WO2016011817A1 - 一种空气干燥机故障自动处理方法及装置 - Google Patents

一种空气干燥机故障自动处理方法及装置 Download PDF

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Publication number
WO2016011817A1
WO2016011817A1 PCT/CN2015/074438 CN2015074438W WO2016011817A1 WO 2016011817 A1 WO2016011817 A1 WO 2016011817A1 CN 2015074438 W CN2015074438 W CN 2015074438W WO 2016011817 A1 WO2016011817 A1 WO 2016011817A1
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Prior art keywords
exhaust
air
air dryer
valve
fault
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PCT/CN2015/074438
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English (en)
French (fr)
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谢成昆
周湘浩
周剑
周定军
刘波
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株洲高新技术产业开发区壹星科技有限公司
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Priority to DE212015000160.1U priority Critical patent/DE212015000160U1/de
Publication of WO2016011817A1 publication Critical patent/WO2016011817A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/26—Drying gases or vapours
    • B01D53/261—Drying gases or vapours by adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • B01D53/0454—Controlling adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/40—Further details for adsorption processes and devices
    • B01D2259/40003—Methods relating to valve switching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/45—Gas separation or purification devices adapted for specific applications
    • B01D2259/4566—Gas separation or purification devices adapted for specific applications for use in transportation means

Definitions

  • the invention relates to a wet air drying control method and device for a locomotive air compressor, in particular to an automatic processing method and device when a large exhaust air occurs when an air dryer malfunctions. It is mainly used for the treatment of failure when the air compressor is dried.
  • the traditional two-tower air dryer wind source system is shown in Figure 1.
  • the air dryer in the traditional two-tower air dryer wind source system includes an electromagnetic blowdown valve 16, two exhaust valves, a check valve, and the existing The oil-water separator 17, the drying tower 18, the plug door 19, and the like in the technology.
  • the traditional two-tower air dryer can not achieve intelligent automatic control of the large faults that occur.
  • the reason is: First, the traditional double tower air dryer adopts the control mode which is the PUC time controller control. Only some control procedures of the conversion time are set, and the intelligent control cannot be realized. Second, the structure of multiple dispersed valves is difficult to achieve intelligent control.
  • Figure 1 this is a diagram of a conventional two-tower air dryer wind source purification system. It can be seen from the figure that when the air dryer fails and the wind is exhausted, the function of automatic cut-off conversion cannot be realized at all. When this happens, it is generally only possible to manually close the plug door K1 and manually open the bypass plug door K3. Some air dryers are installed under the locomotive, and it is impossible to manually open or close the plug door. Automatic control is not possible at all.
  • the invention of the application No. 201210569044.7 discloses a smart boiler control system, comprising a controller and a keyboard module, further comprising a detection module, a fault processing module and an alarm prompting module; the output end of the controller is further connected with a LCD.
  • the invention of Application No. 200510081942.8 discloses a dryer comprising a heater, an exhaust pipe, a switch and a controller, and a control method therefor. A heater is provided to heat the air. Hot air flows through the exhaust pipe, and when the temperature of the heater is outside the preset temperature atmosphere, the switch is turned off and the heater is braked.
  • 201310687704.6 discloses a processing system and method for a locomotive failure, the system comprising an in-vehicle device and a ground device, the in-vehicle device being configured to wirelessly transmit the locomotive fault information and the operational status information to the ground device,
  • the ground device includes a first receiver, a first transmitter, a first processor, and a ground specialist library, the first receiver configured to wirelessly receive vehicle fault information and operational status information, the first processor configured to determine locomotive fault information Whether the indicated fault matches the pre-stored fault in the ground expert repository, extracts the corresponding fault resolution strategy from the ground specialist library in the matched case, and wirelessly transmits the fault resolution strategy to the in-vehicle device through the first transmitter.
  • the utility model with the application number of 200620107003.6 discloses a sewage device with a fault alarm, which is provided with an inlet pipe, a connecting pipe, a sewage ball valve, a water trap and a fault alarm, and the inlet pipe and the connecting pipe are welded in the water.
  • the blowdown ball valve is installed at the bottom of the device and is screwed with the water trap.
  • the fault alarm includes an alarm housing and a sensor. The sensor is installed in the fault alarm and connected to the electric box, and the fault alarm is connected. Connect to the alarm connector.
  • Patent No. CN201180072105.2 entitled “Control Method of Adsorption Heat Pump, Information Processing System and Control Device", which discloses a control method, information processing system and control device for an adsorption heat pump, Even if the temperature of the heat source for supplying heat for regenerating the adsorbent varies greatly, the adsorption heat pump can be operated efficiently.
  • the flow rate adjustment units 43a to 43c are provided to independently adjust the flow rates of the heat mediums supplied to the electronic devices 41a to 41c, and the temperature sensors 45a to 45c can independently detect the heat medium discharged from the electronic devices 41a to 41c.
  • Temperature; control unit 30 controls the flow rate adjustment units 43a to 43c so that the temperatures of the heat medium discharged from the electronic devices 41a to 41c become the same based on the outputs of the temperature sensors 45a to 45c.
  • the patent number is CN200820123078.2, which is entitled "A kind of electric controller for controlling the double tower air dryer of diesel locomotive”.
  • the patent discloses a method for controlling the electric power of the double tower air dryer of diesel locomotive.
  • the controller is characterized in that: the movement part thereof comprises a power module, a PLC controller, a first contactor and a second contactor; a DC voltage and a control signal are respectively input to the power module, and an output of the power module is used as the PLC An input of the controller; an output of the PLC controller is coupled to the first contactor and the second contactor, respectively, and outputs of the first contactor and the second contactor are respectively connected to the electropneumatic valve controlled by the same.
  • the patent number is CN201010266323.7, the invention patent entitled “Drying process control switching time control method based on dew point control”, the patent discloses a drying device flow switching time control method based on dew point control, in an adsorption tower
  • the actual dew point temperature value is compared with the customer's required set value. If the actual value is equal to or higher than the set value, the system continues to switch by time control. If the actual value is lower than the set value, let the adsorption tower continue to work, and another adsorption tower to be switched. At this time The actual dew point temperature value collected is always compared to the customer's required set point.
  • the two tower workflows are switched as soon as the actual value is equal to or higher than the set value requested by the customer, or when the time reaches the set dew point control time value.
  • the object of the present invention is to provide a non-thermal adsorption drying control method and device for an existing air compressor, and there is a problem that the air dryer has a long-discharge failure detection and automatic switching function, and an air dryer failure automatic processing device is provided.
  • the treatment method can solve the problem of large exhaust air caused by the failure of the air dryer.
  • an automatic air blower fault processing method which uses a PLC controller to detect and process a long exhaust fault of an air dryer; the total exhaust of the air dryer A pressure sensor is provided for detecting the pressure of the exhaust gas; a normally open electromagnetic valve is installed on the intake line, and a normally closed electromagnetic valve is installed on the bypass line; the normally open electromagnetic valve, the normally closed electromagnetic valve and the pressure
  • the sensors are electrically connected to the PLC controller; when the air dryer has a large exhaust fault, the pressure sensor installed at the total exhaust port detects the fault signal and transmits the signal to the PLC controller; the PLC controller issues a closed normally open The solenoid valve and the command to open the normally closed solenoid valve; the normally open solenoid valve on the air dryer inlet line is closed, and the normally closed solenoid valve on the bypass line is opened; the compressed air cannot enter the adsorption tower of the air dryer from the bypass tube The road enters the gas-using equipment, thereby realizing automatic switching and
  • the PLC controller adopts a programmable logic control technology, adopts a module integrated method, is matched with a touch screen, and all control electronic components are integrated into one body, and adopts a package form, which can effectively prevent earthquake and ensure reliability of the controller.
  • an alarm device is further disposed between the pressure sensor and the PLC controller, and the alarm device is connected to the pressure sensor and the PLC controller; when the pressure sensor detects the fault signal, the fault alarm signal is sent through the alarm device.
  • a processing system device for realizing the above-mentioned air dryer malfunction automatic processing method comprising an air dryer intake line, a bypass line, an adsorption tower and a gas control valve; the gas control valve is an air control combination valve; The combined valve is provided with a total exhaust port, and a pressure for detecting the pressure of the exhaust gas is installed at the exit position of the total exhaust port.
  • a force sensor a normally open electromagnetic valve is installed on the intake line, and a normally closed electromagnetic valve is installed on the bypass line; the normally open electromagnetic valve, the normally closed electromagnetic valve and the pressure sensor are electrically connected with the PLC controller; when the air dryer In the event of a large exhaust failure, the pressure sensor installed at the total exhaust port detects the fault signal and transmits the signal to the PLC controller; the PLC controller issues a command to close the normally open solenoid valve and open the normally closed solenoid valve; air drying The normally open solenoid valve on the intake pipe of the machine is closed, and the normally closed electromagnetic valve on the bypass line is opened; the compressed air cannot enter the adsorption tower of the air dryer and enters the gas-using device from the bypass pipe, thereby realizing automatic switching and automatic processing.
  • the air dryer has a large exhaust failure.
  • the pneumatic control combination valve includes a valve body, an air intake assembly located at an upper portion of the valve body, an exhaust assembly located at a lower portion of the valve body, a cover sealed at both ends of the valve body, and an air inlet and a drain on the valve body. Air port.
  • the intake assembly includes an intake piston rod and two intake pistons symmetrically mounted at two ends of the intake piston rod, the outer diameter of the intake piston being smaller than the inner diameter of the valve body cavity; each intake piston is adjacent to the cover One end is provided with an intake sliding sleeve;
  • the exhaust assembly includes an exhaust piston rod, an exhaust piston, an exhaust piston sleeve, a guiding block, and a sealing block, and the exhaust piston is mounted on the exhaust piston rod near the cover One end, the guiding block and the sealing block are mounted on the other end of the exhaust piston rod, and the exhaust piston sleeve is set on the exhaust piston and the guiding block, the outer diameter of the exhaust piston sleeve is smaller than the inner diameter of the valve body cavity;
  • the exhausting assembly There are two, the left exhaust component and the right exhaust component, and the left exhaust component and the right exhaust component are symmetrically mounted in the valve body.
  • the PLC controller adopts a programmable logic control technology, adopts a module integrated method, is matched with a touch screen, and all control electronic components are integrated into one body, and adopts a package form, which can effectively prevent earthquake and ensure reliability of the controller.
  • an alarm device is further disposed between the pressure sensor and the PLC controller, and the alarm device is connected to the pressure sensor and the PLC controller; when the pressure sensor detects the fault signal, the fault alarm signal is sent through the alarm device.
  • the invention has the beneficial effects that the invention adopts a programmable logic PLC controller, and when the locomotive air dryer malfunctions, a large exhaust air can be quickly reacted, and the PLC controller receives the electric signal collected by the pressure sensor, and issues an instruction to close the normally open.
  • the solenoid valve opens the normally closed solenoid valve at the same time, and the compressed air is directly supplied to the wind equipment through the bypass line. The quality of the compressed air does not decrease too much, and the quality requirement of the gas can be ensured.
  • the fault alarm signal is sent to the squadron to remind the returning section to perform maintenance processing, at the same time avoiding the fault of the large exhaust air and ensuring the normal operation of the locomotive.
  • FIG. 1 is a diagram of a conventional two-column air dryer wind source purification system in the prior art
  • FIG. 2 is a diagram of a module integrated air dryer wind source purifying system according to the present invention.
  • FIG. 3 is a schematic structural view of an automatic control device for automatically controlling a locomotive air dryer of the present invention
  • FIG. 4 is a schematic diagram of an intelligently controlled locomotive air dryer fault automatic processing device according to the present invention.
  • Figure 5 is a front view showing the structure of the pneumatic control combination valve of the present invention.
  • Figure 6 is a schematic left side view of the pneumatic control combination valve of the present invention.
  • Figure 7 is a schematic structural view of an air intake assembly of the air control combination valve of the present invention.
  • Figure 8 is a schematic view showing the structure of an exhaust unit of the pneumatic control combination valve of the present invention.
  • PLC controller 1 upper cover 2, adsorption tower 3, lower cover 4, pneumatic control combination valve 5, pressure sensor 6, silencer 7, intake line 8, normally open solenoid valve 9, normally closed electromagnetic valve 10, Bypass line 11, oil water separator 12, fine filter 13, dust filter 14, pressure gauge 15, electromagnetic blowdown valve 16, oil water separator 17 of the prior art, dryer 18, plug door 19, valve body 20.
  • the air dryer includes an intake pipe 8 , a bypass pipe 11 , an upper cover plate 2 , a lower cover plate 4 , and an adsorption tower 3 .
  • air control valve 5 pressure sensor 6, muffler 7, oil water separator 12, fine filter 13, dust filter 14, electric control cabinet 15, the air control valve is an air control combination valve 5, the air drying
  • the machine adopts integrated modular structure, integrating upper cover plate, lower cover plate, adsorption tower, air control combination valve and silencer, and only has one total exhaust port. As shown in FIG. 2 and FIG.
  • the air dryer fault automatic processing device is disposed on an air dryer, and the air dryer fault automatic processing device includes a PLC controller 1 and a normally open solenoid valve 9 installed on the intake pipeline.
  • a normally closed solenoid valve 10 installed on the bypass line and a pressure sensor 6 installed at the total exhaust port; the normally open solenoid valve 9, the normally closed solenoid valve 10 and the pressure sensor 6 are both electrically connected to the PLC controller 1 connection.
  • the air dryer with modular integrated structure has only one total exhaust.
  • a pressure sensor is set at the total exhaust port, and when the pressure sensor collects an abnormal pressure signal (when the locomotive is malfunctioning due to a mechanical valve or a circuit failure, the seal fails, and a long row failure occurs), it is fed back to the PLC controller.
  • the PLC controller gives an instruction to close the normally open solenoid valve on the intake line of the air dryer and simultaneously open the normally closed solenoid valve on the bypass line, so that the compressed air is directly supplied to the gas equipment for emergency use, and the air dryer is processed.
  • the purpose of the large exhaust failure is to eliminate accidents that may occur in the locomotive.
  • an alarm signal is sent to remind the locomotive flight attendant to return to the section for maintenance. Therefore, the intelligent control modular locomotive air dryer can automatically handle the fault of the large air exhaust of the locomotive air dryer, which greatly ensures the safety of driving.
  • FIG. 4 it is a schematic diagram of the automatic control device for the automatic control of the locomotive air dryer.
  • the pressure sensor installed at the total exhaust port sends a fault alarm signal and transmits the electrical signal to the PLC controller on the dryer.
  • the PLC controller gives the normally open solenoid valve. After closing and normally closing the solenoid valve, the normally open solenoid valve installed in the intake line of the dryer is closed, and the normally closed solenoid valve on the bypass line is opened, so that the compressed air cannot enter the dryer and enter from the bypass line. Gas equipment. Thereby, the purpose of automatically switching and automatically processing the large exhaust failure of the dryer is realized.
  • Intelligently controlled locomotive air dryer fault automatic processing device how does it realize automatic control of large exhaust faults in locomotive air dryers?
  • a large exhaust fault occurs on the air dryer on the locomotive, it is usually caused by a failure of one of several control valves or at the same time due to the failure of the two pneumatic control valves.
  • Traditional twin tower air dryers cannot be solved due to design and structural reasons.
  • the shut-off valve of the air dryer inlet can only be manually shut off, and the shut-off valve on the bypass line is opened. It is inconvenient to operate and sometimes cannot be solved at all.
  • the intelligent module integrated air dryer can solve this problem well.
  • the air control combination valve on the modular integrated dryer and the total exhaust port of the muffler are equipped with a pressure sensor. When the pressure sensor detects a large exhaust, it causes abnormality.
  • the pressure signal When the pressure signal is sent, the electric signal is transmitted to the PLC controller, and the PLC controller issues a command, the normally open electromagnetic valve installed in the intake pipe of the dryer is closed, and the normally closed electromagnetic valve on the bypass line is simultaneously opened, which is The air dryer body is thrown away so that the air from the air compressor enters the gas service directly from the bypass line. Thereby, the air path of the air exhausting machine with large exhaust failure is cut off, so that the compressed air directly enters the gas-using equipment, and the fault elimination is automatically completed, thereby ensuring the safe operation of the locomotive.
  • the air control combination valve includes a valve body 20, a cover 23 sealed at both ends of the valve body, an end seal ring 24 mounted on the cover, an air intake assembly 21 disposed inside the valve body, An exhaust assembly, a heating plate 26 mounted below the valve body.
  • the valve body is provided with an air control combination valve intake port 27 and an air control combination valve exhaust port 28, the intake assembly is located at an upper portion of the valve body, and the exhaust assembly is located at a lower portion of the valve body.
  • the exhaust assembly includes a left exhaust assembly 22 and a right exhaust assembly 23.
  • the valve body of the pneumatic control combination valve is further provided with a control air port and a right air port 32, and the air outlet port includes a left air outlet port 29 and a right air outlet port 30.
  • the air intake assembly includes an intake piston rod 33 and two intake pistons 37 symmetrically mounted at two ends of the intake piston rod, the outer diameter of the intake piston being smaller than the inner diameter of the valve body cavity; each intake air An end of the piston adjacent to the cover is provided with an intake bushing 38, a second sealing ring 39 and a second sealing seat 40, and the other end is provided with a first sealing seat 34, a first sealing gasket 35 and a first sealing ring 36.
  • the intake piston rod, the first sealing seat, the first sealing gasket, the first sealing ring, the intake piston, the intake sliding sleeve, the second sealing ring and the second sealing seat are sequentially connected.
  • the exhaust assembly includes an exhaust piston rod 41, an exhaust piston 42, an exhaust piston sleeve 47, a guide block 50, and a sealing block 53, which is mounted on the exhaust piston rod.
  • One end of the cover, the guiding block and the sealing block are mounted on the other end of the exhaust piston rod, and the exhaust piston sleeve is set on the exhaust piston and the guiding block, and the outer diameter of the exhaust piston sleeve is smaller than the inner diameter of the valve body cavity;
  • the assembly and the right exhaust assembly are mounted symmetrically in the valve body.
  • the exhaust assembly further includes a return spring 48 between the exhaust piston and the guide block, the return spring being made of a stainless steel material; the exhaust piston is provided with an exhaust sleeve 43 adjacent to one end of the cover, and a second The gasket 44, the third seal ring 45, the third seal seat 46, and the sixth seal ring 55 are provided with a washer 49, a second seal gasket 51, a fourth seal ring 52, and a fifth seal ring 54 at the other end.
  • the present invention can be summarized as an automatic air blower fault processing method, which uses a PLC controller to detect and process a long exhaust fault of an air dryer; in the total exhaust port of the air dryer A pressure sensor is provided for detecting the pressure of the exhaust gas; a normally open electromagnetic valve is installed on the intake line, and a normally closed electromagnetic valve is installed on the bypass line; the normally open electromagnetic valve, the normally closed electromagnetic valve and the pressure sensor Both are electrically connected to the PLC controller; when the air dryer has a large exhaust fault, the pressure sensor installed at the total exhaust port detects the fault signal and transmits the signal to the PLC controller; the PLC controller sends off the normally open electromagnetic Valve and open The normally closed solenoid valve command; the normally open solenoid valve on the air dryer intake line is closed, and the normally closed solenoid valve on the bypass line is opened; the compressed air cannot enter the adsorption tower of the air dryer and enters the gas from the bypass line Equipment, thus achieving automatic switching, automatic processing of air dryer large exhaust
  • the PLC controller adopts a programmable logic control technology, adopts a module integrated method, is matched with a touch screen, and all control electronic components are integrated into one body, and adopts a package form, which can effectively prevent earthquake and ensure reliability of the controller.
  • an alarm device is further disposed between the pressure sensor and the PLC controller, and the alarm device is connected to the pressure sensor and the PLC controller; when the pressure sensor detects the fault signal, the fault alarm signal is sent through the alarm device.

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  • Engineering & Computer Science (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Drying Of Gases (AREA)
  • Valves And Accessory Devices For Braking Systems (AREA)

Abstract

一种空气干燥机故障自动处理方法，采用PLC控制器（1）对空气干燥机的长排风故障进行检测和处理；在空气干燥机的总排气口设置一个压力传感器（6），用于对排出气体的压力进行检测；在进气管路（8）上安装常开电磁阀（9），在旁通管路（11）上安装常闭电磁阀（10）；常开电磁阀（9）、常闭电磁阀（10）和压力传感器（6）均与PLC控制器（1）电连接；当空气干燥机出现大排风故障时，安装在总排气口处的压力传感器（6）检测到故障信号并把信号传给PLC控制器（1）；PLC控制器（1）发出关闭常开电磁阀（9）和打开常闭电磁阀（10）的指令；空气干燥机进气管路（8）上的常开电磁阀（9）关闭、旁通管路（11）上的常闭电磁阀（10）打开；压缩空气不能进入空气干燥机的吸附塔（3）而从旁通管路（11）进入用气设备，从而实现自动切换、自动处理空气干燥机大排风故障。

Description

一种空气干燥机故障自动处理方法及装置 技术领域
本发明涉及一种机车空气压缩机的湿空气干燥控制方法及装置，尤其是涉及到当空气干燥机发生故障出现大排风时的自动处理方法及装置。主要用于对空气压缩机进行干燥处理时发生故障的处理。
背景技术
目前在线运行的电力机车、内燃机车、城轨车、地铁车用空气干燥机时常发生因空气干燥机的故障出现大排风。这样会造成空气压缩机打风不起，风压不足而严重影响到机车的制动刹车系统的制动性能，引发制动失灵而造成机破事故，严重影响到行车安全。是各个运营单位十分头痛而又无法解决的束手问题。而空气干燥机的故障主要反映在：空气干燥机进气阀的故障；空气干燥机排气阀的故障；空气干燥机排污阀的故障；出气止回阀故障等。上述故障都是造成干燥机发生故障而造成大排风的主要原因。
传统式双塔空气干燥器风源系统如图1所示，传统式双塔空气干燥器风源系统中的空气干燥器包括有电磁排污阀16、两个排气阀、止回阀、现有技术中的油水分离器17、干燥塔18、塞门19等。
传统式双塔空气干燥机根本无法实现对出现的故障大排风实现智能自动控制。其原因为；一、传统式双塔空气干燥机采用控制方式是PUC时控器控制，只设置了一些转换时间的控制程序，无法实现智能控制。二、多个分散的阀的结构方式难以实现智能控制。如图1所示，这是一种传统双塔空气干燥机风源净化系统图，从图中可以看出空气干燥机出现故障大排风时，根本无法实现自动截止转换的功能。当出这种情况时一般只能采用人工手动关闭塞门K1、和手动打开旁通塞门K3的方式，有的空气干燥机装在机车底下，根本无法人工打开或关闭塞门。根本无法实现自动控制。
现有技术中，申请号为201210569044.7的发明公开了一种智能锅炉控制系统，包括控制器、键盘模块，还包括检测模块、故障处理模块和报警提示模块；所述控制器的输出端还连接有一液晶显示。申请号为200510081942.8的发明公开了一种干燥机及其控制方法,干燥机包括加热器、排气管、开关和控制器。设置加热器,用以加热空气。热空气流过排气管，当加热器的温度在预设温度氛围以外时,开关断开,制动加热器。申请号为201310687704.6的发明公开了一种机车故障的处理系统及方法，该系统包含车载设备和地面设备，车载设备被配置成无线发送机车故障信息与运行状态信息到地面设备， 地面设备包括第一接收机、第一发射机、第一处理器以及地面专家库，第一接收机被配置成无线接收机车故障信息与运行状态信息，第一处理器被配置成确定机车故障信息所表示的故障是否与地面专家库中预先存储的故障相匹配，在相匹配的情况下从地面专家库提取相应的故障解决策略，以及通过第一发射机将故障解决策略无线发送至车载设备。申请号为200620107003.6的实用新型公开了一种带有故障报警器的排污装置,它设置有进口管、连接管、排污球阀、积水器和故障报警器,进口管和连接管均焊接在积水器上,排污球阀安装在装置的底部,并与积水器通过螺纹连接,故障报警器包括报警器壳体和传感器,传感器安装在故障报警器内,并与电气箱相连,而故障报警器则与报警器连接管连接。以上现有技术，均不能解决因空气干燥机发生故障而造成大排风的问题。
通过国内专利文献检索发现有一些相关的文献报道，与本发明有关的主要有以下一些：
1、专利号为CN201180072105.2，名称为“吸附式热泵的控制方法、信息处理系统及控制装置”的发明专利，该专利公开了一种吸附式热泵的控制方法、信息处理系统及控制装置，即使用于供给再生吸附剂时使用的热量的热源的温度变化很大，也能够使吸附式热泵高效运行。设置有：流量调整部43a～43c，能够分别独立地调整向电子设备41a～41c供给的热介质的流量；温度传感器45a～45c，能够分别独立地检测从电子设备41a～41c排放出的热介质的温度；控制部30。控制部30基于温度传感器45a～45c的输出，以使从电子设备41a～41c排放出的热介质的温度变得相同的方式控制流量调整部43a～43c。
2、专利号为CN200820123078.2，名称为“一种控制内燃机车双塔式空气干燥器的电控器”的实用新型专利，该专利公开了一种控制内燃机车双塔式空气干燥器的电控器，其特征在于：它的机芯部分包括电源模块、PLC控制器、第一接触器、第二接触器；直流电压和控制信号分别输入所述电源模块，电源模块的输出作为所述PLC控制器的输入；PLC控制器的输出分别连接所述第一接触器和所述第二接触器，第一接触器和第二接触器的输出分别连接受其控制的电空阀。
3、专利号为CN201010266323.7，名称为“基于露点控制的干燥器流程切换时间控制方法”的发明专利，该专利公开了一种基于露点控制的干燥器流程切换时间控制方法，在一个吸附塔工作结束，两塔工作流程未切换前，将采集到的露点温度实际值与客户要求的设定值相比较。如果实际值等于或高于设定值，系统继续按时间控制进行切换。如果实际值低于设定值，则让此吸附塔继续工作，另外一个吸附塔待切换。这时将 采集到的露点温度实际值与客户要求的设定值一直进行比较。一直到实际值等于或高于客户要求的设定值，或时间达到设定的露点控制时间值时，两塔工作流程马上切换。
上述这些专利虽然涉及到了空气干燥器的控制，其中在第2个专利中也提出了采用PLC控制器，可仔细分析可以看出，这些专利都没有解决准确反映干燥器成品气的质量指标的问题，而且对于干燥器出现长排故障没有检测和自动切换功能，干燥器控制器吸附再生时间也无法调节，干燥器控制器对进气温度无控制功能，气温低于0°时容易结冰造成出气阀堵塞，极易造成机破事故，难以达到最优的干燥效果。因此很有必要对此加以改进。
发明内容
本发明的目的在于针对现有空气压缩机无热吸附式干燥控制方法及装置，存在空气干燥机故障出现长排故障没有检测和自动切换功能的问题，提供一种空气干燥机故障自动处理装置和处理方法，其能解决因空气干燥机发生故障而造成大排风的问题。
为了实现上述目的，本发明所采取的技术方案是：一种空气干燥机故障自动处理方法，采用PLC控制器对空气干燥机的长排风故障进行检测和处理；在空气干燥机的总排气口设置一个压力传感器，用于对排出气体的压力进行检测；在进气管路上安装常开电磁阀，在旁通管路上安装常闭电磁阀；所述常开电磁阀、常闭电磁阀和压力传感器均与PLC控制器电连接；当空气干燥机出现大排风故障时，安装在总排气口处的压力传感器检测到故障信号并把信号传给PLC控制器；PLC控制器发出关闭常开电磁阀和打开常闭电磁阀的指令；空气干燥机进气管路上的常开电磁阀关闭、旁通管路上的常闭电磁阀打开；压缩空气不能进入空气干燥机的吸附塔而从旁通管路进入用气设备，从而实现自动切换、自动处理空气干燥机大排风故障。
进一步地，所述的PLC控制器采用可编程逻辑控制技术，采用模块集成式方法，搭配触摸屏，所有控制电子元件合成一体，采用封装形式，能有效防震，保证控制器的可靠性。
进一步地，所述的压力传感器和PLC控制器之间还设有报警装置，所述报警装置连接压力传感器和PLC控制器；当压力传感器检测到故障信号时，通过报警装置发出故障报警信号。
一种实现上述空气干燥机故障自动处理方法的处理系统装置，包括空气干燥机进气管路、旁通管路、吸附塔和气控阀；所述的气控阀为气控组合阀；在气控组合阀上设有一个总排气口，在总排气口的出口位置上安装有用于对排出气体的压力进行检测的压 力传感器；在进气管路上安装常开电磁阀，在旁通管路上安装常闭电磁阀；所述常开电磁阀、常闭电磁阀和压力传感器均与PLC控制器电连接；当空气干燥机出现大排风故障时，安装在总排气口处的压力传感器检测到故障信号并把信号传给PLC控制器；PLC控制器发出关闭常开电磁阀和打开常闭电磁阀的指令；空气干燥机进气管路上的常开电磁阀关闭、旁通管路上的常闭电磁阀打开；压缩空气不能进入空气干燥机的吸附塔而从旁通管路进入用气设备，从而实现自动切换、自动处理空气干燥机大排风故障。
进一步地，所述气控组合阀包括阀体、位于阀体内上部的进气组件、位于阀体内下部的排气组件、密封连接在阀体两端的盖，阀体上设有进气口和排气口。
进一步地，所述的进气组件包括进气活塞杆和两个对称安装在进气活塞杆两端的进气活塞，进气活塞外径小于阀体内腔的内径；每个进气活塞上靠近盖的一端设有进气滑套；所述排气组件包括排气活塞杆、排气活塞、排气活塞套、导向块、密封块，所述排气活塞安装在排气活塞杆上靠近盖的一端，导向块和密封块安装在排气活塞杆的另一端，排气活塞套套装在排气活塞和导向块上，排气活塞套的外径小于阀体内腔的内径；所述排气组件有二个，分别是左排气组件和右排气组件，左排气组件和右排气组件左右对称安装在阀体内。
进一步地，所述的PLC控制器采用可编程逻辑控制技术，采用模块集成式方法，搭配触摸屏，所有控制电子元件合成一体，采用封装形式，能有效防震，保证控制器的可靠性。
进一步地，所述的压力传感器和PLC控制器之间还设有报警装置，所述报警装置连接压力传感器和PLC控制器；当压力传感器检测到故障信号时，通过报警装置发出故障报警信号。
本发明的有益效果：本发明采用可编程逻辑PLC控制器，当机车空气干燥机出现故障出现大排风时，能快速反应，PLC控制器接收到压力传感器采集的电信号，发出指令关闭常开电磁阀，同时打开常闭电磁阀，压缩空气直接通过旁通管路供给用风设备，该压缩空气质量不会有太多下降、还能保证用气的品质要求。并发出故障报警信号给司乘人员提醒返段后再作维修处理，与此同时避免了大排风的故障，保证了机车的正常运行。
附图说明
图1为现有技术中的传统双塔空气干燥机风源净化系统图；
图2为本发明中的模块集成式空气干燥机风源净化系统图；
图3为本发明中的智能控制的机车空气干燥机故障自动处理装置的结构示意图；
图4为本发明中的智能控制的机车空气干燥机故障自动处理装置原理图；
图5是本发明中的气控组合阀的主视结构示意图；
图6是本发明中的气控组合阀的左视结构示意图；
图7是本发明中的气控组合阀的进气组件结构示意图；
图8是本发明中的气控组合阀的排气组件结构示意图。
附图标记说明：
PLC控制器1、上盖板2、吸附塔3、下盖板4、气控组合阀5、压力传感器6、消音器7、进气管路8、常开电磁阀9、常闭电磁阀门10、旁通管路11、油水分离器12、精过滤器13、除尘过滤器14、压力表15、电磁排污阀16、现有技术中的油水分离器17、干燥器18、塞门19、阀体20、进气组件21、左排气组件22、盖23、端部密封圈24、右排气组件25、加热板26、气控组合阀进气口27、气控组合阀排气口28、左出气口29、右出气口30、左控制气口31、右控制气口32、进气活塞杆33、第一密封座34、第一密封垫圈35、第一密封圈36、进气活塞37、进气滑套38、第二密封圈39、第二密封座40、排气活塞杆41、排气活塞42、排气滑套43、第二密封垫圈44、第三密封圈45、第三密封座46、排气活塞套47、复位弹簧48、垫圈49、导向块50、第二密封垫圈51、第四密封圈52、密封块53、第五密封圈54、第六密封圈55。
具体实施方式
下面将结合附图和实施例对本发明做进一步的描述。
实施例一
如图2所示，是智能模块集成式空气干燥机风源净化系统图，所述空气干燥机包括进气管路8、旁通管路11、上盖板2、下盖板4、吸附塔3、气控阀5、压力传感器6、消音器7、油水分离器12、精过滤器13、除尘过滤器14、电控柜15，所述气控阀为气控组合阀5，所述空气干燥机采用集成模块式结构，集成上盖板、下盖板、吸附塔、气控组合阀、消音器为一体，并且只设有一个总排气口。如图2、图3所示，所述空气干燥机故障自动处理装置设置在空气干燥机上，所述空气干燥机故障自动处理装置包括PLC控制器1、安装在进气管路上的常开电磁阀9、安装在旁通管路上的常闭电磁阀10和安装在总排气口处的压力传感器6；所述常开电磁阀9、常闭电磁阀10和压力传感器6均与PLC控制器1电连接。
从图2、图3中可以看出，采用模块集成式结构的空气干燥机，只有一个总排气 口，在这个总排气口设置压力传感器，当压力传感器采集到的不正常压力信号(当机车因机械阀门故障或电路故障、密封失效，出现长排故障时)后，反馈到PLC控制器，PLC控制器给出指令，关闭空气干燥机的进气管路上的常开电磁阀并同时打开旁通管路上的常闭电磁阀，使压缩空气直接供给用气设备，达到应急使用，处理空气干燥机大排风的故障的目的，消除机车可能出现的事故。同时发出报警信号以提醒机车乘务员，返段后作维修处理。所以智能控制模块式机车空气干燥机能方便地对机车空气干燥机大排风的故障实现自动处理，极大的保证了行车安全。
如图4所示，为智能控制的机车空气干燥机故障自动处理装置原理图。当智能模块集成式空气干燥机出现大排风故障时，装在总排气口的压力传感器发出故障报警信号并把电信号传给干燥机上的PLC控制器，PLC控制器给出常开电磁阀关闭和常闭电磁阀打开的指令后，装在干燥机进气管路上的常开电磁阀关闭、旁通管路上的常闭电磁阀打开，使压缩空气不能进入干燥机而从旁通管路进入用气设备。从而实现自动切换、自动处理干燥机大排风故障的目的。
下面对本发明的原理作进一步详细说明。
智能控制的机车空气干燥机故障自动处理装置，它是如何实现对机车空气干燥机出现大排风故障实施自动控制的呢？机车上空气干燥机出现大排风故障时，通常是因为几种控制阀中的一种阀出现故障而造成的或者同时因二个气控阀出现故障而造成的。传统双塔空气干燥机因设计及结构上的原因根本无法解决的。当空气干燥机出现大排风故障时，只能人工关断空气干燥机进气口的截断阀门、并打开旁通管路上的截断阀门。操作不便、有时根本无法解决。而智能模块集成式空气干燥机能很好地解决这个问题。因为采用集成模块式结构后，它集成了上盖板、下盖板、吸附塔、气控组合阀、消音器等主要配件为一体、并且只有一个总排气口，这样的优化结构为空气干燥机智能控制的实现提供了便利。当空气干燥机出现大排风的故障时，在模块集成式干燥机上的气控组合阀、消音器的总排气口，装有一压力传感器，当压力传感器检测到大排风而造成不正常的压力信号时，把电信号传到PLC控制器，PLC控制器发出指令，装在干燥机进气管路上的常开电磁阀关闭、并同时打开旁通管路上的常闭电磁阀为开通状态，这时抛开了空气干燥机主体，使从空气压缩机出来的空气直接从旁通管路进入用气设备。从而切断空气干燥机大排风故障的风路，使压缩空气直接进入用气设备，自动完成了故障排除，从而保证了机车运行安全。
以下对上述气控组合阀作进一步说明。
如图5至图6所示，气控组合阀包括阀体20、密封连接在阀体两端的盖23、安装在盖上的端部密封圈24、设置在阀体内部的进气组件21、排气组件、安装在阀体下面的加热板26。阀体上设有气控组合阀进气口27和气控组合阀排气口28，所述进气组件位于阀体内上部，所述排气组件位于阀体内下部。所述排气组件包括左排气组件22和右排气组件23。气控组合阀的阀体上还设置有控制气口和出气口，所述控制气口包括左控制气口31和右控制气口32，所述出气口包括左出气口29和右出气口30。
如图7所示，所述进气组件包括进气活塞杆33和两个对称安装在进气活塞杆两端的进气活塞37，进气活塞外径小于阀体内腔的内径；每个进气活塞靠近盖的一端设有进气滑套38、第二密封圈39和第二密封座40，另一端设有第一密封座34、第一密封垫圈35和第一密封圈36。将进气活塞杆、第一密封座、第一密封垫圈、第一密封圈、进气活塞、进气滑套、第二密封圈、第二密封座依次连接好。
如图8所示，所述排气组件包括排气活塞杆41、排气活塞42、排气活塞套47、导向块50、密封块53，所述排气活塞安装在排气活塞杆上靠近盖的一端，导向块和密封块安装在排气活塞杆的另一端，排气活塞套套装在排气活塞和导向块上，排气活塞套的外径小于阀体内腔的内径；左排气组件和右排气组件左右对称安装在阀体内。所述排气组件还包括位于排气活塞和导向块之间的复位弹簧48，所述复位弹簧采用不锈钢材料制成；所述排气活塞邻近盖的一端设置有排气滑套43、第二密封垫圈44、第三密封圈45、第三密封座46、第六密封圈55，另一端设置有垫圈49、第二密封垫圈51、第四密封圈52、第五密封圈54。将排气活塞杆、排气活塞、排气滑套、第二密封垫圈、第三密封圈、第三密封座、排气活塞套、复位弹簧、垫圈、导向块、第二密封垫圈、第四密封圈、密封块、第五密封圈、第六密封圈依次连接好。
以上所述仅为本发明的优选实施例而已，并不用于限制本发明，对于本领域的技术人员来说，本发明可以有各种更改和变化。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均包含在本发明的保护范围之内。
通过上述实施例可以看出，本发明可以归纳为一种空气干燥机故障自动处理方法，采用PLC控制器对空气干燥机的长排风故障进行检测和处理；在空气干燥机的总排气口设置一个压力传感器，用于对排出气体的压力进行检测；在进气管路上安装常开电磁阀，在旁通管路上安装常闭电磁阀；所述常开电磁阀、常闭电磁阀和压力传感器均与PLC控制器电连接；当空气干燥机出现大排风故障时，安装在总排气口处的压力传感器检测到故障信号并把信号传给PLC控制器；PLC控制器发出关闭常开电磁阀和打开 常闭电磁阀的指令；空气干燥机进气管路上的常开电磁阀关闭、旁通管路上的常闭电磁阀打开；压缩空气不能进入空气干燥机的吸附塔而从旁通管路进入用气设备，从而实现自动切换、自动处理空气干燥机大排风故障。
进一步地，所述的PLC控制器采用可编程逻辑控制技术，采用模块集成式方法，搭配触摸屏，所有控制电子元件合成一体，采用封装形式，能有效防震，保证控制器的可靠性。
进一步地，所述的压力传感器和PLC控制器之间还设有报警装置，所述报警装置连接压力传感器和PLC控制器；当压力传感器检测到故障信号时，通过报警装置发出故障报警信号。
很显然，上述实施例只是本发明所列举的几个实例，理解这些实施方式仅用于说明本发明而不用于限制本发明范围，在阅读本发明后，本领域技术人员对本发明的各种等价形式的修改均落于本发明所要求的保护范围之内。

Claims (9)

  1. 一种空气干燥机故障自动处理方法，其特征是，采用PLC控制器对空气干燥机的长排风故障进行检测和处理；在空气干燥机的总排气口设置一个压力传感器，用于对排出气体的压力进行检测；在进气管路上安装常开电磁阀，在旁通管路上安装常闭电磁阀；所述常开电磁阀、常闭电磁阀和压力传感器均与PLC控制器电连接；当空气干燥机出现大排风故障时，安装在总排气口处的压力传感器检测到故障信号并把信号传给PLC控制器；PLC控制器发出关闭常开电磁阀和打开常闭电磁阀的指令；空气干燥机进气管路上的常开电磁阀关闭、旁通管路上的常闭电磁阀打开；压缩空气不能进入空气干燥机的吸附塔而从旁通管路进入用气设备，从而实现自动切换、自动处理空气干燥机大排风故障。
  2. 如权利要求1所述的空气干燥机故障自动处理方法，其特征是，所述气控组合阀包括阀体、位于阀体内上部的进气组件、位于阀体内下部的排气组件、密封连接在阀体两端的盖，阀体上设有进气口和排气口。
  3. 如权利要求2所述的空气干燥机故障自动处理方法，其特征是，所述的PLC控制器采用可编程逻辑控制技术，采用模块集成式方法，搭配触摸屏，所有控制电子元件合成一体，采用封装形式。
  4. 如权利要求3所述的空气干燥机故障自动处理方法，其特征是，所述的压力传感器和PLC控制器之间还设有报警装置，所述报警装置连接压力传感器和PLC控制器；当压力传感器检测到故障信号时，通过报警装置发出故障报警信号。
  5. 一种空气干燥机故障自动处理装置，包括空气干燥机进气管路、旁通管路、吸附塔和气控阀；其特征是，所述的气控阀为气控组合阀；在气控组合阀上设有一个总排气口，在总排气口的出口位置上安装有用于对排出气体的压力进行检测的压力传感器；在进气管路上安装常开电磁阀，在旁通管路上安装常闭电磁阀；所述常开电磁阀、常闭电磁阀和压力传感器均与PLC控制器电连接；当空气干燥机出现大排风故障时，安装在总排气口处的压力传感器检测到故障信号并把信号传给PLC控制器；PLC控制器发出关闭常开电磁阀和打开常闭电磁阀的指令；空气干燥机进气管路上的常开电磁阀关闭、旁通管路上的常闭电磁阀打开；压缩空气不能进入空气干燥机的吸附塔而从旁通管路进入用气设备，从而实现自动切换、自动处理空气干燥机大排风故障。
  6. 如权利要求5所述的空气干燥机故障自动处理装置，其特征是，所述气控组合阀包括阀体、位于阀体内上部的进气组件、位于阀体内下部的排气组件、密封连接在阀体两端的盖，阀体上设有进气口和排气口。
  7. 如权利要求6所述的空气干燥机故障自动处理装置，其特征是，所述的进气组件包括进 气活塞杆和两个对称安装在进气活塞杆两端的进气活塞，进气活塞外径小于阀体内腔的内径；每个进气活塞上靠近盖的一端设有进气滑套；所述排气组件包括排气活塞杆、排气活塞、排气活塞套、导向块、密封块，所述排气活塞安装在排气活塞杆上靠近盖的一端，导向块和密封块安装在排气活塞杆的另一端，排气活塞套套装在排气活塞和导向块上，排气活塞套的外径小于阀体内腔的内径；所述排气组件有二个，分别是左排气组件和右排气组件，左排气组件和右排气组件左右对称安装在阀体内。
  8. 如权利要求5所述的空气干燥机故障自动处理装置，其特征是，所述的PLC控制器采用可编程逻辑控制技术，采用模块集成式方法，搭配触摸屏，所有控制电子元件合成一体，采用封装形式，能有效防震，保证控制器的可靠性。
  9. 如权利要求5所述的空气干燥机故障自动处理装置，其特征是，所述的压力传感器和PLC控制器之间还设有报警装置，所述报警装置连接压力传感器和PLC控制器；当压力传感器检测到故障信号时，通过报警装置发出故障报警信号。
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