TWI432648B - Portable smart performance diagnosing apparatus for air compressor system and method therefor - Google Patents

Description

Portable intelligent performance diagnostic device for air compression system and method thereof

The present disclosure relates to an air compressor diagnostic technique, and more particularly to a portable intelligent performance diagnostic apparatus and method thereof for an air compressor system.

An air compressor (air compressor) is a mechanical device that generates air pressure energy by inputting mechanical energy, and is generally used to generate compressed air. In many work factories, such as semiconductor, chemical, food, machinery manufacturing, steel, metal and paper industries, it is often necessary to use a large amount of compressed air for transportation, dehydration, packaging, cleaning, control and many other functions. Air compressors can be divided into two types: positive displacement and dynamics. Most of the industrial use volumetric air compressors can be subdivided into reciprocating and rotary according to the pressure generation method. (Rotary) and other types of air compressors.

The air compressor system can be as shown in Fig. 1. Fig. 1 is a schematic diagram of an air compression system 100 used in a general plant. The air compression system 100 may be composed of one or more sets of air compressors (in the embodiment, the air compressors 110_1 to 110_2 are taken as an example), and the compressed air generated by the air compressors 110_1 to 110_2 is sent to the air dryer 130 via the distribution line 120. The air cleaner 140 and the air reservoir 150 and the like respectively perform cooling drying, filtration, and storage of the compressed air. The air compressors 110_1 110 110_2 use the motor 170 to drive the compressor 160 to compress the air to generate compressed air, and perform a preliminary air drying step using the cooler 190. The air compressors 110_1~110_2 are also equipped with a distribution box 180 that conforms to national standards to ensure safe use of electricity. Thereby, the user can take compressed air from the air reservoir 150 and the distribution line 120 to operate the end gas device 192, such as a pneumatic tool or the like.

In terms of plant facilities, the air compression system 100 consumes more power than other types of equipment, so if the air compression system 100 can be effectively and correctly improved, the power consumption of the plant can be reduced and the air compression system can be improved. Electricity efficiency. Moreover, the high-efficiency air compression system 100 is not only provided with an energy-saving motor or a high-efficiency compressor, but the key point is whether the efficiency of the overall system achieves the maximum cost saving effect. However, there are currently few equipments for performance monitoring of the entire air compressor system, and there is also a lack of portable system monitoring and diagnostic tools that can directly perform monitoring and performance analysis functions on existing air compressor systems, so that most of the plant air pressure When the machine system is operating, because the air compressor has low efficiency, poor matching, multiple empty cars at the same time, too high pressure setting, improper piping design, filter blockage, too small storage tank capacity, poor drainage, air leakage, and system The operating unit energy consumption (kWh/m ³ ) is greater than the normal unit energy consumption (kWh/m ³ ), resulting in wasted power but not known.

As described in detail herein, when a general factory planter is responsible for providing the compressed air of the plant, it is usually only considered whether it affects the normal operation of the gas end machine (such as the pneumatic tool of Fig. 1). If the end-of-line machine is tripped due to insufficient pressure or flow and affects production, the number of air compressors will generally be increased to provide sufficient compressed air volume for on-site use. This will result in multiple air compressors simultaneously. Empty vehicles waste was wasted, causing the cost of use to rise without knowing.

The "air compressor performance testing device" of the Chinese Patent Application No. 098102815 (Publication No.: 201028675) includes a detecting rod and a body, and the detecting rod is disposed in the air. In the compressed air storage container of the press, the detecting rod includes at least a first temperature sensor and a pressure sensor for measuring the temperature and pressure in the compressed air storage container. For measuring the temperature in the compressed air storage container; and at least a first pressure sensor for measuring the pressure in the compressed air storage container; the system is electrically connected to the detecting rod, and the body is The utility model comprises a computing processing unit electrically connected to the detecting rod for receiving and analyzing the measured state information of the detecting rod in the container, and generating at least one of the analysis results. An input interface for inputting measurement analysis conditions and a display display unit for displaying analysis results. . However, this air compressor performance test device is a stand-alone performance test tool, and it is impossible to measure the performance data of two or more air compressors at the same time. Compared with this case, multiple air compressors and analysis of system performance are obviously different.

Another conventional technique, for example, the "fluid mechanical on-line monitoring and diagnosis device and method" of the Republic of China Patent No. 515878, which uses a displacement meter and a tachometer to sense information such as the displacement of the center of the rotor and the rotational speed of the fluid machine. It is judged whether the fluid machine being monitored is faulty, so the above technology should not be able to measure the performance of the air compressor and analyze its system performance.

The present disclosure provides a portable performance diagnostic device for an air compression system that can quickly introduce an air compression system without affecting its operation, and is easy to manage the compressed air usage cost of the plant and consider the life cycle of the air compression system.

The present disclosure proposes a portable performance diagnostic device suitable for use in an air compression system comprised of at least one air compressor. The performance diagnostic device includes a measurement module, a data acquisition module and a performance diagnosis module. The measurement module continuously measures various performance parameters of the air compression system and the air compressor over a period of time to generate a plurality of analog signals. The data capture module coupled to the measurement module receives and converts the analog signal into a digital signal. The performance diagnostic module is coupled to the data acquisition module, and receives the digital signal to record and analyze performance information in a time base period according to the performance parameter and the specification parameter group of the air compression system, thereby estimating the above-mentioned time in a specific time. Diagnostic information for air compression equipment and air compression systems.

Viewed from another perspective, the present disclosure proposes a performance diagnostic method suitable for use in an air compression system comprised of at least one air compressor. The performance diagnostic method includes the following steps: continuously measuring various performance parameters of the air compression system and the air compressor over a period of time to generate a plurality of analog signals. And, these analog signals are received to convert them into digital signals. And receiving the digital signals to record and analyze the performance information in the time base period according to the performance parameters and the specification parameter set of the air compression system, thereby estimating the diagnostic information of the air compression device and the air compression system at a specific time.

Based on the above, the portable performance diagnostic device of the disclosed embodiment can be quickly applied to a well-set air compression system and can perform performance monitoring and management without affecting the operation of the air compression system. In detail, in this embodiment, the measurement module is placed in the to-be-measured point of the air compression system, and the relevant performance data of the air compressor system is continuously monitored in a time base period. This information will be collected into the performance diagnostic module for recording and analysis, in order to obtain a lot of performance statistics and further diagnose the life cycle and cost recovery of the air compressor system. On the other hand, the portable performance diagnostic device can also count and judge the air consumption of each period and the optimal operation mode of each air compressor for the user to adjust as a basis to further achieve the energy saving effect.

The above described features and advantages of the present invention will be more apparent from the following description.

The exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. In addition, wherever possible, the elements and/

In general, the air compressor system (hereinafter referred to as the air compressor system) of the current plant has few related equipments capable of providing overall and individual air compressors (air compressors), and lacks direct existing Diagnostic tool for performance analysis on air compressor systems. Therefore, the present embodiment develops a portable performance diagnostic device and a performance diagnosis method according to the above concept, so that it can be quickly applied to an existing air pressure system without affecting its operation, thereby providing an air pressure system and various air pressures. The ratio of specific power (kW/cmm) to unit energy consumption (kWh/m ³ ), electricity data, and even the operation of each air compressor at each time makes it easy to evaluate the effectiveness of the air compressor system and Energy saving.

2 is a block diagram of a portable performance diagnostic apparatus 200 according to an embodiment of the present disclosure, and FIG. 3 is a schematic diagram of a portable performance diagnostic apparatus 200 according to an embodiment of the present disclosure. Referring to FIG. 2 and FIG. 3 together with FIG. 1 , the portable performance diagnostic apparatus 200 is applicable to the air compressor system 100 of FIG. 1 , and includes an organism 210 and a measurement module 220 . The body 210 includes a data capture module 270 . And a performance diagnostic module 280. The housing 210 of FIG. 3 is a portable computer exterior, but is merely an example and is not limited thereto.

In the present embodiment, the portable performance diagnostic apparatus 200 also includes a man-machine interface 290, whereby the user can input commands or parameters, and output or display the performance analysis or diagnosis result of the performance diagnostic apparatus 200. In detail, the human interface can include the display unit 310 of FIG. 3 (here, the touch screen is exemplified, but not limited thereto), the keyboard 320 and the mouse 330, and the user can use the keyboard 320. And the mouse 330 or even the touch screen to input the specification parameters and related instructions, and use the display screen 310 to display information such as graphics or reports to let the user know more about the analysis and diagnosis results. In other embodiments, the human interface may also include various transmission interfaces, such as a video interface Array (VGA) display interface or a universal serial bus (USB) information transmission interface, etc. Analytical diagnostic results are transmitted to other locations for storage, display, and in-depth analysis.

The measurement module 220 reads the required parameters of the air compressor system and each air compressor with various non-destructive sensors. In this embodiment, the measurement module 220 includes a plurality of electrical and physical sensors, such as a current sensor 230 (such as a clip galvanometer, a collective meter or a power meter), and a voltage sensor 240 ( For example, a clamp voltmeter, a collective electric meter or a power meter, in this embodiment, it is not necessary to actually install a voltage sensor under a specific condition, where the voltage value can be directly input by the user as a substitute for the system voltage value), the air flow rate The sensor 250 (for example, a pipeline type or an insertion type flow meter, an ultrasonic flow meter, the application of the embodiment may not need to actually install an air flow sensor under certain conditions, where the air flow value can be directly input by the user. The rated flow rate of the air compressor is replaced by the air pressure sensor 260 and the like. According to design considerations, the sensors of this embodiment are all equipped with communication transmission standards, and the output signals range from 4 to 20 milliamperes (mA), and the sensors are respectively placed in the air compressor system 100 of FIG. .

For example, FIG. 4 is a schematic diagram of the portable performance diagnostic apparatus 200 installed in the air compressor system 100. Referring to FIG. 4 and FIG. 2 and FIG. 3 , the air pressure system 100 and the power distribution board 180 of each air compressor 110 or the input power supply end thereof should be provided with a current sensor 230 and a voltage sensor 240, which are simplified figures. The current sensor 230 and voltage sensor 240 are therefore not depicted in FIG. The air flow sensor 250 and the air pressure sensor 260 are respectively disposed in the end distribution line 120 and the air reservoir 150 required for the air pressure system 100 to be measured.

Thereby, the plurality of sensors 230-260 in the measurement module 220 can respectively generate various analog signals according to their characteristics (for example, analog current signal AIS, analog voltage signal AVS, analog flow signal AQS, and analog pressure). Signal APS). Those skilled in the art can determine the type, quantity, and location of the sensor for the necessary information that is easy to install and vary, and the present invention is not limited thereto. Specifically, the performance parameter of this embodiment may be a current parameter, a voltage parameter, a power parameter (also referred to as an electric power parameter), an air flow parameter, and an air pressure parameter of the air compressor system and each air compressor, but Not limited to this.

Referring to FIG. 2 again, the data acquisition module 270 in the body 210 receives the analog signals (such as the analog current signal AIS, the analog voltage signal AVS, the analog flow signal AQS, and the analog pressure signal APS) to be converted into the digital signal DS, and Output to the performance diagnostic module 280. In this embodiment, the data capture module 270 transmits the digital signal DS to the performance diagnostic module 280 by using the universal serial bus interface and other communication protocols. The data capture module 270 of the present embodiment uses the USB4711A data of Advantech. The acquisition module can take advantage of the plug-and-play and wide versatility of the USB interface, but the disclosure is not limited thereto. Other embodiments of the data capture module 270 and the transmission interface can be utilized by the embodiment. Achieve the above effects. In addition, if the long-distance wire signal attenuation between the data capture module 270 and the sensors 230-260 is considered, a voltage-current converter can be added between the two, and an operational amplifier can be used for signal feedback. Compensation, or wireless transmission of data using a wireless protocol module (such as the ZigBee module).

The performance diagnostic module 280 of FIG. 2 includes a memory unit 282 and a control unit 285, which can be based on a time base set by the user (the time base period of the embodiment can be several seconds to several years, but is not limited thereto) The readings of the sensors 230-260 are received and sorted into log records of various performance parameters for storage in the memory unit 282. The memory unit 282 of this embodiment should have at least 1 GB to 16 GB of permanent memory, but is not limited thereto. In this embodiment, each group of records may contain system operation information of several seconds to several years depending on the length of the time base period.

On the other hand, in the embodiment, the control unit 285 executes a software to analyze and estimate the air compressor system 100 and each air compressor by using the above-mentioned recording matching specification parameter group of the air compressor system 100, the electricity rate and other related information. 110 performance data, performance estimates for specific time (such as seconds to years) and its life cycle estimation. As shown in FIG. 5, FIG. 5 is a flowchart of a performance judging method according to an embodiment of the present disclosure. Referring to FIG. 5 in conjunction with FIG. 2, in step S510, the measurement module 220 of the portable performance diagnostic apparatus 200 first continuously measures the performance parameters of the air compressor system and each air compressor during the time base set by the user. (for example, the current parameter, power parameter, voltage parameter, air flow parameter, and air pressure parameter described above) to generate an analog current signal AIS, an analog voltage signal AVS, an analog flow signal AQS, and an analog pressure signal APS, respectively.

Specifically, if the portable performance diagnostic apparatus 200 interrupts the recording of the performance information due to the power interruption during the time base period, the portable performance diagnostic apparatus 200 automatically continues to record the space after the power is restored. Pressure system and performance information of each air compressor until the end of the time base period. In detail, when the portable performance diagnostic device 200 is activated, its internal recording status file is read to know whether the portable performance diagnostic device 200 is in the time base period. If it is in the time base period, the portable performance diagnostic device 200 directly performs the initialization operation of the data capture module 270, and continues to step S510 to continue recording the above performance information.

Next, in step S520, the data capture module converts the analog signal into a digital signal DS and transmits it to the performance diagnostic module 280 using a USB interface. The performance diagnosis module 280 sorts and stores the readings of the above performance parameters into a log record in step S530 for use in performance analysis and estimation. In addition, during the time base period, the present embodiment reads the readings of the respective sensors 230-260 at intervals of time, and when there is any reading (step S510) or storage reading (step S530), etc. When the error occurs, the error information is stored in the recording area of the memory unit 282, and then the portable performance diagnostic apparatus 200 is restarted to continue the operations of reading, sorting, storing, and the like.

Next, in step S540, the performance diagnosis module 280 can perform the specification parameter set according to the above-mentioned log record, air compressor system and each air compressor (the user can use the human machine interface 290 to set the specification parameter, but is not limited to This) to analyze the performance information in the time base period (such as the air compressor system and the operating time of each air compressor, power consumption statistics, load ratio and outflow statistics, energy efficiency and operating costs). Moreover, the performance diagnosis module 280 can further estimate the diagnostic information of each of the tested air compressors and the air conditioning system in a specific time (for example, in the next year or years, etc.), and the detailed procedure flow is shown in FIG. 6 FIG. 6 is a detailed flowchart of step S540 of FIG. 5.

As shown in FIG. 6, step S610 uses the current parameter, the voltage parameter, and/or the power parameter in each performance parameter to measure each air compressor at full load (herein referred to as a heavy vehicle state, that is, a gas supply state) or The power consumption of no load (referred to as the empty vehicle state, that is, the airless state, but the air compressor's motor continues to operate, so it is ineffective operation), thereby calculating the air compressor and the overall system Running time and power consumption statistics. The implementation manner of the calculation system power consumption can be as shown in FIG. 7, and FIG. 7 is a flow chart of the steps of calculating the system power consumption statistics in step S610. Since the present embodiment can use a collective electric meter or a clip-type galvanometer/voltmeter as the sensor, the individual power consumption of each air compressor can be measured, so that it is convenient to judge the sensor type in step S710.

When the measurement is performed by the collective electric meter, the process proceeds from step S710 to step S720, and the individual power consumption readings measured on the collective electric meters are summed to calculate the system power consumption of the air compressor system. In contrast, if a clip galvanometer/voltmeter is used, step S710 proceeds to step S730 to measure current parameters and voltage parameters of each air compressor by means of a clip galvanometer/voltmeter, and respectively in step S740. Calculate the individual power consumption of each air compressor and sum the power consumption of each air compressor to calculate the system power consumption of the air compressor system. The equation for calculating the individual power consumption is shown in equation (1):

D = I × V × PF × 1.732 .................. (1)

Where D is the individual power consumption of each air compressor, I is the current parameter measured by each air compressor, V is the voltage parameter measured by each air compressor, and PF is the power of each air compressor. Factor, in other words, PF is the ratio of effective electrical power to output electrical power in each air compressor. In this embodiment, the PF can also be a user-defined parameter. Those skilled in the art should be aware of the calculation method of the power factor, and will not be described here.

Next, please return to refer to FIG. 6. Step S620 can calculate the actual air outlet amount and the air consumption amount of the air compressor system and each air compressor by using the air flow parameter and the air pressure parameter. In this embodiment, the system air output of the air compressor system can be calculated as shown in FIG. 8. FIG. 8 is a flow chart of the steps of calculating the system air volume statistics in step S620. As shown in FIG. 8, when the performance diagnostic device 200 is equipped with an air flow sensor (or flow meter) in the end delivery line of the air compressor system, step S810 can be followed to step S820 to utilize the air flow sense. The reading on the detector is used as the system air output of the air compressor system.

In contrast, if the air flow sensor is not installed in the end distribution line of the air compressor system, the process proceeds from step S810 to step S830, and each air is calculated according to the rated output flow value of each air compressor and the individual load state. The individual outgassing amounts of the press are summed at step S840 to calculate the theoretical system outflow. Among them, the rated value of each air compressor (such as the rated output flow value, rated power consumption, rated air output and other information) can be inquired by the manual, the nameplate installed on the air compressor.

Fig. 9 is a flow chart for calculating the individual outgassing statistics of the respective air compressors in step S620. Since the calculation of the air volume of the air compressor is based on the operation mode of the air compressor, the air compressor and its unit time in three different modes (air and heavy vehicle mode/frequency conversion mode/capacity mode) are listed in this embodiment. The method of calculating the amount of gas output. Those skilled in the art should be aware that the air compressor should have other modes of operation and calculation of the amount of gas per unit time, and should not be limited to this.

Referring to FIG. 9, when the operation mode of the air compressor is the empty and heavy vehicle mode, the process proceeds from step S910 to step S920. The portable performance diagnostic device 200 utilizes the rated output flow value Q _rated of the air compressor and the air compressor is located at the weight. The ratio of the time between the vehicle mode and the empty vehicle mode is used to calculate the individual air output of the air compressor. The rated output flow rate value Q _rated can be set by the user after referring to the manual of each air compressor or the data imprinted on the nameplate. When the air compressor is in the state of heavy truck (full load), the air output at this time is the rated output flow value Q _rated , and when the air compressor is in the empty (no load) state, the air output is 0.

In addition, when the operation mode of the air compressor is the frequency conversion mode, the steps S910 and S930 proceed to step S940, and the calculation method of the air volume is as shown in the formula (2):

Among them, C is the air output of the air compressor, Q _{rated is} the rated output flow value of the air compressor, f _{act is} the actual running frequency of the air compressor, and f _{full is the} air compressor under full load. Operating frequency.

If the operation mode of the air compressor is the tolerance mode, then step S910 proceeds to step S960 via steps S930 and S950, and the calculation method of the air volume is as shown in equation (3):

Among them, C is the air _{output of the} air compressor, I _{act is} the actual running current of the air compressor, I _noload is the running current of the air compressor under no load (also known as no-load current), I _full The running current of the air compressor under full load (also known as full load running current), and Q _{rated is} the rated output flow value of this air compressor. In general, the no-load current of a volumetric air compressor is approximately 60% of the full-load operating current. Based on the above, the method illustrated in FIG. 9 should be able to calculate the individual air output of all air compressors 110 in the air compressor system 100 of FIG.

Next, returning to FIG. 6, step S630 considers various strategies to confirm the theoretical output gas volume of each air compressor, to determine the energy consumption benchmark of each air compressor, and determine the power consumption per unit air volume, thereby establishing compressed air. The relationship between power consumption and power consumption is used to truly measure the performance of the air pressure system.

Those skilled in the art should have a variety of considerations in step S630 to confirm the theoretical output gas volume of each air compressor. Three types of considerations are proposed here: empty vehicle control, volume control and frequency conversion control. The empty and heavy vehicle control integrates and adds the air outlets of all the heavy vehicle states, thereby obtaining the theoretical air volume and integrating all the heavy vehicle states with the air compressor power consumption of the empty vehicle state. Get information such as actual power consumption. The tolerance control is similar to the variable frequency control, which is to interpolate the power consumption at each time point to obtain the ratio of the air volume at each time point (the frequency of the air flow is changed due to the variable frequency air compressor opportunity, so the air volume ratio It can also be called the speed ratio), and the integral sum is added to obtain the theoretical air volume (as shown in Figures 8 and 9) and the actual power consumption.

Please continue to refer to FIG. 6. Step S640 divides the operation time of each air compressor by the running time (if the whole day is used, the time base period is taken as the standard), thereby calculating the air compressors. Load ratio. Moreover, in step S650, the energy consumption of the air compressor system and each air compressor is separately divided by the output air volume, and the energy consumption ratio of the power consumption amount and the output air volume can be calculated, that is, the specific power value (kW/cmm). ), and divide the specific power value (kW/cmm) by 60 to obtain the unit energy consumption (kWh/m ³ ). On the other hand, in step S660, the portable performance diagnostic apparatus 200 can also use the electricity rate, the operation time of each air compressor, and the related operation information of the system to calculate the operating cost information of the system and each air compressor.

Through the calculation statistics of steps S610 to S650, the portable performance diagnostic apparatus 200 performs statistical operations on the performance records of the time base one by one, and displays these available charts. In addition, the portable performance diagnostic apparatus 200 may also estimate the power consumption prediction information, the load ratio information, and the air pressure of the air compressor system and each air compressor at a specific time (for example, one year or several years thereafter) at step S660. The life cycle information of the machine, and whether or not the air compressor needs to be replaced, and in the step S680 of the embodiment, the operation matching suggestions of the air compressors under different time conditions are established, thereby indicating the optimal energy-saving operation state and the like. Item information. In other words, the portable performance diagnostic apparatus 200 can calculate in accordance with the percentage of time of the air compressor system at full load operation (ie, the heavy vehicle state) and the percentage of the partial load operation time of the individual air compressors in step S680, thereby achieving savings. Energy recommendations and changes in usage scenarios based on time conditions so that air compressor systems can achieve energy savings based on these scenarios.

The following describes various embodiments and the flow of steps of FIGS. 10 to 14 to support step S680, thereby providing suggestions for improvement in related operational matching, energy saving, and warning abnormality. FIG. 10 and FIG. 11 are flowcharts for determining the improvement of the individual power consumption and the individual air output of each air compressor by the portable performance diagnostic apparatus 200, and FIG. 12 to FIG. 14 are respectively portable performance diagnostics. A flow chart for determining the improvement of the system air output, system pressure, and specific power of the air compressor system by the device 200. It is specifically noted that the embodiments are in accordance with the relevant examples of the disclosure, but those skilled in the art should readily understand that the disclosure is not limited to the embodiments.

Referring to FIG. 10, the portable performance diagnostic apparatus 200 uses the individual power consumption of each air compressor to perform power saving improvement suggestions. In detail, in step S1010, the rated power consumption P _rated of each air compressor and the judgment parameter E set by the user are used first to calculate the maximum power consumption threshold P _max and the minimum power consumption threshold P _min , and the calculation thereof is calculated. The equation is as shown in equation (4):

_{P max = (100% + E} %) × P rated

_{P min = (100% - E} %) × P rated .................. (4)

The judgment parameter E refers here to the tolerance parameter of the power consumption and/or the outflow amount of each air compressor, and this parameter is changed according to the model and operation mode of the air compressor. In general, the judgment parameter E can be set to 20, but the present invention is not limited thereto. The application of this embodiment can also set different judgment parameters E for air compressors of different machine types.

Next, in step S1020, it is determined whether the individual power consumption of the air compressor is greater than the maximum power consumption threshold P _max or less than the minimum power consumption threshold P _min , thereby determining whether the power consumption of the air compressor is reasonable. In the scope. If the power consumption of the air compressor is within a reasonable range, no action such as warning and suggestion is required (step S1040). In contrast, if the power consumption of the air compressor is out of the reasonable range (step S1030), the user needs to be alerted that the power consumption value of the air compressor has abnormalized, and the portable performance diagnostic apparatus 200 is utilized. The integrated information proposes improvements to the individual power consumption of this air compressor.

Referring to FIG. 11, the portable performance diagnostic apparatus 200 performs power saving improvement suggestions using the individual air outlet amounts of the air compressors. In detail, in step S1110, the rated outflow F _rated of each air compressor and the judgment parameter E set by the user are used first to calculate the minimum exit threshold F _min , and the calculation equation is as shown in the formula (5):

F _min = (100% - E %) × F _rated ..................(5)

The determination parameter E of the embodiment is the same as the determination parameter E of the embodiment of FIG. 10, and the determination parameter E of the power consumption and the air output amount can be separately set for each model of the air compressor, without being limited to this.

Thereby, in step S1120, it is determined whether the individual air outlet amount of the air compressor is less than the minimum air outlet threshold _Fmin , thereby determining whether the air outlet amount of the air compressor is within a reasonable range. If the air volume of the air compressor is within a reasonable range, no action such as warning and suggestion is required (step S1140). In contrast, if the air volume of the air compressor is lower than the reasonable range (step S1130), the user needs to be alerted that the air outlet value of the air compressor has abnormality, and is integrated by the portable performance diagnostic device 200. The information suggests improvements to the individual air output of this air compressor.

Referring to FIG. 12, the portable performance diagnostic apparatus 200 uses the total outgas flow statistics of the air compressor system to perform power saving improvement suggestions. In detail, in step S1210, the maximum outflow amount _Bmax and the minimum outflow amount _{Bmin of the} total gas output of the system are obtained by using the previous statistical data, thereby calculating the maximum value _Bdiff of the air pressure system in the flow difference (ie, The flow difference maximum value B _diff is equal to the maximum outflow amount B _{max of the} total system outflow amount minus the minimum out air volume B _min ). Moreover, the portable performance diagnostic apparatus 200 determines in step S1220 whether the air compressors in the air compressor system are not variable frequency air compressors, so as to propose relevant operation suggestions.

If all the air compressors are not variable frequency air compressors, then proceed to step 1230, the portable performance diagnostic device 200 will suggest that the user replace or add a variable frequency air compressor, the frequency conversion air compressor The output gas volume should be greater than the maximum value of the flow difference B _diff . In this way, the old air-to-air vehicle air compressor can be used as the basic load, and the operating frequency of the above-mentioned variable frequency air compressor can be dynamically adjusted to provide an insufficient variable air volume, thereby providing energy saving improvement suggestions according to the system air output. . In contrast, if all the air compressors have a variable frequency air compressor, other energy saving improvement suggestions are proposed in step S1240.

Referring to FIG. 13, the portable performance diagnostic apparatus 200 utilizes system pressure statistics of the air compressor system to perform power saving improvement suggestions. In detail, in step S1310, the maximum pressure value S _max and the minimum pressure value S _min of the system pressure are obtained by using the previous system pressure statistics, and the difference maximum value S _diff of the pressure change of the system pressure is calculated (ie, The pressure difference maximum value S _diff is equal to the maximum pressure value S _{max of the} system pressure minus the minimum pressure value S _min ).

Then, if the air compressors in the air compressor system are all air compressors in the empty and heavy vehicle mode (step S1320), and when the pressure difference maximum value S _{diff is} greater than the unloading pressure setting value and the loading pressure setting value of the entire air compressor system When the difference is between (step S1330), it means that the actual amount of compressed air in the moment is greater than the sum of the maximum flow of each air compressor in the air compressor system. In other words, the measured compressed air consumption is too large. Therefore, it is judged that the air pressure system causes the compressed air to be worn out or overflowed during the process of transmitting the compressed air. Therefore, it is convenient to warn the user in step S1340 that the pressure drop is too large and abnormal, and it is recommended to further perform related checks on the air pressure system, such as whether the distribution pipeline is leaking, whether the pipeline is too small, whether the gas storage tank is too small, and whether the filter is Blocking, etc., to avoid the loss or overflow of compressed air.

When the load change of the system pressure is the preset minimum value of the system, the process proceeds to step S1360 by step S1350, so that the portable performance diagnostic apparatus 200 can prompt the system pressure without affecting the normal operation of the end gas service device. It has a space for down-regulation and provides suggestions to gradually reduce the system pressure of the air compression system to reduce the demand for electricity, and also allows the end gas equipment to operate normally. In addition, the portable performance diagnostic device 200 also utilizes system pressure to provide other power saving suggestions in step S1370.

Referring to FIG. 14, the portable performance diagnostic apparatus 200 utilizes specific power statistics of the air compressor system to perform power saving improvement suggestions. In detail, in step S1410, the portable performance diagnostic apparatus 200 divides the system power consumption (in kW) by the total system air output (unit is cmm, that is, how many cubic meters of compressed air is output per minute). Value) to calculate the system specific power (kW/cmm) of the air compression system, and use this system to divide the power by 60 to calculate the system energy consumption per second (kWh/m ³ ).

Next, it is convenient to determine in step S1420 whether the power consumption of the system specific power/system unit is greater than the system specific power/system unit energy consumption in the normal state. If the actual system power consumption/system unit energy consumption is less than or equal to the normal value, it means that the power consumption is normal, and no action such as warning and suggestion is required (step S1440). In contrast, if the actual system power/system unit energy consumption is greater than the normal value, step S1420 proceeds to step S1430 to alert the power consumption abnormality message, and proposes energy saving improvement related to the specific power/system unit energy consumption. Suggest.

Herein, the above description is exemplified, and FIG. 15 is a schematic diagram for providing an operation and recommendation of the air compressors 110_1 to 110_2. Here, the air compressors 110_1 to 110_2 of the same FIG. 1 are taken as an example, and it is assumed that the horsepower and the models of the air compressors 110_1 to 110_2 are the same. The air-to-air vehicle waveform 1510 of the air compressors 110_1~110_2 indicates that the air compressors 110_1~110_2 are in the full load state (the heavy vehicle state) when the high pulse is present, and the air compressors 110_1~110_2 are in the low load when the low pulse is present. Status (empty state). As shown in FIG. 15, the portable performance diagnostic apparatus 200 can calculate the empty vehicle state of the air compressors 110_1~110_2 (that is, the empty weight vehicle waveform 1510) according to steps S610 to S670 of FIG. 6, and utilize these empty The percentage of heavy vehicle running time of the presses 110_1~110_2 is calculated to obtain space for saving energy. Thereby, from the percentage of the empty and heavy vehicle time of FIG. 15, the load ratio of the air compressor 110_2 is low, and the air compressor 110_1 can be fully utilized to make up the load.

Therefore, the portable performance diagnostic apparatus 200 proposes the operation matching suggestion at step S680, so that the air compressor 110_1 is often in the heavy vehicle state, and the air compressor 110_2 is in the low speed idling state or even the air compressor 110_2 is turned off, thereby exempting the air compressor 110_2. The air compressor 110_2 consumes electric energy in an empty state. In general, the air compressor consumes about 1/3 to 1/2 of the state of the heavy vehicle in the empty state. Alternatively, when the air compressors 110_1~110_2 are air compressors in the inverter mode, the speed ratio recommendations of the air compressors 110_1~110_2 can also be dynamically proposed (as indicated by the operation matching recommendation 1530).

In the above, the smart performance diagnostic apparatus 200 of the present disclosure utilizes the air pressure system and the operation characteristics of the power supply and the distributed load of each air compressor, and transmits the measurement of FIG. 2 within the time limit (several seconds to several years). The module captures the readings of the relevant operational information and uses the input air compressor characteristics and performance data to predict the operating efficiency and trend of the air compressor system and each air compressor, so that the operating efficiency of the system that was difficult to obtain in the past is not only More accurate, and cost-predictable by quantitative results, allowing plant managers to control, improve and maintain the air pressure system, with a higher reference value of the diagnostic analysis report for plant energy management.

In summary, the portable performance diagnostic apparatus of the disclosed embodiment can be quickly applied to a well-set air compression system and can perform performance monitoring and management without affecting the operation of the air compression system. In detail, in this embodiment, the measurement module is placed in the to-be-measured point of the air compression system, and the relevant performance data of the air compressor system is continuously monitored in a time base period. This information will be collected into the performance diagnostic module for recording and analysis, in order to obtain a lot of performance statistics and further diagnose the life cycle and cost recovery of the air compressor system. On the other hand, the portable performance diagnostic device can also count and judge the air consumption of each period and the optimal operation mode of each air compressor for the user to adjust as a basis to further achieve the energy saving effect.

The present disclosure has been disclosed in the above embodiments, but it is not intended to limit the disclosure, and any one of ordinary skill in the art can make some changes and refinements without departing from the spirit and scope of the disclosure. The scope of protection of this disclosure is subject to the definition of the scope of the patent application.

100. . . Air compression system

110_1~110_2. . . Air compressor

120. . . Distribution line

130. . . Air dryer

140. . . air filter

150. . . Gas storage tank

160. . . compressor

170. . . motor

180. . . Distribution box

190. . . Cooler

192. . . End gas equipment

200. . . Portable intelligent performance diagnostic device

210. . . Body

220. . . Measurement module

230. . . Current sensor

240. . . Voltage sensor

250. . . Air flow sensor

260. . . Air pressure sensor

270‧‧‧ data capture module

280‧‧‧Development Diagnostic Module

282‧‧‧ memory unit

285‧‧‧Control unit

290‧‧‧Human Machine Interface

310‧‧‧Display unit

320‧‧‧ keyboard

330‧‧‧ Mouse

1510‧‧‧ Empty and heavy vehicle waveform

1520, 1530‧‧‧ Operational recommendations

AIS‧‧‧ analog current signal

AVS‧‧‧ analog voltage signal

AQS‧‧‧ analog flow signal

APS‧‧‧ analog pressure signal

DS‧‧‧ digital signal

S510~S1440‧‧‧Steps

Figure 1 is a schematic diagram of an air compression system used in a general plant.

2 is a block diagram of a portable performance diagnostic apparatus according to an embodiment of the present disclosure.

FIG. 3 is a schematic diagram of a portable performance diagnostic apparatus according to an embodiment of the disclosure.

4 is a flow chart of a performance determination method according to an embodiment of the present disclosure.

FIG. 5 is a flowchart of a performance determination method according to an embodiment of the present disclosure.

Figure 6 is a detailed flow chart of step S540 of Figure 5.

FIG. 7 is a flow chart showing the steps of calculating the system power consumption statistics in step S610.

FIG. 8 is a flow chart showing the steps of calculating the system air volume statistics in step S620.

Fig. 9 is a flow chart for calculating the individual outgassing statistics of the respective air compressors in step S620.

FIG. 10 and FIG. 11 are flowcharts for determining the improvement of the individual power consumption and the individual air output of each air compressor by the portable performance diagnostic device.

12 to FIG. 14 are flowcharts for judging the improvement of the system air output, system pressure and specific power of the air compressor system by the portable performance diagnostic device.

Fig. 15 is a schematic view showing the advice of the operation of the air compressor.

200. . . Portable intelligent performance diagnostic device

210. . . Body

220. . . Measurement module

230. . . Current sensor

240. . . Voltage sensor

250. . . Air flow sensor

260. . . Air pressure sensor

270. . . Data capture module

280. . . Performance diagnostic module

282. . . Memory unit

285. . . control unit

290. . . Human machine interface

Claims (15)

A performance diagnostic method for an air compression system consisting of at least one air compressor, the performance diagnosis method comprising: continuously measuring the air compression system and various performance parameters of the air compressors over a period of time, Generating a plurality of analog signals; receiving and converting the analog signals into a plurality of digital signals; and receiving the digital signals to record and analyze the time base period according to the performance parameters and a specification parameter group of the air compression system a performance information for estimating a diagnostic information generated by the air compression device and the air compression system at a specific time, wherein the performance parameters include the air compression system and a plurality of current parameters of the air compressors The voltage parameter, the plurality of air flow parameters and the plurality of air pressure parameters, and recording and analyzing the performance information according to the performance parameters and the specification parameter group include the following steps: calculating a current parameter according to the current parameters and the voltage parameters System running time, one system power consumption statistics, one other running time and one consumption Quantitative statistics; according to the air flow parameters and the air pressure parameters, to calculate and measure a system air volume statistics and a different gas output statistics; consider the theoretical air volume statistics of the air compressors and The individual air volume statistics are determined; the individual running time is divided by a total running time to calculate an additional load ratio statistics; and the system power consumption statistics are divided by a system output air volume statistics to generate a system energy consumption efficiency statistics. And dividing the individual power consumption statistics by a different output air volume statistics to generate an energy consumption efficiency statistic, wherein calculating the system power consumption statistics further includes the following steps: when using multiple collective meters to measure the air When a plurality of power parameters of the compressor are used, the plurality of individual power consumptions measured by the collective meter are summed to calculate a system power consumption; when multiple clip galvanometers and multiple clip voltages are used Calculating the respective current parameters of the air compressors and the voltage parameters, respectively calculating the individual power consumption of each air compressor, and These individual consumption summed to calculate the power consumption of the system, and calculated for each of the respective air compressor power consumption equation is: D = I × V × PF × 1.732 wherein, D for individual consumption The quantity, I is the current parameter corresponding to each air compressor, V is the voltage parameter corresponding to each air compressor, and PF is the power factor of each air compressor. The performance diagnosis method of claim 1, wherein the performance information includes system operation time, system power consumption statistics, system air volume statistics, system air consumption statistics, and system of the air compression system during the time base period. Energy efficiency statistics, system operating cost information, individual operating hours of each air compressor, individual power consumption statistics, individual gas output statistics, individual energy efficiency statistics, and individual operating cost information. According to the performance diagnosis method described in claim 2, the performance information is recorded and analyzed according to the performance parameters and the specification parameter group, including the following steps: calculating the operation of the system according to the current parameters and the voltage parameters. Time, the system power consumption statistics, the individual operating time and the individual power consumption statistics; according to the air flow parameters and the air pressure parameters, calculate and measure the system air volume statistics and the individual air volume statistics Considering a plurality of theoretical airflow statistics of the air compressors and determining the individual airflow statistics according to the calculation; dividing the individual operating hours by a total running time to calculate the individual load ratio statistics; and calculating the system consumption The electricity consumption is divided by the output air volume statistics of the system to generate energy consumption efficiency statistics of the system, and the individual power consumption statistics are divided by the individual output air volume statistics to generate the individual energy consumption efficiency statistics. According to the performance diagnosis method described in claim 3, the performance information is recorded and analyzed according to the performance parameters and the specification parameter group, and the following steps are further included: according to an electricity rate, the system running time, and the individual operation. Time to calculate the system operating cost information of the air compression system and the individual operating cost information of each air compressor. For the performance diagnosis method described in claim 1, the recording and analyzing the performance information according to the performance parameters and the specification parameter group further includes the following steps: The percentage of time counted according to the system load ratio is calculated and the percentage of time counted for the individual load ratio is calculated to obtain an energy saving recommendation. The performance diagnostic method of claim 1, wherein the diagnostic information includes an air compression device and an operational matching suggestion of the air compression system under different time conditions. The performance diagnostic method of claim 1, wherein the diagnostic information includes a power consumption improvement suggestion, and the generating the individual power consumption improvement suggestion comprises the following steps: when a preset air compressor is consumed When the power is greater than a maximum power consumption threshold of the preset air compressor or less than a minimum power consumption threshold of the preset air compressor, the power consumption value of the preset air compressor is abnormal, and the individual is proposed The power consumption improvement suggestion, wherein the equation for calculating the maximum power consumption threshold and the minimum power consumption threshold is: P _max = (100% + E %) × P _rated P _min = (100% - E %) × P _rated P _{max is} the maximum power consumption threshold, P _{min is} the minimum power consumption threshold, P _rated is a rated power consumption of the preset air compressor, and E is a determination parameter. The performance diagnostic method according to claim 1, wherein the diagnostic information includes a proposal for improvement of the gas output, and the improvement of the individual gas output includes the following steps: when a predetermined air compressor has a different gas output amount When the minimum air outlet threshold of the preset air compressor is less than the minimum air outlet threshold of the preset air compressor, the air outlet value of the preset air compressor is abnormal, and the individual air volume improvement suggestion is proposed, wherein the equation for calculating the minimum air outlet threshold is: F _min = (100% - E %) × F _rated F _{max is} the minimum outlet enthalpy value, F _rated is a rated air output of the preset air compressor, and E is a judgment parameter. The performance diagnosis method according to claim 1, wherein the diagnosis information includes a system air volume improvement suggestion, and the system air supply improvement suggestion includes the following steps: obtaining the system air volume in the system air volume statistics One of the maximum outflow and one minimum outflow to calculate the maximum difference in the flow rate of the system; and when the operating modes of the air compressors are not in the inverter mode, it is recommended to replace or add a new one. The air compressor and the air compressors in the heavy vehicle mode are used as the base load, so that the variable frequency air compressor provides insufficient variation of the air volume, wherein the output air volume of the frequency conversion air compressor is greater than the maximum difference of the flow variation . The performance diagnostic method of claim 1, wherein the performance information includes a system pressure statistic, the system includes a system pressure improvement suggestion, and the system pressure improvement recommendation includes the following steps: pressure statistics in the system Obtaining a maximum pressure value and a minimum pressure value of a system pressure to calculate a maximum value of a pressure change difference of the system pressure; and when the operation modes of the air compressors are all empty and heavy vehicle modes, and the pressure change The difference maximum is greater than an unloading pressure setting and a loading pressure When the difference between the set values is set, the pressure drop of the air compression system is warned to be too large, and it is recommended to check the air compression system. The performance diagnosis method according to claim 1, wherein the system pressure improvement suggestion further comprises the following steps: when the load change of the system pressure is a preset minimum value, prompting without affecting normal operation The system pressure has a down-conversion space and provides recommendations to gradually reduce the system pressure of the air compression system. The performance diagnostic method of claim 1, wherein the diagnostic information includes a specific power improvement suggestion, and the generating the specific power improvement suggesting includes the following steps: calculating a system specific power of the air compression system, wherein the system The specific power is a system power consumption divided by the value of a system air output; and when the system specific power is greater than the normal system specific power, a power consumption abnormality message is alerted, and the specific power improvement suggestion is proposed. For example, the performance diagnosis method described in claim 1 further includes: automatically recording the performance information after the power is restored in the event that the performance information is interrupted due to the power interruption until the end of the time base period. A performance diagnostic method for an air compression system consisting of at least one air compressor, the performance diagnosis method comprising: continuously measuring the air compression system and various performance parameters of the air compressors over a period of time, Generating a plurality of analog signals; receiving and converting the analog signals into a plurality of digital signals; Receiving the digital signals to record and analyze one of the time base periods according to the performance parameters and a specification parameter set of the air compression system, thereby estimating the air compression devices and the air generated in a specific time a diagnostic information of the compression system, wherein the performance parameters include the air compression system and the plurality of current parameters of the air compressor, the plurality of voltage parameters, the plurality of air flow parameters, and the plurality of air pressure parameters, according to the performance The parameter and the parameter parameter group are used to record and analyze the performance information, including the following steps: calculating a system running time, a system power consumption statistics, a different running time, and a power consumption according to the current parameters and the voltage parameters. Quantitative statistics; according to the air flow parameters and the air pressure parameters, to calculate and measure a system air volume statistics and a different gas output statistics; consider the theoretical air volume statistics of the air compressors and The individual air volume statistics are determined; the individual running time is divided by a total running time to calculate a different Load ratio statistics; and divide the system power consumption statistics by a system output air volume statistics to generate a system energy consumption efficiency statistics, and divide the individual power consumption statistics by a separate output air volume statistics to generate an energy consumption efficiency Statistics, wherein calculating the system air volume statistics further comprises the following steps: when an air flow sensor is used, a system air output of the air compression system is a reading of the air flow sensor; When the air flow sensor is not used, an air output of each air compressor is calculated according to a rated output flow value of each air compressor and the corresponding individual load ratio, and the individual The amount of gas output is added to calculate the gas output of the system. A performance diagnostic method for an air compression system consisting of at least one air compressor, the performance diagnosis method comprising: continuously measuring the air compression system and various performance parameters of the air compressors over a period of time, Generating a plurality of analog signals; receiving and converting the analog signals into a plurality of digital signals; and receiving the digital signals to record and analyze the time base period according to the performance parameters and a specification parameter group of the air compression system a performance information for estimating a diagnostic information generated by the air compression device and the air compression system at a specific time, wherein the performance parameters include the air compression system and a plurality of current parameters of the air compressors The voltage parameter, the plurality of air flow parameters and the plurality of air pressure parameters, and recording and analyzing the performance information according to the performance parameters and the specification parameter group include the following steps: calculating a current parameter according to the current parameters and the voltage parameters System running time, one system power consumption statistics, one other running time and one consumption Quantitative statistics; according to the air flow parameters and the air pressure parameters, to calculate and measure a system air volume statistics and a different gas output statistics; consider the theoretical air volume statistics of the air compressors and The individual air volume statistics are determined; the individual running time is divided by a total running time to calculate an additional load ratio statistics; and the system power consumption statistics are divided by a system output air volume statistics to generate a system energy consumption efficiency statistics. And dividing the individual power consumption statistics by a different output air volume statistics to generate an energy consumption efficiency statistic, wherein calculating the individual air output statistics of each air compressor further comprises the following steps: when a preset air compressor When the operation mode is the empty and heavy vehicle mode, according to a rated output flow value of the preset air compressor and a time ratio between the preset air compressor and the empty vehicle mode and the empty vehicle mode, an air output amount is calculated, Wherein the preset air compressor is one of the air compressors; and when the operation mode of the preset air compressor is the frequency conversion mode, the individual air outlet amount The rated output flow value is multiplied by an actual operating frequency of the preset air compressor and divided by a value of a full-load operating frequency of the preset air compressor; and when the operating mode of the preset air compressor is a tolerance In the mode, the equation for calculating the individual outgassing amount is: Where C is the individual air _output , _{Iact is} the actual running current of the preset air compressor, I _{noload is} the no-load current of the preset air compressor, and I _{full is} the full-load running current of the preset air compressor And Q _{rated is} the rated output flow value.