JP2002098061A - Diagnostic device for electric air compressor or compressed air supply system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a device capable of diagnosing the working state of a compressor at real time. SOLUTION: Each electric air compressor connected to a compressed air supply system is provided with a sensor for detecting the state of the electric air compressor. Signals from the sensor is recorded and transmitted to a wireless or wire communication means, and the propriety of the working state of the compressed air supply system itself or the electric air compressor connected to the compressed air supply system is computed on the basis of the signals.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a compressed air supply system in a compressed air supply system in which a plurality of electric air compressors are connected to a common air tank, or to the above-mentioned electric air compressor connected thereto. The present invention relates to a determination device for determining whether a use state is appropriate.

[0002]

2. Description of the Related Art Conventionally, in factories that use air tools such as a plurality of air actuators and air motors, a plurality of electric air compressors are used in order to constantly supply compressed air having a stable pressure to each of a plurality of air tools. It is common to use a compressed air supply system that stores compressed air from the air tank in a common air tank (receiver tank) and distributes the compressed air from the air tank to a plurality of air tools. As means for judging the state of each electric air compressor or the whole compressed air supply system, there is known a means for calculating a power cost of the compressor by calculating a suction air amount of the compressor and a load factor of the compressor. (See JP-A-9-32806).

In the conventional technique, data is collected on site, the obtained data is stored in a recording medium such as an FD, and the data is brought to a place where an analysis device is located, analyzed, and the result is analyzed. They were printed and viewed on a monitor.

[0004] Such a thing is also necessary for the compressor itself, but a plurality of compressors are connected and used.
Needless to say, it is also necessary for the entire compressed air supply system to increase the efficiency as a whole. For example, 5 in one air tank
In the compressed air supply system to which the air compressors of the compressors are connected, the number of air compressors 1 to 5 is 8 in accordance with the air consumption.
It is operated at an arbitrary load factor such as 0%, 72%, 100%, 15%, 55%, etc., and when the amount of consumed air fluctuates, each load factor of Units 1 to 5 automatically fluctuates according to this fluctuation. Although it is used in such a way, it cannot be said that this is an efficient use of the compressor as a whole.

[0005] Because, as described above, when a plurality of air compressors are operated at any one of the load factors of 0 to 100% in accordance with the amount of consumed air, in the air compressor which operates at a load factor of 100%, Although the power work efficiency is maximized and there is no problem in terms of economy, air compressors operating at a load factor of 80%, 70%, 15%, etc. have poor power work efficiency and waste power energy. This increases the power consumption of the entire air compressor.

As means for solving such a problem, there is known a unit control panel in which a plurality of air compressors are selected and used as efficiently as possible according to the amount of consumed air. This unit control panel uses a plurality of air compressors at a load factor of 100% as much as possible in the same time zone to reduce the power consumption cost with respect to the air consumption, and has the following functions.

A number control panel is installed in a compressed air supply system in which a plurality of air compressors, for example, the first to fifth air compressors are connected to one air tank, and the first air compressor, for example, is used as a starter in the number control panel. , 2-5 are set as the latecomers. A pressure sensor for the compressed air discharge pressure is installed in the discharge main pipe of the air tank,
The first control unit is operated as a capacity regulator at a load ratio of 0 to 100% by a unit control panel so that the discharge pressure detected by the pressure sensor is maintained within a predetermined range. Nos. 2 to 5 are respectively operated at a fixed load ratio of 100% in a predetermined order.

[0008] For example, when the amount of consumed air discharged from the air tank and consumed is 450%, the first machine of the first machine is 50%
Driving at the load factor, 100% of each of the last four units 2-5
Operating at a load factor, a total of 450% compressed air is supplied. When the air consumption fluctuates by several tens of percent around 450%,
In response to this change, only the load factor of the starter fluctuates by several tens of percent, the air discharge pressure from the air tank is maintained within an allowable range, and the supply of compressed air at a predetermined pressure is maintained.

When the amount of consumed air fluctuates to 400% or less, the first unit of the first engine is stopped when the load factor drops to 0%, and the stopped first unit is the last one of the last units. And prepare for the next operation restart. At the same time, the second of the late engines operating at the 100% load factor is upgraded to the first engine as a capacity adjuster, and is designated as the next stop priority device and continues to operate at the 0-100% load factor.

As described above, by installing the unit control panel in the compressed air supply system, only one of the plurality of air compressors operates at a load factor of 0 to 100%, and the rest operates at a load factor of 1 to 100%.
Since the operation is performed at the load rate of 00% or the operation is stopped, the energy saving operation of the plurality of air compressors as a whole is performed as much as possible, and the overall power consumption is reduced. In addition, the air compressors that do not need to be operated are automatically stopped by the unit control panel, so that the compressed air supply system can be completely unmanned and labor costs can be reduced.

[0011]

However, the technique disclosed in Japanese Patent Application Laid-Open No. Hei 9-32806 is suitable for determining whether the compressor is used economically. It is hard to say that the usage status of the device is properly determined. This is because the adequacy of compressor usage and the economics do not always match.
For example, no matter how good it is used economically, it is hard to say that it is used properly if abnormally humid compressed air is supplied or if the produced compressed air is mixed with an odor. Because. That is, it is important to make a diagnosis in consideration of air quality.

[0012] Also, it is a serious problem whether the usage condition of the compressor is appropriate, and it is desirable to display the analysis result to the user in real time for the compressor having the problem, if possible. By doing so, it should be possible to perform appropriate processing before it becomes important. However, as in the past, data collected once was placed on a floppy disk, returned to the laboratory, and analyzed again. It was not possible to achieve the service of identifying a compressor with an abnormality or taking an early action on it.

Further, the economical advantage of installing a unit control panel in the compressed air supply system is as described above and known, but it is difficult to determine whether the unit control panel correctly achieves its function. The technology could not confirm it.

Accordingly, an object of the present invention is to clarify the degree of energy saving operation of a compressed air supply system using a plurality of electric air compressors at an arbitrary time zone and to control the number of control units for the compressed air supply system. It is an object of the present invention to provide a method and an apparatus for diagnosing an energy-saving driving degree which can be effectively used for judging whether or not to introduce the method.

[0015]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention provides a compressed air supply system for distributing compressed air to an external device from an air tank to which a plurality of electric air compressors are connected. The diagnostic device for the electric air compressor or the compressed air supply system which determines whether or not the use state of the electric air compressor connected to the compressed air supply system is proper or not. A sensor for detecting the state of the electric air compressor, data recording means for recording a signal from the sensor, and wirelessly or Transmitting means for transmitting to the wired communication means, and using the compressed air supply system itself or the electric air compressor connected to the compressed air supply system based on a signal from the transmission means. A diagnostic device for an electric air compressor or a compressed air supply system, comprising: a propriety calculating means for calculating propriety of a state; and an output means for outputting a calculation result by the propriety calculating means. I have.

As the above-mentioned sensor, a pressure sensor for detecting a suction pressure or a discharge pressure can be used. In this case, the data recording means records the detected suction pressure data or discharge pressure data at fixed time intervals, and the calculating means calculates the load of each electric air compressor based on the suction pressure data or discharge pressure data. The ratio can be determined at fixed time intervals, but with such a configuration, all electric compressors controlled by the unit control panel can be used while appropriately exhibiting the effect of unit control. You can check in real time whether you are. Further, an odor sensor for detecting the odor of the compressed air discharged from the electric air compressor can be used as the sensor. In this example, countermeasures are taken against the usage conditions that are not related to economics, such as abnormal heat generation of the packing due to poor usage conditions, and before distributing compressed air with an odor to the factory. It is possible to judge the suitability of the usage situation different from the economics, such as being able to do things. Further, the sensor may be configured as a humidity sensor for detecting the moisture of the compressed air discharged from the electric air compressor. In this case, distribution of the compressed air containing water harmful to the air tool can be prevented.

[0017]

Embodiments of the present invention will be described below with reference to the drawings.

The compressed air supply system 1 shown in FIG. 1 has a plurality of, for example, five (1st to 5th) electric air compressors 2,. Tank 3
Supplies compressed air to a plurality of external devices, for example, air tools 4,. The five air compressors 2,... Are driven by drive motors 5,.

The relay device 10 performs a relay function for collecting signals from various sensors 11 provided in the air compressor 2 and sending the signals to the transmitter 30 shown in FIG. The transceiver 30 transmits the data stored in the repeater 10 to the repeater 33 wirelessly. The data recording device 34 is a relay device 3
3 is a part for temporarily storing the data from. The data stored in the data recording device 34 is wirelessly transmitted from the transmitting / receiving device 35 to the transmitting / receiving device 36. The data received by the transmission / reception device 36 is sent to a computer 37, where the data is subjected to predetermined processing, and is subjected to diagnosis of the compressors 2, 2,. The result of the diagnosis is issued as a medical certificate by the printer PRT. The network between the transmission / reception devices 35 and 36 is not limited to wireless, but may be a network such as the Internet. The above-mentioned various sensors are provided in each of the air compressors, and detect measurement data for calculating the operation status data of the discharge air amount, discharge air and power consumption of the corresponding air compressors 2,. Specifically, the above-mentioned sensor detects a compressor suction pressure Ps [kgf / cm2G], a pressure sensor 21 which detects a compressor discharge pressure Pd [kgf / cm2G], and detects a compressor discharge temperature Td [° C]. Temperature sensor 22, the input current I of the compressor drive motor 5
A current sensor 23 and a voltage sensor 24 for detecting m [A] and an input voltage Vm [V], and a pressure sensor 25 for detecting a discharge pressure Pu [kgf / cm2G] of a discharge main pipe of the air tank 3 (in the unit) G represents the gauge pressure). In some cases, a moisture sensor 31 for detecting the moisture of the compressed air on the discharge side or an odor sensor 32 for detecting the odor may be used. Further, as another sensor, a smoke sensor, a microphone for detecting noise generated by the compressor, a vibration sensor for detecting vibration of the compressor, a sensor for detecting oil content, and a sensor for detecting solid particles may be used. is there. The above sensors are
It is sufficient to use a commercially available product conventionally used for the purpose of grasping the failure and the occurrence of abnormality of the compressor. For example, an XP-329 series (trade name) manufactured by Shin Cosmo Electric Co., Ltd. can be used as the odor sensor. This sensor, which senses various odors in general, is also commercially available with high sensitivity to hydrogen sulfide odor and ammonia. The compressor suction pressure Ps
The sensors 22 to 25 other than the sensor 20 for detecting [kgf / cm2G] or the pressure sensor 21 for detecting the compressor discharge pressure Pd [kgf / cm2G] are indispensable for obtaining the load factor, power consumption and discharge air amount. It is not used, but is selectively used as necessary in diagnosing the usage of the compressor. As described later, the pressure sensor 20 (or 21)
The load factor, the power consumption cost, and the discharge air amount can be obtained based on the data from. In this embodiment, a compressed air supply system 1 itself distributes and supplies compressed air from an air tank 3 to which a plurality of electric air compressors 2, 2,. Alternatively, the present invention relates to a diagnosis apparatus for an electric air compressor or a compressed air supply system for determining whether or not the use state of the electric air compressors 2, 2, ... connected to the compressed air supply system is appropriate. In particular, specifically, each of the electric air compressors 2, 2,... Connected to the compressed air supply system 1 is provided.
, A data recording means 34 for recording a signal from the sensor, and a transmission means (35) for transmitting data recorded in the data recording means 34 to a wireless or wired communication means. , 36), and based on the signal from the transmission means, whether the use state of the compressed air supply system 1 itself or the electric air compressors 2, 2,... Connected to the compressed air supply system 1 is appropriate. And a computer 37 which is an example of an appropriateness calculating means for calculating the above, and PRT which is an example of an output means for outputting a calculation result by the appropriateness calculating means.

Next, a specific diagnosis procedure will be described.
The detection signals from the noise sensor, the vibration sensor, the pressure sensor, the odor sensor, the moisture sensor, and the smoke sensor shown in “Diagnosis of individual compressors” are transmitted from the relay 10 to the transceivers 30 and 33 →
The data is sent to the computer 37 via the data recording device 34 → transceivers 35 and 36. The computer 37 may output (or display) the raw data as it is on the printer PRT or the monitor as it is, or may output a result of statistical processing of the continuous or intermittent data. In many cases, statistical processing is more effective in elucidating the cause of an abnormality. In this embodiment, the repeater 10 is placed in a factory where a compressor is installed. The data recording device 34 may be located in a factory, but will usually be located in a company office. The computer 37 may be located on the Internet server side, but is often located at a compressor maintenance service company. Of course, it is also possible to load a computer on a bus owned by a maintenance service company and to carry out maintenance services by going around each company. Wireless transmission / reception device 3
5 and 36 are useful because they enable wireless connection between the factory and the bus. With such a configuration, it is not necessary to transport the data stored in the data recording device to a floppy desk or the like, and the diagnosis can be immediately performed using the real-time data. The data processing procedure and where to place each device are the same in the case of the next diagnosis of the number control device.

"Diagnosis of the number control device" As described above,
As shown in FIG. 1, in this embodiment, various measurement data detected by various sensors are sent to the data recording device 34. This recording time interval can be set arbitrarily.
Usually, the interval is 30 minutes or 1 hour. The intake pressure and discharge pressure data recorded by the data recording unit 34 are sent to the computer 37 as they are. Computer 37
Calculates and records the load factors of the air compressors 2, at regular time intervals, at regular time intervals based on the current operating condition data input from the data recording device 34. Since the process of calculating the load factor from the intake pressure or the like is known, its description is omitted. As a result, the computer 37 records the change of the load factor every hour for each compressor as shown in Table 1.
In Table 1, the total air consumption is a sum of the load factors or a value proportional to the sum of the load factors. A load condition, that is, a load factor of 0 indicates that the compressor is stopped. By the way, as described above, in the unit control, one of the plurality of compressors (hereinafter referred to as a specific machine) is used at a load ratio exceeding 0% and less than 100%, and the other compressors are used at a load ratio of 0%.
By using either% or 100%, the efficiency of the other compressors described above is always maintained at the maximum, and an appropriate use situation is obtained when such use is performed.
In other words, if there are two or more specific machines that are used at a load factor of more than 0% and less than 100%, this means an inappropriate use situation as a number control device. Therefore,
The computer that obtained the results of Table 1 above searched Table 1 once an hour, and found in the data that the compressor used at a load factor of more than 0% and less than 100%, that is, If there are two or more machines, it is determined that the number control device is not operating properly. The result is output to an alarm device (not shown) or to the printer PRT. Explaining more specifically in Table 1, at 8:00, Unit 1 had a load factor of 9%.
Therefore, it is a specific compressor and other compressors are 0% or 100%.
%, And since there is only one specific device, it is determined that the device is normal. Even at 9 o'clock, the second machine is the specific machine, and the other machines are 0% or 100%, which is normal. In this way, the normal state continues until 17:00, but at 18:00, the first compressor is 22%, the third is 60%, and the two compressors are the specific compressors. You can see that it is running properly.

[0022]

In the above embodiment, a description has been given of the case where the diagnosis is performed on the use state of each compressor and the case where the number control device is diagnosed. However, the present invention is not limited to this. It is needless to say that the present invention is applied to all the cases where the connection is controlled to the air tank.

[Table 1]

[0023]

According to the present invention, a compressed air supply system for supplying and distributing compressed air to an external device from an air tank to which a plurality of electric air compressors are connected, or a compressed air supply system connected to the compressed air supply system. In the diagnostic apparatus for an electric air compressor or a compressed air supply system for judging whether or not the use state of the electric air compressor is used, the electric air compressor is provided in each electric air compressor connected to the compressed air supply system. A sensor for detecting a state of the electric air compressor, data recording means for recording a signal from the sensor, transmission means for transmitting data recorded in the data recording means to a wireless or wired communication means, A propriety calculating means for calculating propriety of a use state of the compressed air supply system itself or the electric air compressor connected to the compressed air supply system based on a signal from the transmitting means; And it is configured as a diagnostic device for an electric air compressor or compressed air supply system characterized by comprising equipped and output means for outputting the operation result by the advisability calculating means. Therefore, the appropriateness of the use state of the compressor is appropriately diagnosed, and the result of the diagnosis is output in real time, thereby eliminating the problem of causing an unexpected large accident.

For example, when a pressure sensor for detecting a suction pressure or a discharge pressure is used as the above sensor, the load factor of the compressor can be calculated, thereby diagnosing whether the compressor is used properly. You can do it. In this case, the data recording means records the detected suction pressure data or discharge pressure data at fixed time intervals, and the calculating means calculates the load of each electric air compressor based on the suction pressure data or discharge pressure data. The ratio can be determined at fixed time intervals, but with such a configuration, all electric compressors controlled by the unit control panel can be used while appropriately exhibiting the effect of unit control. You can check in real time whether you are. Further, an odor sensor for detecting the odor of the compressed air discharged from the electric air compressor can be used as the sensor. In this example, countermeasures are taken against the usage conditions that are not related to economics, such as abnormal heat generation of the packing due to poor usage conditions, and before distributing compressed air with an odor to the factory. It is possible to judge the suitability of the usage situation different from the economics, such as being able to do things. Further, the sensor may be configured as a humidity sensor for detecting the moisture of the compressed air discharged from the electric air compressor. In this case, distribution of the compressed air containing water harmful to the air tool can be prevented.

[Brief description of the drawings]

FIG. 1 is a block diagram of a compressed air supply system to which a diagnostic device for an air compressor according to an embodiment of the present invention can be applied.

FIG. 2 is a block diagram of the diagnostic device in FIG. 1;

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 compressed air supply system 2 air compressor 3 air tank 5 drive motor 10 repeater 30, 33, 35, 36 transmitting and receiving device 31 moisture sensor 32 odor sensor 34 data recording device 37 computer

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Masaaki Nose 3-8-2 Oyodonaka, Kita-ku, Osaka-shi EA11 EA13 EA16 EA20 EA23 EA38 EA49 EA50 3H089 BB01 CC01 CC11 DA05 FF01 FF07 FF12 GG03 JJ20

Claims (6)

[Claims] 1. A compressed air supply system itself for distributing compressed air to an external device from an air tank to which a plurality of electric air compressors are connected, or the electric air compression system connected to the compressed air supply system In a diagnostic device for an electric air compressor or a compressed air supply system for judging whether or not a use state of a compressor is appropriate, the diagnostic device is provided for each electric air compressor connected to the compressed air supply system. A sensor for detecting a state, data recording means for recording a signal from the sensor, transmission means for transmitting data recorded in the data recording means to a wireless or wired communication means, and a signal from the transmission means. Based on the compressed air supply system itself or the electrically operated air compressor connected to the compressed air supply system, and And an output means for outputting a calculation result. The diagnostic apparatus for an electric air compressor or a compressed air supply system. 2. The diagnostic apparatus for an electric air compressor or a compressed air supply system according to claim 1, wherein said sensor is a pressure sensor for detecting a suction pressure or a discharge pressure. 3. The data recording means records the detected suction pressure data or discharge pressure data at fixed time intervals, and the arithmetic means controls each electric air compressor based on the suction pressure data or discharge pressure data. 3. The diagnostic apparatus for an electric air compressor or a compressed air supply system according to claim 1, wherein the load factor is obtained at regular time intervals. 4. The diagnostic apparatus for an electric air compressor or a compressed air supply system according to claim 1, wherein said sensor is an odor sensor for detecting an odor of compressed air discharged from the electric air compressor. 5. A diagnostic device for an electric air compressor or a compressed air supply system according to claim 1, wherein said sensor is a humidity sensor for detecting the moisture of the compressed air discharged from the electric air compressor. 6. A diagnostic device for an electric air compressor or a compressed air supply system according to claim 1, wherein said sensor and said data recording device are connected by a predetermined communication means.