, subsequent to the fifth time interval t5 and such that t6 - t5 = ∆tON, in which the ENABLE activation signal passes from the logic value “1” to the logic value “0”. In correspondence with the sixth time interval t6, having finished an unloading cycle, the unloading device 18a can send diagnostic signals to the controller 24, including the unloading time duration ∆tDRAIN. Optionally, the maintenance time interval ∆tHOLD is subtracted from the discharge time duration ∆tDRAIN sent to the controller 24. Then, at the sixth time interval t6, the discharge device 18a returns to a waiting state.

Figure 3 schematically illustrates, by block diagram, a condensate discharge method implemented by each discharge device 18a-18f. In particular, for simplicity of discussion, reference will be made hereinafter to the first discharge device 18a by way of example. It is evident that the same considerations apply to each of the other discharge devices 18b-18f.

The unloading method of Figure 3 first begins with step 30 of checking whether a new configuration has been received for the unloading device 18a. In particular, in the course of step 30, the control unit of the unloading device 18a checks whether a new configuration has previously been received from the controller 24. In particular, the new configuration includes a different duration of the waiting time interval ∆tOFF from that to which the timer of the unloading device 18a is currently configured. In particular, during a first unloading cycle of the unloading device 18a, the duration of the waiting time interval ∆tOFF and the duration of the activity time interval ∆tON have a preset value, for example by a system installer. pneumatic 1, for example on the basis of the characteristics of the compressed air treatment module to which the exhaust device 18a is operatively coupled, and on the basis of the climatic conditions characteristic of the place where the pneumatic system 1 is installed.

If the check carried out in the course of step 30 is successful, that is, if a new configuration has been received, one passes to step 32 of updating the configuration of the unloading device 18a. In particular, during phase 32 the control unit of the unloading device 18a pilots the respective timer in order to update the duration of the waiting time interval ∆tOFF to the value received during phase 30.

After step 32, or after step 30 if a new configuration has not been received, one passes to step 34 of discharging the condensate. In particular, in the course of step 34 the condensate accumulated in the discharge device 18a is discharged at least in part.

In particular, consistently with what has been described with reference to Figures 2A-2D on the time course of the signals processed by the discharge device 18a, the condensate discharge step implemented in the course of step 34 of the method of Figure 3 begins at the beginning of a time interval of activity ∆tON. As described in detail with reference to Figures 2A-2D, the discharge solenoid valve of the discharge device 18a is opened during step 34 if and only if the sensor for the presence of condensation detects condensation accumulated in the discharge device 18a. Once it stops detecting condensation, the drain solenoid valve is closed even if the ∆tON activity time interval has not yet ended.

Generally, the method of Figure 3 and in particular the step 34 of discharging the condensate can be implemented at the same time by all the discharge devices 18a-18f of the intelligent discharge system.

However, in some cases the electric power available to drive the intelligent exhaust system may be insufficient; for example, the electric power available could be insufficient to guarantee the possibility of opening at the same time all the drain solenoid valves of all the drain devices 18a-18f of the intelligent drain system.

In these cases, the controller 24 may also have the function of regulating access to electrical power by the discharge devices 18a-18f; in particular, the controller 24 can be configured to drive the control units of each discharge device 18a-18f so that they can open the respective discharge solenoid valve only after having received an authorization signal from the controller 24. In this way it is avoided overloading an electrical supply circuit common to the controller 24 and the discharge devices 18a-18f. For example, the queue of requests from the discharge devices 18a-18f to open their discharge solenoid valve is managed with a FIFO method, with the possibility of managing higher priorities in the event of conflicts, for example in the case of manual interventions for a maintenance of the pneumatic system 1 or in the case of any other high priority event.

After step 34, step 36 of sending diagnostic data is passed. In particular, during the step 36, the unloading device 18a sends diagnostic data to the controller 24. In particular, the step 36 is performed following the end of the previous state of activity of the unloading device 18a.

In particular, the diagnostic data include the identification code of the discharge device 18a and the duration of discharge time ∆tDRAIN relating to the condensate discharge carried out during step 34.

Optionally, the diagnostic data may further comprise: a supply voltage; a current necessary for opening the drain solenoid valve; a frequency of discharge; a signal of the presence of condensation from the beginning of the ∆tON activity time interval corresponding to the previous discharge phase 34; a signaling of the presence of residual condensate at the end of the discharge step 34; the temperature inside the discharge device 18a (provided by a temperature sensor optionally included in the discharge device 18a).

Optionally, the diagnostic data can also include the amount of water discharged during step 30. In this case, the amount of water discharged is calculated on the basis of the drain time duration ∆tDRAIN, multiplying it by the nominal flow rate of the drain device 18a. In particular, the nominal flow rate of the discharge device 18a can be controlled by a flow limiter optionally included in the discharge device 18a. Furthermore, the calculation of the quantity of discharged water can be made more accurate by replacing the nominal flow rate with the actual flow rate of the discharge device 18a, obtained on the basis of the operating pressure of the pneumatic system 1 in a manner known per se to the expert. of the technical branch of reference.

Optionally, the transmission of the diagnostic data is not performed at each iteration of the method of Figure 3, but at regular time intervals, for example following requests from the controller 24. In this case, the diagnostic data includes an average duration of unloading and optionally an average unloading frequency.

Subsequent to step 36, step 38 of waiting for a waiting time interval ∆tOFF is passed following the end of the previous state of activity of the unloading device 18a. Once the waiting time interval ∆tOFF has passed, return to step 30 to check if a new configuration has been received for the unloading device 18a.

Figure 4 schematically illustrates, by means of a block diagram, a method of controlling the discharge devices 18a-18f, implemented by the controller 24 of Figure 1.

The method of Figure 4 first begins with the step 40 of receiving diagnostic data; in particular, during step 40, the controller 24 receives diagnostic data from any of the discharge devices 18a-18f sent during step 36 of the discharge method of figure 3. For clarity of description, reference will be made hereinafter to case in which in the course of step 40 the controller 24 receives diagnostic data from the first unloading device 18a. A similar argument can be made in the case in which the controller 24 receives diagnostic data from any other discharge device 18b-18f.

Then, step 42 is passed to save the diagnostic data received during step 40, for example in an internal memory of the controller 24. In other embodiments, step 42 could be absent.

Subsequent to step 42, step 44 of sending the diagnostic data is passed. In particular, in the course of step 44, the controller 24 sends the diagnostic data received in the course of step 40 to the data analysis module 28.

Preferably, the sending of diagnostic data received from different unloading devices 18a-18f can follow a time schedule stored in the controller 24, capable of handling simultaneous requests from multiple unloading devices 18a-18f.

Subsequent to step 44, step 46 of receiving a new configuration is passed. In particular, during phase 46 the controller 24 receives a new configuration for the unloading device 18a, relative to which diagnostic data had been sent during phase 44, following an analysis of said diagnostic data carried out by the control module. data analysis 28 as better described below.

Subsequent to step 46, step 48 of sending the new configuration is passed. In particular, during step 48 the controller 24 sends the new configuration received during step 46 to the unloading device 18a, that is to the unloading device for which diagnostic data had been received during step 40. Said new configuration sent the unloading device 18a is then received by the unloading device 18a in the course of step 30 of the unloading method of Figure 3.

Subsequent to step 48, there is a return to step 40 of receiving further diagnostic data for any one of the exhaust devices 18a-18f.

Optionally, new configurations can be received during step 46 for a plurality of exhaust devices 18a-18f of the smart exhaust system and not only for the exhaust device 18a for which diagnostic data was sent during step 44. Said new configurations are in any case processed starting from said diagnostic data, and are subsequently sent to the respective unloading devices 18a-18f during step 48 of the method.

It is also evident that various iterations of the control method of Figure 4, relating to different diagnostic data, can take place at least partially in parallel over time. For example, after sending a first set of diagnostic data (step 44) from the controller 24 to the data analysis module 28 and before receiving a new configuration (step 46) for a first unloading device, the controller 24 can receiving a second set of diagnostic data (step 40) from a second discharge device.

Figure 5 schematically illustrates, by means of a block diagram, a data analysis and processing method implemented by the data analysis module 28 of Figure 1.

In particular, the method of Figure 5 begins first of all with the step 50 of receiving diagnostic data from the controller 24 (sent, as said, in the course of the step 44 of the control method of Figure 4). In particular, for clarity of description, it will be assumed hereinafter that the diagnostic data received in step 50 were originally sent from the first discharge device 18a to the controller 24 (step 36 of the method of Figure 3). Similar considerations apply to the other 18b-18f exhaust devices.

After step 50, step 52 is moved to save said diagnostic data, for example in the database of the cloud infrastructure. Saving a series of diagnostic data over time for the same unloading device allows you to analyze the time course of said diagnostic data and possibly detect anomalies.

Subsequent to step 52, step 54 of detecting anomalies is passed. In particular, during step 54 the diagnostic data received during step 50 are analyzed, per se and / or related to diagnostic data previously stored during step 52 of previous iterations of the analysis method. Based on this analysis, described in detail below, anomalies in the operation of the pneumatic system can be detected 1. These anomalies are stored, for example in the database of the cloud infrastructure. These anomalies can also be reported to an operator, a maintenance technician and / or an administrator of the pneumatic system 1. For example, the reporting of anomalies can be aimed at preventing any problems due to malfunctions. Furthermore, the signaling of anomalies can also include the position in the pneumatic system 1 of the compressed air treatment module to which the anomaly is related, in order to provide a maintenance technician with a possible cause of the anomaly, reducing intervention and consequently the related costs.

After step 54, step 56 of receiving atmospheric data is passed. In particular, during phase 56 the data analysis module 28 receives data relating to the atmospheric conditions in the environment in which the pneumatic system 1 is located, such as atmospheric pressure, atmospheric temperature and relative atmospheric humidity. Optionally, atmospheric data includes saturation pressure and saturated vapor pressure.

Said atmospheric data can be read directly through a weather station included in the cloud platform or can be read through online weather services. The updating of atmospheric data can be carried out substantially in real time.

Subsequently to step 56, one moves on to step 58 of calculating a new configuration for the unloading device 18a, or for the unloading device to which the diagnostic data received in the course of step 50 refer, on the basis of the atmospheric data received in the course. of step 56. During step 58, a new configuration can also be calculated for one or more of the other exhaust devices 18b-18f, on the basis of the same atmospheric data.

In particular, the new configuration calculated during step 58 comprises a duration of a theoretical waiting time interval ∆tOFF for the unloading device 18a and optionally a respective theoretical waiting time interval ∆tOFF for one or more of the other devices. 18b-18f, on the basis of the atmospheric data received during phase 56. In particular, as better described with an example below, the atmospheric data allow to calculate an estimate of the quantity of condensate expected in each treatment module of the compressed air to which an exhaust device 18a-18f of the intelligent exhaust system is operatively coupled. Depending on the quantity of condensate expected and the nominal flow rate of each drain device 18a-18f, it is possible to calculate how often it is preferable to activate each drain device 18a-18f, and consequently estimate the theoretical duration of the waiting time interval. ∆tOFF in order to increase an unloading efficiency of the unloading system 2. Preferably, the new configuration is saved in the database of the cloud infrastructure and associated with the related unloading device 18a-18f.

After step 58, you move on to step 60 to check if the new configuration is different from the current configuration, for example due to climatic changes in the place where the pneumatic system 1 is installed. Preferably, the current configuration is stored in the base of cloud infrastructure data. Alternatively, the current configuration is sent from the controller 24 to the remote server.

If the check carried out during phase 60 has a negative result, i.e. if the new configuration is unchanged with respect to the current configuration, it returns to phase 50 to receive further diagnostic data, from the same exhaust device 18a or from other exhaust devices 18b- 18f.

If the check carried out during phase 60 is successful, i.e. if the new configuration is different from the current configuration, one passes to phase 62 to send the new configuration to the controller 24 (the new configuration being received by the controller 24 during the 46 of the control method of figure 4).

After step 62, it returns to step 50 of receiving diagnostic data.

According to an aspect of the present invention, it is possible to carry out steps 56-62 relating to the calculation and sending of a new configuration only if anomalies have been detected during step 54. In this variant of the method, if in step 54 they are not detected anomalies, you return to step 50 of receiving diagnostic data.

Below are more details on the implementation of phase 54 to detect anomalies of the analysis method in figure 5. As mentioned, any anomalies are detected by analyzing the diagnostic data received during phase 50.

In particular, the analysis of diagnostic data may include a comparison with diagnostic data received and stored in the past from the same discharge device; in addition, the analysis may include a comparison with diagnostic data relating to other exhaust devices.

As mentioned, the diagnostic data include a discharge time duration ∆tDRAIN of a discharge cycle of a discharge device, or an average discharge time duration calculated for several discharge cycles of the same discharge device.

In particular, the analysis of diagnostic data can include a comparison between the measured duration of discharge time ∆tDRAIN and the expected discharge time duration for the same discharge device. As better detailed below, the expected discharge time duration for a discharge device is calculated by the data analysis module 28 during step 58 of the method of Figure 5, in which the new configuration of one or more discharge devices is calculated. 18a-18f exhaust as a function of atmospheric data.

In particular, the step of comparing the measured unloading time duration and the expected unloading time duration includes verifying whether a variation between the expected unloading time duration and the measured unloading time duration is included in a reliability threshold. , for which, for example, the variation must be less than 5% of the measured discharge time duration. Said value of the trust threshold is preset as a default value, conveniently modifiable by an operator or an administrator of the pneumatic system 1 using an appropriate control panel, for example included in the cloud infrastructure.

In a first example of analysis of the diagnostic data, the discharge time duration ∆tDRAIN measured for the first discharge device 18a, operatively coupled to the compressor 4, is different from the discharge time duration expected for the same discharge device, but the variation is within the reliability threshold.

In this case, it is verified whether the other discharge devices 18b-18f also recorded the same variation with respect to their respective expected discharge time duration.

If so, it can be assumed that the measured variation is due to a change in atmospheric conditions. Consequently, no anomalies are reported and the step of calculating the new configuration for all the discharge devices 18a-18f is proceeded.

If not, if the change is reported only by the first discharge device 18a, the change could be due to excessive contamination of a compressor 4 filter. Consequently, the anomaly is recorded but not necessarily reported.

In a second example of analysis of the diagnostic data, the discharge time duration ∆tDRAIN measured for the first discharge device 18a, operatively coupled to the compressor 4, is different from the discharge time duration expected for the same discharge device, and moreover, the change is outside the reliability threshold.

In this case, it is verified whether the other discharge devices 18b-18f also recorded the same variation with respect to their respective expected discharge time duration.

If so, it is possible to check whether the measured variation may be due to a considerable change in atmospheric conditions. In this case, no anomalies are reported and one proceeds with the step of calculating the new configuration for all the exhaust devices 18a-18f. Otherwise, it can be assumed that the system is stopped, unused or with low air consumption.

If not, if the change is reported only by the first discharge device 18a, the change could be due to excessive contamination of the compressor 4 filter. Consequently, the anomaly is recorded and reported. In particular, an emergency signal is sent to the controller 24, capable of triggering an emergency procedure according to which the duration of the anomaly is monitored for how long; once a time threshold is exceeded in which the anomaly continues to be detected, for example between 30 minutes and 45 minutes, an intervention by a maintenance technician is required, for example aimed at replacing the filter of compressor 4.

In a third example of analysis of the diagnostic data, the discharge time duration ∆tDRAIN measured for the first discharge device 18a, operatively coupled to the compressor 4, is less than the discharge time duration expected for the same discharge device, and moreover, the change is outside the reliability threshold.

In this case, it is checked whether the unloading time duration ∆tDRAIN measured for the downstream unloading device, that is the second unloading device 18b, is, on the contrary, greater than the expected unloading time duration.

If so, a possible discrepancy on compressor 4 can be assumed as the cause of the variation. Consequently, any discrepancies on compressor 4 are signaled and an intervention by a maintenance technician is possibly required.

In a fourth example of diagnostic data analysis, the drain time duration ∆tDRAIN measured for the second drain device 18b, operatively coupled to the aftercooler 6, is different from the drain time duration expected for the same drain device, but the variation is within the reliability threshold.

In this case, it is verified whether the other discharge devices 18a, 18c-18f also recorded the same variation with respect to the respective expected discharge time duration.

If so, it can be assumed that the measured variation is due to a change in atmospheric conditions. Consequently, no anomalies are reported and one proceeds with the step of calculating a new configuration for each of the exhaust devices 18a-18f.

If not, if the same variation is not reported by the upstream exhaust device, i.e. by the first exhaust device 18a, the variation could be due to excessive contamination of an aftercooler filter 6. Consequently, the anomaly is recorded but not necessarily reported.

In a fifth example of diagnostic data analysis, the discharge time duration ∆tDRAIN measured for the second discharge device 18b, operatively coupled to the aftercooler 6, is different from the discharge time duration expected for the same discharge device, and moreover, the change is outside the reliability threshold.

In this case, it is verified whether the other discharge devices 18a, 18c-18f also recorded the same variation with respect to the respective expected discharge time duration.

If so, it is possible to check whether the measured variation may be due to a considerable change in atmospheric conditions. In this case, no anomalies are reported and one proceeds with the step of calculating the new configuration for each of the exhaust devices 18a-18f. Otherwise, it can be assumed that the plant is stopped or unused.

If not, if the change is reported only by the second exhaust device 18b, the change could be due to excessive contamination of the aftercooler filter 6. Consequently, the anomaly is recorded and reported, similarly to what is described for the first. discharge device 18a in discussing the second example of diagnostic data analysis.

In a sixth example of analysis of diagnostic data, the discharge time duration ∆tDRAIN measured for the second discharge device 18b, operatively coupled to the aftercooler 6, is less than the discharge time duration expected for the same discharge device, and moreover, the change is outside the reliability threshold.

In this case, it is checked whether the unloading time duration ∆tDRAIN measured for the downstream unloading device, i.e. the third unloading device 18c, is, on the contrary, greater than the expected unloading time duration.

If so, a possible discrepancy on the aftercooler can be assumed as the cause of the change 6.

Consequently, any discrepancies on the aftercooler 6 are signaled and an intervention by a maintenance technician is possibly required.

In a seventh example of diagnostic data analysis, the unloading time duration ∆tDRAIN measured for the fifth unloading device 18e, operatively coupled to the dryer 12, is different from the expected unloading time duration for the same unloading device, but the variation is within the reliability threshold.

In this case, it is verified whether the other unloading devices 18a-18d, 18f also recorded the same variation with respect to the respective expected unloading time duration.

If so, it can be assumed that the measured variation is due to a change in atmospheric conditions. Consequently, no anomalies are reported and the step of calculating the new configuration for all the exhaust devices 18a-18f is proceeded.

If not, if the same variation is not reported by the upstream exhaust device, i.e. the fourth exhaust device 18d, the variation could be due to excessive contamination of a filter of the dryer 12. Consequently, the anomaly is recorded and proceeds with the step of calculating the new configuration for the fifth discharge device 18e.

In an eighth example of diagnostic data analysis, the unloading time duration ∆tDRAIN measured for the fifth unloading device 18e, operatively coupled to the dryer 12, is different from the expected unloading time duration for the same unloading device, and furthermore the variation is outside the reliability threshold.

In this case, it is verified whether the other unloading devices 18a-18d, 18f also recorded the same variation with respect to the respective expected unloading time duration.

If so, it is possible to check whether the measured variation is due to a considerable change in atmospheric conditions. In this case, no anomalies are reported and one proceeds with the step of calculating the new configuration for all the exhaust devices 18a-18f. Otherwise, it can be assumed that the plant is stopped or unused.

If not, if the change is reported only by the fifth discharge device 18e, the change could be due to excessive contamination of the filter of the dryer 12. Consequently, the anomaly is recorded and reported, similarly to what is described for the first discharge device 18a in discussing the second diagnostic data analysis example. Furthermore, one proceeds with the step of calculating the new configuration for the fifth discharge device 18e.

In a ninth example of diagnostic data analysis, the unloading time duration ∆tDRAIN measured for the fifth unloading device 18e, operatively coupled to the dryer 12, is less than the unloading time duration expected for the same unloading device, and furthermore the variation is outside the reliability threshold.

In this case, it is checked whether the unloading time duration ∆tDRAIN measured for the downstream unloading device, that is the sixth unloading device 18f, is, on the contrary, greater than the expected unloading time duration.

If so, a possible discrepancy on the dryer 12 can be assumed as the cause of the variation. Consequently, any discrepancies on the dryer 12 are reported and an intervention by a maintenance technician is possibly required.

In a tenth example of diagnostic data analysis, the exhaust time duration ∆tDRAIN measured for any one of the fourth exhaust device 18d and the sixth exhaust device 18f, operatively coupled to the prefilter 10 and the filter 14, respectively, is different. from the expected discharge time duration for the same discharge device, but the variation is within the reliability threshold.

In this case, one proceeds in the same way as described for the fifth discharge device 18 and in the case of the seventh example of analysis of the diagnostic data.

In an eleventh example of diagnostic data analysis, the exhaust time duration ∆tDRAIN measured for one of the fourth exhaust device 18d and the sixth exhaust device 18f, operatively coupled to the prefilter 10 and to the filter 14, respectively, is different from duration of unloading time expected for the same unloading device, and furthermore the variation is outside the reliability threshold.

In this case, we proceed similarly to what has been said for the fifth discharge device 18 and in the case of the eighth example of diagnostic data analysis.

In a twelfth example of analysis of the diagnostic data, the discharge time duration ∆tDRAIN measured for the sixth discharge device 18f, operatively coupled to the filter 14, is greater than the discharge time duration expected for the same discharge device, and moreover, the change is outside the reliability threshold.

In this case, it occurs if the unloading time duration ∆tDRAIN measured for the other unloading devices 18a-18e does not show the same variation.

In the positive case, since the sixth discharge device 18f is positioned at the end of the compressed air treatment line, it is possible to assume the presence of water in the pneumatic system 1. Consequently, a possible presence of water in the pneumatic system 1 and an intervention by a maintenance technician is required.

Details are given below on step 58 of the analysis method of Figure 5, suitable for calculating a new configuration for one or more exhaust devices 18a-18f.

In general, phase 58 is divided into a first sub-phase in which, for one or more discharge devices 18a-18f, the quantity of condensate to be discharged per unit of time is estimated, and in a second sub-phase in which the frequency is estimated. necessary to discharge said quantity of condensate per unit of time, and consequently the theoretical duration ∆tOFF of the waiting intervals.

Equations and concepts useful to continue with the description of the calculation method of a new configuration are reported below.

As is known, a quantity of water VH2O present, in the vapor phase, in a mixture of humid air having a VAIR volume can be calculated using the following equation:

where d is the density of the humid air mixture and t is the title of the humid air mixture. For example, VAIR (measured in m <3>) can be the volume of humid air sucked in by compressor 4. In this case, VH2O is the maximum amount of water present in the pneumatic system 1. Furthermore, equation (1) it can be expressed in terms of flow rather than volume; in this case, VAIR (measured in m <3> / s) is the volumetric flow rate of the humid air sucked in by compressor 4, i.e. the quantity of humid air sucked by compressor 4 per unit of time, while VH20 is the quantity of water per unit of time included in said humid air.

The density d of the mixture can be calculated by means of the following equation:

where P is the pressure of the mixture (measured in Pa), T is the temperature of the mixture (measured in kelvin), RA = 287.058 J / (kg K) is the specific constant of dry air, RV = 461.495 J / ( kg · K) is the specific constant of water vapor and PS is the saturation pressure; the saturation pressure PS can be included between the atmospheric data received in step 56, or it can be obtained from tables available in the literature as a function of the temperature T, or it can be calculated using the following equation:

Consequently, the density d of the mixture depends only on atmospheric data such as the pressure P and the temperature T, received in step 56 of the method of figure 5.

Furthermore, the t title of the mixture can be calculated using the following equation:

where PVS = UR · PS is the saturated vapor pressure, and UR is the relative humidity of the mixture (percentage expressed as a number between 0 and 1). Therefore, the density d of the mixture also depends only on atmospheric data. Optionally, the saturated vapor pressure PVS can be received directly between the atmospheric data of step 56 of the method of figure 5,

Consequently, knowing atmospheric data such as pressure, temperature and relative humidity, it is possible to calculate the quantity of water in a volume of humid air, and similarly the maximum quantity of condensate in a volume of humid air introduced into a pneumatic system of production and treatment of compressed air.

Once the quantity of condensate to be discharged is known, and the characteristics of each discharge device are known, it is possible to calculate the time required to discharge said quantity of condensate.

In particular, once known, for example, an expected condensate flow rate Vexp for the first discharge device 18a, on the basis of the atmospheric data (pressure P, temperature T and relative humidity UR) received during phase 56, it is possible to calculate the new configuration of the first unloading device 18a, and in particular estimating the theoretical duration of the waiting time interval ∆tOFF, for example according to the following equation:

where C is the condensate accumulation capacity of the first discharge device 18a. In other words, in this example the theoretical duration of the waiting time interval ∆tOFF calculated for the new configuration corresponds to the time required to reach the maximum amount of condensate that can be accumulated in the drain device. In other examples, said theoretical waiting duration ∆tOFF could be lower, for example by 10%, to introduce safety margins.

The new configuration calculated in step 58 also includes the new duration of the time interval of ΔtON activity, calculated using the following equation:

where SN is the nominal discharge flow rate of the first discharge device 18a. In other words, in this example, the preferable duration of the ∆tON activity time interval corresponds to the time required to completely discharge a drain device in which the maximum amount of accumulated condensate had previously been reached.

It is evident that a similar argument applies to the other discharge devices 18b-18f, for which it is also possible to apply equations (5) and (6) as described above.

According to an aspect of the present invention, the duration of the activity time interval ΔtON calculated by means of equation (6) is the expected discharge time duration used for the comparison, carried out in step 54, with the discharge time duration ∆tDRAIN measured for the same unloader.

Below is an example of the calculation of the new configuration (step 58) for the pneumatic system 1.

First of all, the volume of water present in the suction of compressor 4 is calculated in a unit of time. For example, knowing that in the place where the pneumatic system is installed the atmospheric pressure is P = 1.08 bar, the temperature is T = 18 ° C and the relative humidity is UR = 0.68, by applying equation (4) we obtain an input title t = 8.1941 · 10 <-3> and applying equation (2) we obtain an input density d = 1.2859 kg / m <3>. Therefore, knowing that the inlet humid air flow rate, i.e. the humid air intake flow rate by the compressor is VAIR = 30 m <3> / min, applying equation (1) we obtain a water flow rate entering the compressor 4 equal to VH20 = 18.9662 l / h. Said flow rate of water VH20 entering compressor 4 is equal to the total flow of water introduced into the pneumatic system 1 in the unit of time.

Then, the temperature Ta of the air leaving compressor 4 is calculated by means of the following equation:

where Pa is the operating pressure at which the air is compressed by means of compressor 4, for example Pa = 7.5 bar, while k = CPV / CPA is the ratio between the specific heat of the water vapor CPV = 1.005 kJ / (kg K) and the specific heat of dry air CPA = 1.82 kJ / (kg K). From equation (7) it results Ta = 42.87 ° C.

Therefore, starting from the pressure Pa and the temperature Ta of the air mixture leaving the compressor 4, it is possible to calculate the density from and the title ta of the mixture after compressor 4; in this example, the titer is equal to ta = 7.1176 · 10 <-3> and the density a da = 8.2319 kg / m <3>.

Furthermore, as known, to obtain the real flow rate Va of compressor 4 it is necessary to divide the nominal flow rate Van of compressor 4 by the operating pressure Pa of compressor 4. For example, for a nominal flow rate Van = 30 m <3> / min, a real flow rate Va = 4 m <3> / min is obtained.

Therefore, once the actual flow rate and the title of the mixture after compressor 4 are known, it is possible to apply equation (1) to obtain a quantity of water VH2Oa = da ta It must be contained in the air coming out of compressor 4 and passing through for the pneumatic duct 16a. In particular, in this example we obtain VH20a = 14.0619 l / h. Since VH2Oa is less than VH2O, it is evident that part of the water introduced into the pneumatic system 1 is converted into condensate in compressor 4.

Therefore, the quantity of condensate Vca generated in the compressor 4, to be discharged by means of the first discharge device 18a, is equal to the difference between the quantity of water VH20 introduced into the pneumatic system and the quantity of water VH20a in the compressed air leaving the compressor 4. In this example, Vca = VH2O - VH2Oa = 4.9042 l / h is obtained.

It is therefore possible to calculate the preferable duration of the waiting time interval ∆tOFF for the first discharge device 18a by applying equation (5), in which the expected condensate flow rate Vexp is equal to the Vca parameter as calculated above.

As for the preferable duration of the ∆tON activity time interval, it is sufficient to apply equation (6) knowing the characteristics of the first discharge device 18a.

A similar argument to that described for the calculation of the new configuration for the first discharge device 18a applies to the calculation of the new configuration for the second discharge device 18b, operatively coupled to the aftercooler 6, and for the fifth discharge device 18e, operatively coupled to the dryer 12.

For example, for the second exhaust device 18b it is necessary to consider that the air leaving the aftercooler 6 will have a temperature Tb lower than the temperature Ta of the air leaving the compressor 4.

The variation in temperature makes it necessary to recalculate the tb and density db of the mixture at the outlet of the aftercooler 6, while in the absence of a change in pressure it can be assumed that the flow rate of the air flow Vb at the outlet of the aftercooler 6 is equal to the flow rate Goes to the compressor 4 outlet. Once the above parameters have been calculated, it is possible to obtain the water flow rate VH2Ob = tb · db · Vb included in the air leaving the aftercooler 6, and therefore the quantity of condensate Vcb = VH2Oa - VH2Ob generated in the aftercooler 6.

Once the quantity of condensate Vcb is known, it is therefore possible to calculate the preferable duration of the waiting time interval ∆tOFF and the activity time interval ∆tON for the second discharge device 18b. For example, if the second discharge device 18b has a nominal discharge flow rate SNb = 0.09 l / s and a condensate accumulation capacity Cb = 0.2 l, an activity interval duration equal to ∆tON = 2.22 s is obtained.

It is also possible that an exhaust device is operatively coupled to a compressed air treatment module for which it is not possible to accurately estimate an expected condensate flow rate as described above for the compressor 4, for the aftercooler 6 and for the dryer 12.

For example, for the tank 8 it is not possible to accurately estimate the quantity of water that could condense, so this value can be deduced from empirical tests carried out on pilot pneumatic systems, and / or expressed as a function of the quantity of VH2O water introduced by the compressor 4 in the pneumatic system 1 sucking in humid air. For example, it is possible to estimate that, in the absence of anomalies in the operation of the pneumatic system 1, the amount of condensate in the tank 8 is approximately equal to 2% of the total amount of water VH2O.

Similar considerations apply to filter 14. Similarly, based on empirical formulations, the Applicant has verified that, in the absence of anomalies in the operation of the pneumatic system 1, the quantity of condensate in the filter 14 is equal to 1.5% of the quantity of water total VH2O.

In general, the data analysis module 28 is configured to store information on each air handling module 4-14 included in the pneumatic system 1. In particular, considering that any air handling module 4-14 is configured to receive a respective inlet air flow and to provide a respective outlet air flow resulting from the inlet air flow, the data analysis module 28 is configured to receive, for each air treatment module 4-14, respective treatment parameters of air indicative of the treatment of the respective inlet air flow.

In particular, the air treatment parameters include a first pressure variation factor, a first temperature variation factor and a first relative humidity variation factor. Each of said variation factors is for example expressed as a percentage and makes it possible to calculate, starting from the pressure, temperature and relative humidity of an inlet air flow, respectively, the pressure, temperature and relative humidity of the flow of output air resulting from the treatment of air. It is evident that in some cases the variation factors can be zero, so that a pressure, a temperature or a relative humidity of an air flow remains unchanged following the passage through an air treatment module.

Furthermore, it is possible to assume that the pneumatic ducts 16a-16e allow two consecutive air handling modules to be coupled so that the pressure, temperature, relative humidity and flow rate of an outlet air flow of a treatment module of air are equal respectively to the pressure, temperature, relative humidity and flow rate of the inlet air flow of the next air handling module.

It is therefore possible for the data analysis module 28, knowing the atmospheric data and therefore the pressure, temperature and relative humidity of the air sucked in by the compressor 4, to estimate the pressure, the temperature and the relative humidity of each flow of air passing through the pneumatic ducts 16a-16f of the pneumatic system 1.

From an examination of the characteristics of the invention described and illustrated here, the advantages that it allows to be obtained are evident.

For example, the fact that the analysis module 28 is configured to acquire atmospheric data relating to the environment in which the pneumatic system is located, estimate on the basis of said atmospheric data the flow of condensate generated inside the pneumatic system and calculating a theoretical waiting time for each exhaust device of the exhaust system, allows automatic calibration of the exhaust devices. Consequently, if the drain devices are timed drain devices with condensation sensor, it is possible to increase their drain efficiency and / or make them reconfigurable according to changes in climatic conditions without increasing complexity or costs of exhaust devices. Furthermore, memorizing the compressed air treatment parameters of the various air treatment modules of the pneumatic system 1 allows an accurate estimate of the flow rate of water, in the vapor phase, included in the compressed air flows inside the 'pneumatic system.

Furthermore, the ability to accurately estimate the flow rate of water included in the compressed air flows inside the pneumatic system allows you to accurately estimate the flow rate of condensate generated in each compressed air treatment module included in the pneumatic system.

In addition, the ability to accurately estimate the flow rate of condensate generated in each compressed air treatment module allows you to accurately estimate a theoretical discharge time and waiting time for each discharge device included in the discharge system. As a result, each exhaust device can be automatically calibrated so that the actual waiting time for each exhaust device matches the theoretical waiting time.

In addition, the ability to accurately calculate a theoretical exhaust time for each exhaust device allows you to compare the theoretical exhaust time with an actual exhaust time in order to detect abnormalities in the operation of the exhaust device or air handling module tablet to which it is operatively coupled.

Furthermore, the presence of a controller operatively coupled to each unloading device by means of a data bus allows to manage the sending of diagnostic data and the reception of new calibration configurations by means of a precise time scheduling to avoid transmission conflicts. data.

In addition, the presence of a data bus designed to provide electrical power allows you to manage access to the power supply by the unloading devices, avoiding overloading an electrical power supply common to all unloading devices.

Finally, it is clear that modifications and variations can be made to the invention described and illustrated here without thereby departing from the protective scope of the present invention, as defined in the attached claims.

For example, it is clear that the cloud infrastructure can be shared by a plurality of unloading systems according to an embodiment of the present invention. For example, different controllers of different unloading systems can be in bidirectional communication with the same data analysis module or respective remote servers included in the same cloud infrastructure.

In addition, the local network is optionally expandable by integrating additional sensors or actuators such as flow sensors, in-line dew point sensors, temperature, humidity and local pressure meters or remotely controllable valves. Any data collected integrate the climatic data used for the formulation of new configurations of the exhaust devices. The diagnostic functions can also be extended to sensors or optional valves and accessories.

Furthermore, as said, the discharge devices 18a-18f can be of different types and not necessarily timed discharge devices; for example, the discharge devices 18a-18f may be maximum and minimum level sensor discharge devices. In this case, the presence of the level sensor means that in principle it is not necessary to calculate the expected condensate flow rate Vexp in order to reprogram the drain device, as the maximum level sensor allows to establish in real time when interrupt a waiting interval and the minimum level sensor allows you to establish in real time when to interrupt an activity interval.

However, the advantageous technical effects linked to the analysis of the diagnostic data described with reference to the method of figure 5 remain also for the level sensor discharge devices. In particular, in the case of level sensor discharge devices, the diagnostic data collected and sent during step 36 of the method of figure 3 include both the discharge time and the waiting time (condensate accumulation), so as to be able to calculate the discharge frequency; it is therefore possible to compare an expected discharge duration (or frequency) with a measured discharge duration (or frequency), in order to monitor the correct functioning of the pneumatic system in which the exhaust system is installed.

Furthermore, in other embodiments the data analysis module 28 could be absent; in this case, the data analysis and processing method of Figure 5 is implemented by the controller 24.

Claims (16)

CLAIMS 1. Discharge system (2) for discharging condensate of a pneumatic system (1) comprising a first air treatment module (4; 6; 8; 10; 12; 14), the discharge system (2) comprising: - a first discharge device (18a; 18b; 18c; 18d; 18e; 18f) suitable for discharging (34) of a first condensate into the first air treatment module; And - a data analysis module (24; 28) operatively coupled to the first unloading device and configured for: acquire (56) atmospheric data (P, T, Ur) relating to an environment in which the pneumatic system is located (1), estimate (58), based on said atmospheric data, a flow rate of the first condensate (Vac), calculate (58) a first theoretical waiting time (∆tOFF) inversely proportional to the flow rate of the first condensate (Vca), and command (32) the first unloading device so that a first effective waiting time (∆tOFF) between consecutive discharges performed (34) by the first unloading device (18a; 18b-18f) is equal to the first theoretical waiting time ( ∆tOFF). Exhaust system (2) according to claim 1, wherein the first air handling module (4; 6; 8; 10; 12; 14) is configured to receive a first flow of inlet air and to provide a first outlet air stream resulting from a treatment of the first inlet air stream, and wherein the data analysis module (24; 28) is further configured to: receive air treatment parameters of the first air treatment module indicative of the treatment of the first inlet air stream, receive a flow rate of the first inlet air stream (VAIR), estimate (58) a flow rate of water (VH2O; VH2Oa) in the vapor phase included in the first inlet air flow based on said atmospheric data (P, T, Ur) and on the flow rate of the first inlet air flow (VAIR ), calculate (58) a flow rate of the first outlet air stream (Va) based on the flow rate of the first inlet air stream (VAIR) and the air handling parameters of the first air handling module, estimate (58) a water flow rate (VH2Oa; VH2Ob) included in the first outlet air flow on the basis of said atmospheric data (P, T, Ur), the air treatment parameters of the first air treatment module and the flow rate of the first outlet air flow (Va), e estimate (58) the flow rate of the first condensate (Vca) by subtracting the flow rate of water included in the first flow of outlet air (VH2Oa; VH2Ob) from the flow rate of water included in the first flow of inlet air (VH2O; VH2Oa). Discharge system (2) according to claim 2, wherein the data analysis module (24; 28) is further configured for: calculate (58) a density (d) and a title (t) of the first inlet air flow on the basis of said atmospheric data (P, T, Ur), calculate (58) a density (da) and a titer (ta) of the first outlet air flow based on said atmospheric data (P, T, Ur) and the air treatment parameters of the first air treatment module ( 4; 6; 8; 10; 12; 14), estimate (58) the flow rate of water included in the first inlet air stream (VH2O; VH2Oa) on the basis of a product of the density (d), the titer (t) and the flow rate (VAIR) of the first inlet air stream , And estimate (58) the flow rate of water included in the first outlet air stream (VH2Oa; VH2Ob) on the basis of a product of the density (da), the title (ta) and the flow rate (Va) of the first outlet air stream . Exhaust system (2) according to claim 3, wherein said atmospheric data (P, T, Ur) comprises an atmospheric pressure (P), an atmospheric temperature (T) and an atmospheric relative humidity (UR) in the environment in which the pneumatic system (1) is located, and in which said air treatment parameters of the first air treatment module (4) comprise a first pressure variation factor, a first temperature variation factor and a first relative humidity variation factor, and in which the data analysis module (24; 28) is also configured for: calculate (58) the density (d) and titer (t) of the first inlet air stream using the following equations: where d is the density of the first inlet air stream, t is the title of the first inlet air stream, P is the atmospheric pressure, T is the atmospheric temperature, RA is the specific constant of dry air, RV is the water vapor specific constant and PS is a saturation pressure corresponding to the atmospheric temperature (T), calculate (58) the flow rate of the first outlet air flow (Va) by applying the first pressure change factor to the flow rate of the first flow of inlet air (VAIR), calculate (58) a pressure (Pa), a temperature (Ta) and a relative humidity (Ura) of the first outlet air flow by applying the first pressure change factor, the first temperature change factor and the first factor respectively relative humidity variation respectively to atmospheric pressure (P), atmospheric temperature (T) and relative atmospheric humidity (RH), and calculate (58) the density (da) and titer (ta) of the first outlet air stream using the following equations: where da is the density of the first outlet air stream, ta is the title of the first outlet air stream, Pa is the pressure of the first outlet air stream, Ta is the temperature of the first outlet air stream, URa is the relative humidity of the first outlet air stream, and PSa is a saturation pressure corresponding to the temperature of the first outlet air stream (Ta). Exhaust system (2) according to any one of claims 2 to 4, wherein the pneumatic system (1) further comprises a second air handling module (6) configured to receive a second flow of inlet air and to provide a second outlet air stream resulting from a treatment of the second inlet air stream, the second air treatment module (6) being operatively coupled to the first air treatment module (4) so that a flow rate ( Va) of the second inlet air flow and a water flow rate (VH2Oa) in the vapor phase included in the second inlet air flow are equal respectively to the flow rate (Va) of the first outlet air flow and to the water flow rate ( VH2Oa) included in the first outlet air flow, and wherein the discharge system (2) further comprises a second discharge device (18b) adapted to discharge (34) of a second condensate into the second air treatment module (6), and in which the data analysis module (24; 28) is also configured for: receive air treatment parameters of the second air treatment module (6), indicative of the treatment of the second inlet air stream, calculate (58) a flow rate of the second outlet air stream (Vb) based on the flow rate of the first inlet air stream (Va) and the air handling parameters of the second air handling module (6), estimate (58) a water flow rate (VH2Ob) included in the second outlet air flow based on said atmospheric data (P, T, Ur), the air treatment parameters of the second air treatment module and the flow rate of the second outlet air flow (Vb), estimate (58) the flow rate of the second condensate (Vcb) by subtracting the flow rate of water included in the second flow of outlet air (VH2Ob) from the flow rate of water included in the second flow of inlet air (VH2Oa), calculate (58) a second theoretical waiting time (∆tOFF) inversely proportional to the flow rate of the second condensate (Vcb), and command (32) the second unloading device (18b) so that a second effective waiting time (∆tOFF) between consecutive discharges performed (34) by the second unloading device (18b) is equal to the second theoretical waiting time (∆ tOFF). Exhaust system (2) according to claim 5, wherein the second air handling module (6) is operatively coupled to the first air handling module (4) so that a pressure (Pa), a temperature ( Ta) and a relative humidity (Ura) of the second inlet air stream are respectively equal to the pressure (Pa), temperature (Ta) and relative humidity (Ura) of the first outlet air stream, and in which the data analysis module (24; 28) is also configured for: receive a second pressure variation factor, a second temperature variation factor and a second relative humidity variation factor, calculate (58) the flow rate of the second outlet air flow (Vb) by applying the second variation factor of the pressure at the flow rate of the second inlet air flow (Va), calculate (58) a pressure (Pb), a temperature (Tb) and a relative humidity (Urb) of the second outlet air flow by applying the second pressure change factor, the second temperature change factor and the second factor respectively relative humidity variation respectively to the pressure (Pa), to the temperature (Ta) and to the relative humidity (URa) of the second inlet air flow, calculate (58) a density (db) and a title (tb) of the second outlet air flow using the following equations: where db is the density of the second outlet air stream, tb is the title of the second outlet air stream, Pb is the pressure of the second outlet air stream, Tb is the temperature of the second outlet air stream, URb is the relative humidity of the second outlet air stream, and PSb is a saturation pressure corresponding to the temperature of the second outlet air stream (Tb), and estimate (58) the flow rate of water included in the second air stream of outlet (VH2Ob) based on a product of the density (db), the title (tb) and the flow rate (Vb) of the second outlet air flow. Discharge system (2) according to any one of the preceding claims, in which the first discharge device (18a; 18b-18f) is enabled to discharge the first condensate (Vca) during a first time interval of activity (∆tON) , and in which the data analysis module (24; 28) is also configured for: - acquire the first time interval of activity (∆tON); - acquiring (50, 52) a first unloading time duration (∆tDRAIN) of the first unloading device (18a; 18b-18f); - calculate (54) a first variation between the first activity time interval (∆tON) and the first discharge time duration (∆tDRAIN) in order to detect anomalies (54) in the operation of the first discharge device (18a; 18b -18f). Drain system (2) according to claim 6, wherein the data analysis module (24; 28) is further configured to update (56) the atmospheric data and the estimate of the flow rate of the first condensate (Vca) in the case in where the first change is outside a reliability threshold. 9. Discharge system (2) according to claim 7 or 8 when dependent on 5, in which the second discharge device (18b) is enabled to discharge the second condensate (Vcb) during a second time interval of activity (∆tON) , and in which the data analysis module (24; 28) is also configured for: - acquire the second activity time interval (∆tON); - acquiring (50, 52) a second unloading time duration (∆tDRAIN) of the second unloading device (18b); - calculating (54) a second variation between the second activity time interval (∆tON) and the second discharge time duration (∆tDRAIN) so as to detect anomalies (54) in the operation of the second discharge device (18b); - update (56) the atmospheric data and each between the estimate of the flow rate of the first condensate (Vca) and the estimate of the flow rate of the second condensate (Vcb) if the first variation is different from the second variation. Discharge system (2) according to any one of the preceding claims wherein the data analysis module (28) is a remote module, and in which the unloading system (2) further comprises a controller (24) operatively coupled to the first unloading device (18a; 18b-18f) and in bidirectional communication with the data analysis module (28), the controller (24) being configured for: - receiving (40, 42) from the first unloading device (18a; 18b-18f) the first unloading time duration (∆tDRAIN); - send (44) the first download time duration (∆tDRAIN) to the data analysis module (28); - receiving (46, 62) the first theoretical waiting time (∆tOFF) from the data analysis module (28); - command (32) the first unloading device (18a; 18b-18f) so that the first effective waiting time (∆tOFF) is equal to the first theoretical waiting time (∆tOFF). Unloading system (2) according to claim 10 when dependent on 5, wherein the controller (24) is operatively coupled to the second unloading device (18b) and is also configured for: - receiving (40, 42) from the second unloading device (18b) the second duration of unloading time (∆tDRAIN); - send (44) the second download time duration (∆tDRAIN) to the data analysis module (28); - receiving (46, 62) the second theoretical waiting time (∆tOFF) from the data analysis module (28); - controlling (32) the second unloading device (18b) so that the second effective waiting time (∆tOFF) is equal to the second theoretical waiting time (∆tOFF); - follow a time schedule designed to prevent data transmission conflicts between the controller (24) and the data analysis module (28). Discharge system (2) according to claim 10 when dependent on 5 or according to claim 11, further comprising a bus (26), in which the controller (24) is operatively coupled to the second discharge device (18b) and to the first unloading device (18a) via the bus (26), and is also configured to schedule for the first unloading device (18a) and for the second unloading device (18b) a respective access to a common electrical power supply by controlling ( 32) the first discharge device (18a) and the second discharge device (18b) so that respective discharges do not occur at the same time. 13. Discharge method for discharging condensate of a pneumatic system (1) comprising an air treatment module (4; 6; 8; 10; 12; 14), comprising the steps of: - discharging a condensate (34) into the air treatment module by means of a discharge device (18a; 18b-18f); - acquire (56) atmospheric data (P, T, Ur) relating to an environment in which the pneumatic system is located (1); - estimate (58), on the basis of said atmospheric data, a condensate flow rate (Vca); - calculate (58) a theoretical waiting time (∆tOFF) inversely proportional to the condensate flow rate (Vca); - command (32) the unloading device (18a; 18b-18f) so that an effective waiting time (∆tOFF) between consecutive discharges performed by the unloading device (18a; 18b-18f) is equal to the theoretical waiting time (∆tOFF); The method according to claim 13, wherein the air handling module (4; 6; 8; 10; 12; 14) is configured to receive an inlet air stream and to provide an outlet air stream resulting from a treatment of the inlet air flow, the method further comprising the steps of: - receiving air treatment parameters of the air treatment module, indicative of the treatment of the inlet air flow; - receive a flow rate of the inlet air flow (VAIR); - estimating (58) a water flow rate (VH2O; VH2Oa) included in the inlet air flow based on said atmospheric data (P, T, Ur) and on the inlet air flow rate (VAIR); - calculating (58) an outlet air flow rate (Va) based on the inlet air flow rate (VAIR) and the air handling parameters of the air handling module; - estimate (58) a water flow rate (VH2Oa; VH2Ob) included in the outlet air flow based on said atmospheric data (P, T, Ur), on the air treatment parameters of the air treatment module and on the flow of the outlet air flow (Va); And - estimate (58) the condensate flow rate (Vca) by subtracting the water flow rate included in the outlet air flow (VH2Oa; VH2Ob) from the water flow rate included in the inlet air flow (VH2O; VH2Oa). Method according to claim 13 or 14, further comprising the steps of: - enabling the discharge device (18a; 18b-18f) to discharge (34) the condensate (Vca) during a time interval of activity (∆tON); - acquiring (50, 52) an unloading time duration (∆tDRAIN) of the unloading device (18a; 18b-18f); - calculate (54) a variation between the activity time interval (∆tON) and the discharge time duration (∆tDRAIN) in order to detect anomalies (54) in the operation of the discharge device (18a; 18b-18f) ; - update (56) the atmospheric data and the estimate of the condensate flow rate (Vac) in the event that the deviation is outside a reliability threshold. Pneumatic system (1) comprising an exhaust system (2) according to any one of claims 1 to 11 and the first air treatment module (4; 6; 8; 10; 12; 14), wherein the first exhaust device (18a; 18b-18f) is operatively coupled to the first air treatment module.