阅读说明：本技术 一种空气压缩机组智能流量调节方法和系统 (Intelligent flow adjusting method and system for air compressor set ) 是由 刘少权 王海军 任道远 朱伟 张亦凡 杨晓辉 王洪磊 于 2021-08-09 设计创作，主要内容包括：本公开关于一种空气压缩机组智能流量调节方法和系统。所述调节方法包括以下步骤：上电并且初始化；针对每一个空气压缩机组,计算其历史运行时间与历史容积流量的乘积；以及基于计算的乘积并且根据流量需求与空气压缩机组的额定容积流量的比较,确定调节方案。利用这样的方法和系统,能够实现多机组联动控制,使各机组保持在既不太高又不太低的转速运行,并且能够利用主控制器自动调控各机组的轮值运行。(The disclosure relates to an intelligent flow regulating method and system for an air compressor set. The adjusting method comprises the following steps: powering on and initializing; calculating the product of the historical operating time and the historical volume flow of each air compressor unit; and determining a regulating scheme based on the calculated product and according to a comparison of the flow demand with a rated volume flow of the air compressor package. By using the method and the system, multi-unit linkage control can be realized, each unit can be kept to operate at a rotating speed which is neither too high nor too low, and the wheel value operation of each unit can be automatically regulated and controlled by using the main controller.)

1. An intelligent flow regulating method of an air compressor unit is characterized by comprising the following steps:

powering on and initializing;

calculating the product of the historical operating time and the historical volume flow of each air compressor unit; and

based on the calculated product and on a comparison of the flow demand with a setpoint volume flow of the air compressor group, a control strategy is determined.

2. The intelligent flow regulation method of an air compressor bank of claim 1, wherein the air compressor bank having the maximum value of the product is set to a standby state and the remaining banks are powered on.

3. The intelligent flow regulation method of an air compressor set of claim 1, wherein the following regulation scheme is determined from a comparison of the flow demand and a rated volumetric flow of the air compressor set: if the flow demand is less than the rated volume flow, the air compressor set with the minimum product value is operated, and the other sets are closed; if the flow demand is larger than the rated volume flow and smaller than N times of the rated volume flow, the flow demand is evenly distributed to the active units for adjustment; and if the flow demand is greater than N times the rated volume flow, indicating that the air consumption load is excessive, adopting a temporary scheme to start the standby unit to operate, wherein N is the number of the air compressor units in use.

4. The air compressor string intelligent flow regulation method of claim 1, wherein the flow demand is directly proportional to a rotational speed of the air compressor string according to thermodynamic and hydrodynamic principles, and wherein the magnitude of the rotational speed of the air compressor string is controlled by the motor controller depending on the flow demand.

5. The intelligent flow regulating method of an air compressor set as claimed in claim 4, wherein the automatic control of the load regulation of the unit duty operation and the unit daily operation is realized by controlling the motor controller by a main controller.

6. An air compressor set intelligent flow regulation system, comprising:

the initialization module is used for electrifying and initializing the system;

a product calculation module for calculating, for each air compressor set, a product of its historical operating time and historical volumetric flow; and

a regulation scheme determination module for determining a regulation scheme based on the calculated product and based on a comparison of the flow demand with a rated volumetric flow of the air compressor package.

7. The air compressor string intelligent flow regulation system of claim 6, further comprising a flow sensor for measuring flow demand.

8. The air compressor bank intelligent flow regulation system of claim 6, wherein the adjustment scheme determination module sets the air compressor bank having the product maximum to a standby state and powers on the remaining banks.

9. The air compressor train intelligent flow regulation system of claim 6, wherein the adjustment scheme determination module determines the following adjustment scheme based on a comparison of the flow demand and a rated volume flow of the air compressor train: if the flow demand is less than the rated volume flow, the air compressor set with the minimum product value is operated, and the other sets are closed; if the flow demand is larger than the rated volume flow and is smaller than N times of the rated volume flow, evenly distributing the flow demand to a reuse unit for regulation; and if the flow demand is greater than N times the rated volume flow, indicating that the air consumption load is excessive, adopting a temporary scheme to start the standby unit to operate, wherein N is the number of the air compressor units in use.

10. The air compressor string intelligent flow regulation method of claim 6, wherein the flow demand is directly proportional to a rotational speed of the air compressor string according to thermodynamic and hydrodynamic principles, and wherein the magnitude of the rotational speed of the air compressor string is controlled by the motor controller depending on the flow demand.

Technical Field

The present disclosure relates to air compressor sets, and more particularly to intelligent flow regulation of air compressor sets.

Background

Compressed air is increasingly widely applied to production processes in various industry fields, particularly in the coal mining industry, the compressed air is used for power such as pneumatic jumbolters, pneumatic tools, pneumatic manipulators and pneumatic conveying of solid particles, and can also be used for a mine compressed air self-rescue system, so that air used for breathing is provided for operating personnel in a closed space or a toxic and harmful gas area, and the life safety and occupational health of workers are guaranteed.

3 air compressors are usually selected for the coal mine compressed air station, 1 air compressor is used for 2 air stations, and the types of the air compressors are not more than two. The main function of the standby unit is to ensure that the air supply requirement when the air compressor is periodically overhauled and the normal requirement of production is not influenced by the air supply quantity when the temporary shutdown is needed for accidents possibly occurring in the operation.

In addition, the wheel value of each air compressor is required to be operated, so that fatigue of some units due to overlong working time is avoided, and the abrasion of some units due to long-term non-operation of some units is avoided, so that the abrasion of each unit is uniform, and the service life of each unit is balanced.

CN209083521U relates to an energy-saving air compressor unit, wherein an energy-saving air compressor unit described herein includes a main controller, a first air compressor and a second air compressor. The exhaust ends of the first air compressor and the second air compressor are communicated with the cold dryer after being connected in parallel through air pipes, and one-way valves are arranged on the air pipes close to the exhaust ends of the first air compressor and the second air compressor. According to the air load condition, the first air compressor and the second air compressor are enabled to operate independently or in a cross mode, the air compressors are enabled to keep proper operation and standby interval time, better operation efficiency is achieved, the purposes of saving energy and severely punishing the service life of the air compressors are achieved, and when one air compressor is damaged or maintained, the other air compressor can keep emergency operation, and air supply interruption is avoided.

The volume flow regulating method of the air compressor comprises various methods such as electric speed regulation, machinery, pneumatics and the like. The volume flow and the rotating speed of the air compressor are in a direct proportion relation, and the main advantage of volume flow regulation by utilizing electric speed regulation is that the structure of a unit does not need to be changed, and the working process of air in the compressor is basically the same under the regulation working condition, so that the electric speed regulation method is an economic and efficient technical route with development prospect.

The air compressor set adjusting method in the prior art has the following defects:

(1) during electric speed regulation, in a low rotating speed area, internal leakage in the air compressor can cause exhaust temperature to obviously rise, the efficiency of the motor is lower when the motor operates at a low rotating speed, and in an overhigh rotating speed area, the shortage of the lubricating oil can cause unit failure.

(2) The existing frequency conversion speed regulation technology mainly carries out single machine control, and multiple units cannot be controlled in a linkage manner, so that the energy-saving effect is not optimized.

(3) The existing control strategy is mainly used for adjusting the volume flow according to the pressure change of a compressed air storage tank and a pipeline, and the pressure is greatly influenced by external factors such as the ambient temperature, the altitude and the like, so that the adjusting precision is not accurate enough.

(4) The running of the duty of each unit is mainly controlled manually according to manual experience or automatically according to the working time of each unit, and the load difference factor of each unit is not considered, so the control method is not scientific and reasonable.

To this end, it is desirable to provide an improved intelligent flow regulation method and system for an air compressor set.

Disclosure of Invention

The present disclosure provides an intelligent flow regulating method and system for an air compressor unit, in which multi-unit linkage control is implemented to keep each unit running at a rotational speed which is neither too high nor too low, and the main controller can be used to automatically regulate and control the running of the wheel value of each unit.

According to one aspect of the present disclosure, an intelligent flow rate adjusting method for an air compressor set is provided, which is characterized by comprising the following steps: powering on and initializing; calculating the product of the historical operating time and the historical volume flow of each air compressor unit; and determining a regulating scheme based on the calculated product and according to a comparison of the flow demand with a rated volume flow of the air compressor package.

In one embodiment, the air compressor set having the maximum product is set to standby and the remaining units are powered on.

In a further exemplary embodiment, the following control strategy is determined as a function of the flow demand in comparison with the setpoint volume flow of the air compressor group: if the flow demand is less than the rated volume flow, the air compressor set with the minimum product value is operated, and the other sets are closed; if the flow demand is larger than the rated volume flow and smaller than N times of the rated volume flow, the flow demand is evenly distributed to the active units for adjustment; and if the flow demand is greater than N times the rated volume flow, indicating that the air consumption load is excessive, adopting a temporary scheme to start the standby unit to operate, wherein N is the number of the air compressor units in use.

In yet another embodiment, the flow demand is proportional to the rotational speed of the air compressor according to thermodynamic and hydrodynamic principles, and wherein the magnitude of the rotational speed of the air compressor is controlled by the motor controller depending on the flow demand.

In another embodiment, the motor controller is controlled by the main controller to realize automatic control of the load regulation of the unit running and daily running.

According to a second aspect of the present disclosure, there is provided an intelligent flow regulating system for an air compressor set, comprising: the initialization module is used for electrifying and initializing the system; a product calculation module for calculating, for each air compressor set, a product of its historical operating time and historical volumetric flow; and a regulation scheme determination module for determining a regulation scheme based on the calculated product and based on a comparison of the flow demand with a rated volume flow of the air compressor package.

In one embodiment of the present disclosure, a flow sensor is further included for measuring a flow demand; the adjustment scheme determination module sets the air compressor group having the maximum value of the product to a standby state and starts up the remaining units.

In another embodiment of the disclosure, the adjustment scheme determination module determines the following adjustment scheme based on a comparison of the flow demand and a rated volumetric flow of the air compressor package: if the flow demand is less than the rated volume flow, the air compressor unit with the minimum product is operated, and the rest units are closed; if the flow demand is larger than the rated volume flow and is smaller than N times of the rated volume flow, evenly distributing the flow demand to a reuse unit for regulation; and if the flow demand is greater than N times the rated volume flow, indicating that the air consumption load is excessive, adopting a temporary scheme to start the standby unit to operate, wherein N is the number of the air compressor units in use.

In yet another embodiment of the present disclosure, the flow demand is proportional to the rotational speed of the air compressor according to thermodynamic and hydrodynamic principles, and wherein the magnitude of the rotational speed of the air compressor is controlled by the motor controller depending on the flow demand.

According to the intelligent flow adjusting method and system for the air compressor unit, after the system is electrified and initialized; calculating the product of the historical operating time and the historical volume flow of each air compressor unit; and determining a regulating scheme based on the calculated product and according to a comparison of the flow demand with a rated volume flow of the air compressor package. Based on the method, the master controller can be used for multi-unit linkage control and wheel value operation control; the motor power control device can enable all units to be operated at a rotating speed which is neither too high nor too low, and enables the motor power to be in an efficient area.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present disclosure and, together with the description, serve to explain the principles of the disclosure and are not to be construed as limiting the disclosure.

FIG. 1 is a schematic diagram of intelligent flow regulation of an air compressor package according to an embodiment of the present disclosure.

FIG. 2 is a flow chart of an air compressor package intelligent flow regulation method according to an embodiment of the present disclosure.

FIG. 3 is a detailed operational flow diagram for determining a modulation scheme based on a calculated product and based on a comparison of a flow demand and a rated volumetric flow of an air compressor package according to an embodiment of the present disclosure.

FIG. 4 is a block diagram of an air compressor package intelligent flow regulation system according to an embodiment of the present disclosure.

Detailed Description

In order to make the technical solutions of the present disclosure better understood by those of ordinary skill in the art, the technical solutions in the embodiments of the present disclosure will be clearly and completely described below with reference to the accompanying drawings.

It should be noted that the terms "first," "second," and the like in the description and claims of the present disclosure and in the above-described drawings are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the disclosure described herein are capable of operation in sequences other than those illustrated or otherwise described herein. The implementations described in the exemplary embodiments below are not intended to represent all implementations consistent with the present disclosure. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the present disclosure, as detailed in the appended claims.

FIG. 1 is a schematic diagram of intelligent flow regulation of an air compressor package according to an embodiment of the present disclosure. In fig. 1, an air compression system is shown that includes three air compressor packages, each air compressor package including a motor controller, a motor controller, and a compressed air storage tank. The main controller is responsible for controlling the entire air compression system and the flow sensor is used to measure the flow demand of the air compression system. The dashed lines in fig. 1 are signal lines and control lines, the solid lines are strong electric wires, and the compressed air tank output is a compressed air pipe, and in the schematic diagram of fig. 1, accessories such as valves and switches are omitted.

The working flow of the intelligent flow regulating method of the air compressor set according to the embodiment of the disclosure is explained with reference to fig. 2.

First, the system is powered up and initialized.

Then, in step 201, for each air compressor package, the product of its historical operating time and historical volumetric flow is calculated. Specifically, for a first air compressor set, assuming the historical operating time of the first air compressor set to be t1 and the historical volume flow rate to be Qv1, the product value of t1 × Qv1 is calculated; for a second air compressor set, assuming the historical operating time of the second air compressor set is t2 and the historical volumetric flow rate is Qv2, calculating the product value of t2 x Qv 2; and for the third air compressor package, calculating the product of t3 by Qv3 assuming a historical operating time of the third air compressor package of t3 and a historical volumetric flow rate of Qv 3.

Next, in step 202, a regulation scheme is determined based on the product value calculated for each air compressor package and based on a comparison of the flow demand with the rated volumetric flow of the air compressor package.

Specifically, after the product of the historical operating time and the historical volume flow rate of each air compressor group is calculated in step 201 above, the air compressor group having the maximum value of the product is set to the standby state, and the remaining groups are started up for operation. For the flow rate adjustment system in fig. 1, the total number of air compressor groups is 3, and after the air compressor group having the largest product is set to the standby state, the number of remaining air compressor groups is 2.

Further, with the flow sensor of fig. 1, the flow demand Qv of the entire air compression system is measured. In addition, assume that the nominal volume flow of the known air compressor assemblies is Qve, wherein the nominal volume flow of each air compressor assembly is the same. With reference to fig. 3, the following regulation scheme is determined as a function of the flow demand in comparison with the rated volumetric flow of the air compressor group: if the flow demand Qv is less than the nominal volume flow Qve, the air compressor group with the smallest product is operated, and the remaining groups are closed; if the flow demand Qv is greater than the nominal volume flow Qve and less than 2 times the nominal volume flow Qve, then the regulation is carried out according to the flow demand being divided equally between the two consumers; and if the flow demand Qv is greater than 2 times the rated volume flow Qve, indicating an excessive gas load, a temporary scheme is taken to start the backup unit operation. That is, in the flow rate adjustment method according to the present invention, first, the air compressor group having the largest product value is set as the backup group, and then only one active air compressor group is activated in a case where the flow rate demand Qv can be satisfied by using one air compressor group, and two active air compressor groups are simultaneously activated in a case where the flow rate demand Qv can be satisfied by using two air compressor groups, and the backup group is activated in a case where the flow rate demand Qv cannot be satisfied by using two air compressor groups.

It will be apparent to those skilled in the art that the flow demand is directly proportional to the rotational speed of the air compressor package, based on thermodynamic and hydrodynamic principles. When the flow demand is greater, the speed of the air compressor package is faster and, when the flow demand is less, the speed of the air compressor package is slower.

In one example of the present invention, the speed regulation range corresponding to the high efficiency region of the air compressor set is from nmin (corresponding to the volume flow rate Qvmin) to ne (corresponding to the volume flow rate Qve), where nmin is less than ne; qvmin is less than Qve. Where nmin represents the minimum rotational speed of the air compressor assembly and ne represents the nominal rotational speed of the air compressor assembly. When the air compressor set is operated at the minimum rotation speed nmin, the corresponding volume flow Qvmin is the minimum volume flow of the air compressor set; and when the air compressor package is operating at the rated speed ne, the corresponding volumetric flow Qve is the rated volumetric flow of the air compressor package. For each respective air compressor group, its operating speed is between the minimum speed nmin and the nominal speed ne, so that its volume flow is between the minimum air volume flow Qvmin and the nominal volume flow Qve.

In one example of the invention, the rotational speed of the air compressor package, which is dependent on the flow demand, is controlled by a motor controller. The motor controller controls each air compressor unit according to the flow demand received from the flow sensor, so that the rotating speed of the air compressor units is controlled, the required flow demand can be met by the cooperation of the three air compressor units, and the intelligent flow regulation of the air compressor units is realized. Namely, the motor controller is controlled by the main controller to realize automatic control of load adjustment of unit duty running and unit daily running.

FIG. 4 is a block diagram of an air compressor package intelligent flow regulation system according to an embodiment of the present disclosure. Referring to fig. 4, the intelligent flow regulating system of the air compressor set according to the present invention includes an initialization module for powering up and initializing the system; a product calculation module for calculating for each air compressor package the product of its historical operating time and historical volumetric flow; and a control strategy determination module for determining a control strategy on the basis of the calculated product and as a function of a comparison of the flow demand with a target volume flow of the air compressor assembly. The system further includes a flow sensor for measuring a flow demand. The air compressor set intelligent flow regulation system shown in fig. 4 operates according to the intelligent flow regulation method described above with reference to fig. 2 and 3.

According to the intelligent flow regulating method and system for the air compressor, the product of the historical running time and the historical volume flow is calculated by considering both the historical running time and the historical volume, and the regulating scheme is determined based on the calculated product and according to the comparison between the flow demand and the rated volume flow of the air compressor unit. Based on the method and the system, the main controller can be used for carrying out multi-unit linkage control and wheel value operation control, and each unit can be kept to operate at a rotating speed which is neither too high nor too low, so that the power of the motor is in a high-efficiency area.

Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure disclosed herein. This application is intended to cover any variations, uses, or adaptations of the disclosure following, in general, the principles of the disclosure and including such departures from the present disclosure as come within known or customary practice within the art to which the disclosure pertains. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.

It will be understood that the present disclosure is not limited to the precise arrangements described above and shown in the drawings and that various modifications and changes may be made without departing from the scope thereof. The scope of the present disclosure is limited only by the appended claims.