WO2011057606A2

WO2011057606A2 - Compressor for producing compressed air

Info

Publication number: WO2011057606A2
Application number: PCT/DE2010/001304
Authority: WO
Inventors: Christian KÜBRICH
Original assignee: Kübrich Ingenieurgesellschaft Mbh & Co. Kg
Priority date: 2009-11-11
Filing date: 2010-11-11
Publication date: 2011-05-19
Also published as: WO2011057606A3; DE102009052510A1

Abstract

The invention relates to a compressor for producing compressed air, comprising a compressor unit for compressing, a compressed-air tank, an electrical drive unit having a control device, and a connecting and/or converting device for connecting to the power grid, wherein the compressor has a processor-controlled control device for a variable compressed-air amount and/or pressure, which is accomplished by means of a variable, controllable output or rotational speed of the drive unit, and the compressor has means for detecting operating parameters, which can be fed to the control device.

Description

Compressor for generating compressed air

description

The present invention relates to a compressor for generating compressed air, in particular its components for driving a compression unit and the control of this drive, and the compressed air reservoir.

Many classic compressors for the production of compressed air are equipped with a reciprocating compressor, which is driven by an electric motor, which compresses air and conveys it into a reservoir. The drive is usually done with an AC motor which is directly connected to the drive shaft of the reciprocating compressor.

Such compressors are available in numerous designs from small flow rates to larger systems or combinations of several compressors.

A common version of small to medium size compressors used in workshops, on construction sites or for the mobile use of craftsmen works in a pressure range between 3 to 6 bar and has a compressed air supply steel tank of different sizes.

Usually, the compressors have a device, which is adjustable on some models, to detect the prevailing pressure and to switch off the engine when a set pressure is reached by means of a switch. As a rule, the engine is only disconnected from the mains.

As a drive for the reciprocating compressor usually an AC motor is used and such common asynchronous motors not ge

CONFIRMATION COPY gen high torque can start, according to the prior art, the pressure line between the compressor and the compressed air reservoir with switching off the engine, upon reaching the target pressure, vented. Such a compressor is disclosed by way of example in DE 39 23 882 C2, in which the engine can start easily due to the vent when switching on again.

Such widespread AC motors as are used for compressors are usually designed, when applied to a 50 to 60 Hz power grid, to a synchronization speed of about 3500 rpm and are expensive, e.g. Adjustable in frequency by means of frequency converter.

The usual, widespread compressor, therefore, starts at full speed of the drive motor and generated via the compressor, the predetermined pressure in the pressure tank. When the specified pressure is reached, the engine is completely switched off and the pressure line between the compressor and the pressure tank is vented, which is known to be accompanied by a typical hiss when the engine is switched off.

If the pressure falls below a certain value, the motor is reconnected to the mains and starts again at full speed to drive the compressor and the process repeats itself.

All systems operating in this way have the disadvantage that they unnecessarily consume a great deal of energy, in particular due to the release of the overpressure and the constant situation of the switching on and off of the drive motor. Such a process is comparable to a driving style of a vehicle with constantly maximum acceleration and strong deceleration before an obstacle, which is not very energy efficient.

It would be desirable to have a compressor or a system of a compressor which has a more efficient handling of the energy used, being compact, quieter and more flexible than known systems. Object of the present invention is to provide a compressor or a system for a compressor, which minimizes the known disadvantages of compressors, in particular those of the type described, and provides a more energy efficient, quieter and more compact compressor available.

This object is achieved with the features of the characterizing part of claim 1. Further developments and advantageous embodiments of the invention are included in the subclaims and in the following.

According to the invention, a compressor for generating compressed air, consisting of a compression unit for compressing a compressed air tank and an electric drive unit with a control device and a connection and / or conversion device to the power grid, wherein the compressor with a processor-controlled control device for a variable Druckluftmenge- and / or pressure is executed which takes place via a variable, controllable power output or rotational speed of the drive unit and the compressor has means to detect operating parameters which can be supplied to the control device.

The compressor is equipped, for example with a reciprocating compressor and the drive unit connected to the crankshaft, which takes place directly or via a suitable gear. Since according to the invention, the performance of the compressor is variable and is set via an operating interface of the control device, the compressor is equipped with a drive unit which is well variable in speed. Preferably, the compressor, due to the good efficiency and numerous other known advantages, with a brushless DC motor, also called brushless motor, equipped as a drive unit. Due to the relatively compact design with very good power output of such brushless motors, the compressor is also very compact and weight-optimized feasible.

Another great advantage of the preferred brushless motor is the fact that such motors can start against high torques at startup. Therefore, the compressor does not have to drain the pressure line from the compressor to the compressed air tank when switching off its drive unit, as is the case in the prior art compressor described.

The drive unit is connected to the control device, which is equipped with a controller for brushless motors or via a

Interface has to control such and communicate with them, wherein the control device is preferably designed as a unit with an integrated controller. The engine parameters and conditions under which the brushless motor is operated can be adjusted by means of a control unit controlled by an operating device on the processor. This makes it possible to set motor parameters, such as maximum power, max. Set start-up torque comfortably and adjust the operation of the compressor.

The integrated or connected controller also allows adjustment of a start-up phase when the compressor is turned on as well as various scenarios when reaching set maximum values, resulting in optimized motor protection and energy-efficient operation. The adjustment is made by means of an interface on the control device, e.g. via a computer to be connected or via a control panel on the control device, which is equipped with a display and an operating guide, with which the user himself can set some parameters and influence the operation.

Due to the good adjustability of the running parameters of the brushless motor with a suitable controller, the speed of the drive motor adjusted very quickly and accurately, or adjusted, whereby the compressed air power is adjustable over a wide range.

The drive motor is preferably not always run at full speed until reaching a pressure and / or degree of filling of the compressed air tank, but will preferably adapt to the power requirements, or the need for pressure and / or capacity, which is a high Engerieeffizienz and a allows quieter running.

For this purpose, the compressor is equipped with various measuring or detection devices which can communicate with the control device.

The compressor preferably has means for detecting the pressure, airflow and temperature, which are reported to the control unit to affect operations. The desired available pressure is either factory default and programmed into the processor-controlled control device or can be programmed or selected by the user via the control panel of the controller. With the available data, the required power of the compressor is determined and controlled the drive unit via the control device and the controller for the drive unit accordingly. The speed of the engine is adjusted to the required power and also preferably tracked during operation, which is always the pressure actually required and the required flow available.

According to a further preferred embodiment, the compressor or the system of a compressor has further means for detecting vibrations, high-frequency signals and other operating conditions, whereby the drive eg when reaching a particularly critical speed at which very strong vibrations occur, this speed range changed by the modules to protect. The detection of certain high-frequency signals is used, for example, to switch off the activity of a mobile telephone in the vicinity of the compressor, which leads to a reduction in the risk of injury when working. The functions mentioned are variable or adjustable by the operator via the control panel or an interface to the control device.

The compressor is equipped for connection to the power supply with a power supply, which is preferably designed as a wide-range power supply, so that the compressor is very flexible operable on a variety of Stromnetzten. By using such, preferably used, wide-range power supply for example, a voltage range of 110 to 270 volts and frequencies of 50 to 60 Hz, a worldwide use of the compressor in only one version is possible, with changes to the power supply remain possible. Preferably, the power supply unit, the control unit together with the display and an operating guide designed as a compact unit and arranged on the compressor. The described, power demand-oriented control of the drive unit allows the use of a compact compressed air tank, as can be reacted very quickly on the detection of air flow and the drive unit means of the control unit is excited to a higher speed to cover the current air flow requirements. The same applies to the detection of a small amount of air required, in which the speed of the drive unit is reduced further and finally turned off. The compressed air tank is designed according to a further preferred embodiment as a compact compressed air tank in lightweight construction. A further, preferred variant provides a plastic compressed air tank, which is particularly lightweight and inexpensive and is used for applications up to the permissible pressurization. This one embodiment of the invention of a compressed air tank on the compressor allows the determination of the prevailing pressure by determining the expansion of the tank, including the current temperature. Such a variant is a simple and inexpensive design to determine the pressure and the operating conditions of the To consider compressor. Such a device for determining the expansion of the compressed air tank is preferably integrated as a stretch band in the plastic tank, such as poured or injected into this.

The compressor according to the invention, with the ambient and / or operating states detected and further processed by the control device and / or detection devices, represents a simple and very energy-efficient, comfortable design of a compressor with a large field of application. The comfort becomes according to a further, preferred embodiment in which the compressor or the control device has additional communication means with which data is transmitted between the compressor and a further compressor and / or a connected compressed air tool.

Such an embodiment allows e.g. the automatic pressure control when connecting a compressed air tool which for the said data communication e.g. has an integrated chip by means of which a communication with the control device takes place. When connecting such a tool, the compressor automatically detects the pressure and air flow requirements and adjusts the parameters accordingly and forwards them to the control and drive unit for the optimum speed. The same applies to the communication between two or more compressors, which can be connected to a more powerful unit.

The communication device between the compressor and the other end of a compressed air line is preferably carried out without additional wiring and transmits signals, data and / or media streams by preferential Aufmodulierung a sound signal on or in the compressed air line or the guided pressure medium.

By means of the continuous, bidirectional connection at the end of the compressed air line and the compressor, or the control device of the Compressor can be set and tracked the supplied pressure connection very needs. The embodiment with the communication device described also allows very effective records of the operation of the compressed air tool on a compressed air line, such as determining the current and / or require compressed air flow or recording with which compressed air tool at which port is working.

For some applications, records required with this can be recorded directly, such as, for example, the riveting of safety-relevant components such as aerofoil wings or the like. For some applications, an additional camera can be integrated with the pneumatic tool and the data or the recording stream can be transmitted to the control device for storage. This makes it possible to record the entire work step for any security checks and to log the required requirements.

There are numerous use cases for a required determination and logging of processing parameters. Other examples include the recording and logging of torques with which various connections have been made, filled pressures or air flows during sensitive coating or application processes.

In the following the invention will be described by way of example with reference to drawings. Showing:

Fig. 1 is a perspective view of a compressor according to the prior art

Fig. 2 is a perspective view of an inventive

compressor

Fig. 3 is an illustration of a control and drive unit 4 is a block diagram of the compressor controller

1 shows a compressor 1 ^' according to the prior art, which is shown in direct comparison to a compressor 1 according to the invention in Fig. 2. Clearly visible is the difference in the size of the compressed air tank 5 and the drive motor. 2

For the comparison chosen here piston cylinder 4 of the same size were shown to allow a suitable comparison of the two compressors 1 and 1 ^' .

Although the control unit 3 does not necessarily differ in size, the control unit 3 has the much larger functional scope, in particular with the additional detection elements according to the invention for the consideration of e.g. Pressure, temperature,

Airflow, vibration and other signals such as Radio frequency signals. The clearly visible in Fig. 2 smaller dimensions of a compressor 1 can be seen that a compressor of the same power class is made significantly smaller and lighter. The preferably carried out in plastic compressed air tank 5 is very simple and inexpensive to produce models with a corresponding pressure range of up to 6 to 8 bar and has a dezutlich lower weight than previous steel containers. By way of example, FIG. 3 shows a control device 3, which comprises an electronic part 6 and a display and / or operating part 7, and which is connected to the drive unit 2, preferably a brushless motor. A controller for the brushless motor 2 is accommodated in the control unit 3, connected thereto or integrated on the electronic part 6 of the control unit 3.

On the display or control unit 7 controls 8 and a display 9 are arranged around the user on the one hand information about to provide the operating state of the compressor and to be able to set working parameters. The operator can easily set a desired pressure and / or an airflow. Also, preferred special functions can be activated and selected via the operating unit, such as emergency shutdown for incoming RF signals from a mobile telephone or comfort functions with regard to the connected compressed air tools.

The determined parameters which are supplied to the control unit can be processed in the electronic unit 6 of the control unit 3 by means of a processor 10 and a memory, and functions and activities stored or learned on various parameters can be carried out, e.g. the power tracking with increased air volume extraction.

FIG. 4 shows a block diagram which represents exemplary preferred functions and / or sequences. The compressor is connected to the power supply with its power supply, which is preferably designed as a wide-range power supply unit. The power supply has various voltage outputs to supply the electronic components as needed. An arithmetic unit collects, manages, utilizes and distributes the stored and supplied data via various detection device such as RF signals, vibration, pressure, temperature and air flow and executes stored or learned processes and functions.

By means of a display and an operating device, such as buttons and / or switches and a menu navigation, the user can view and change various parameters to adapt the function and performance of the compressor to his needs.

The control unit or the computing unit controls the motor controller and / or the motor protection to drive the drive unit with the desired speed. The compressor according to the invention is in comparison to the compressor of the prior art, smaller, cost-effective, very universally applicable, quieter, energy efficient working execution, which offers a much higher range of operation, comfort and setting.

Due to the additional possibilities of communication with other compressors in order to connect them together or the communication between compressor and pneumatic tools also reduces the rate of incorrect operation and the system contributes to accident prevention. In particular, a variant of the invention, which has a detection of RF signals in the environment of the compressor actively contributes to accident prevention. It can thus be used e.g. Cell phone calls can be detected and the controller can be set so that in case of a detected call, the compressor shuts off and / or interrupt the compressed air delivery because in the case of calls the operators of pneumatic tools are distracted which greatly increases the risk of accidents.

Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to these precise embodiments and applications, and that various changes and modifications may be made thereto by those skilled in the art without departing from the scope of the The invention as defined in the appended claims is deviated.

Claims

claims

1. Compressor for generating compressed air, consisting of a compression unit for compressing, a compressed air tank and an electric drive unit with a control device and a connection and / or conversion device to the power grid,

characterized,

that the compressor is designed with a processor-controlled control device for a variable amount of compressed air and / or pressure which takes place via a variable, controllable power output or rotational speed of the drive unit,

the compressor has means for detecting operating parameters which can be supplied to the control device.

2. Compressor according to claim 1,

characterized,

that the drive unit is designed as a brushless DC motor.

3. Compressor according to claim 1,

characterized,

the control device is equipped with a controller for brushless DC motors.

4. Compressor according to claim 1,

characterized, that the compressor is equipped with a lightweight, compact compressed air tank.

5. A compressor according to claim 1 and 4,

characterized,

that the compressed air tank is made of plastic.

6. A compressor according to claim 1,

characterized,

the compressor is designed with a wide-range power supply unit or a wide-range power supply unit for connection to the power grid.

7. A compressor according to claim 1,

characterized,

the control unit has an operating device and / or a computer interface.

8. A compressor according to claim 1,

characterized,

that the compressor is equipped with a detection device for the air flow measurement and / or pressure measurement.

9. A compressor according to claim 1,

characterized,

that the compressor is equipped with a temperature measuring device.

10. A compressor according to claim 1,

characterized,

that the compressor is equipped with a vibration detection unit.

11. A compressor according to claim 1,

characterized,

in that the compressor or the control device is equipped with a detection device for HF signals.

12. A compressor according to claim 1,

characterized,

the compressor or the control device has communication devices for air pressure devices and / or other compressors.

13. A compressor according to claim 1 and 12,

characterized,

that the communication device between the control unit of a compressor to another and / or a compressed air tool is designed as a signal connection to the compressed air line.

14. A compressor according to claim 1 and 12,

characterized, that the communication device between the control unit of a compressor to another and / or a compressed air tool is designed as a modulated sound signal to the compressed air line.

15. A compressor according to claim 1 and 12 to 14,

characterized,

the communication device between the control unit and the connection to the compressed air tool is designed as a data or media transmission.

16. A compressor according to claim 1 and 12 to 15,

characterized,

in that the data transported via the communication device between the control unit and the connection to the compressed air tool as data or media transmission is stored and / or processed in the control device.