阅读说明：本技术 一种智能空压站的运行保护系统 (Operation protection system of intelligent air compression station ) 是由 胡培生 孙小琴 杨瑞清 胡明辛 于 2021-08-24 设计创作，主要内容包括：本发明公开了一种智能空压站的运行保护系统,涉及空压机技术领域,包括水垢监测模块、运行保护模块、控制器、散热模块、气体泄漏检测模块；所述水垢监测模块与空压机相连接,在空压机停机后或启动前,用于检测空压机是否存在水垢,并根据水垢的堵塞情况判断空压机是否需要清洗；避免空压机由于长期运行导致设备被水垢堵塞,造成资源损耗；所述运行保护模块用于根据空压机的实时工作参数对空压机进行保护调节,防止出现爆炸险情；所述气体泄漏检测模块用于检测空压机运行过程中是否存在气体泄漏,并及时提示工作人员对空压机进行检修,有效提高空压机的运行安全。(The invention discloses an operation protection system of an intelligent air compression station, which relates to the technical field of air compressors and comprises a scale monitoring module, an operation protection module, a controller, a heat dissipation module and a gas leakage detection module; the scale monitoring module is connected with the air compressor, and is used for detecting whether the air compressor has scale or not after the air compressor is stopped or before the air compressor is started, and judging whether the air compressor needs to be cleaned or not according to the blocking condition of the scale; the problem that the air compressor is blocked by water scale due to long-term operation to cause resource loss is avoided; the operation protection module is used for protecting and adjusting the air compressor according to real-time working parameters of the air compressor so as to prevent explosion dangerous situations; the gas leakage detection module is used for detecting whether gas leakage exists in the running process of the air compressor or not, and timely prompts workers to overhaul the air compressor, so that the running safety of the air compressor is effectively improved.)

1. An operation protection system of an intelligent air compression station is characterized by comprising a database, a scale monitoring module, a controller, a cleaning module, an information acquisition module, an operation protection module and a heat dissipation module;

scale monitoring module: the water quality monitoring device is connected with the air compressor and is used for detecting whether the air compressor has scale or not after the air compressor is stopped or before the air compressor is started and judging whether the air compressor needs to be cleaned or not according to the blocking condition of the scale;

a cleaning module: the air compressor cleaning device is used for cleaning the air compressor by workers;

the information acquisition module: the system comprises an operation protection module, a real-time working parameter acquisition module and a real-time working parameter acquisition module, wherein the real-time working parameter acquisition module is used for acquiring the real-time working parameter of the air compressor and sending the real-time working parameter to the operation protection module; the operation protection module: the method is used for protecting and adjusting the air compressor in the running process of the air compressor, and comprises the following specific steps:

v1: powering on the air compressor, and performing starting detection on the air compressor;

v2: after starting up detection, the air compressor is normally started and stopped, real-time working parameters of the air compressor are collected, and the air compressor is protected and adjusted according to the real-time working parameters;

a heat dissipation module: the air compressor cooling device is used for cooling and radiating the air compressor.

2. The operation protection system of the intelligent air compressor station is characterized in that the database stores standard parameter information and standard image information of the air compressor; the standard parameter information comprises standard weight, model, length, width and height; the real-time working parameters comprise the real-time temperature of the air compressor, the air pressure of the air cylinder and the air displacement.

3. The operation protection system of the intelligent air compression station as claimed in claim 1, wherein the scale monitoring module comprises a weight detection unit, an image detection unit and an infrared scanning probe, and the operation steps are as follows:

acquiring the weight ratio of scale, the number of scale areas, the area ratio of scale and the thickness of scale of the air compressor; if the weight ratio of the water scale is larger than or equal to the ratio threshold, generating a cleaning signal;

evaluating the cleaning coefficient of the air compressor according to the distribution quantity of the scale areas, the area ratio of the scale areas and the thickness of the scale; if the cleaning coefficient is larger than or equal to a preset coefficient threshold value, generating a cleaning signal;

the scale monitoring module is used for transmitting the cleaning signal to the controller, and the controller is used for sending reminding information to the cleaning module after receiving the cleaning signal.

4. The operation protection system of the intelligent air compression station as claimed in claim 3, wherein the method for acquiring the scale weight ratio, the scale area distribution number, the scale area ratio and the scale thickness of the air compressor comprises the following steps:

monitoring the weight of the air compressor in real time through a weight detection unit, and marking as Z1;

acquiring standard parameter information of the air compressor from a database, and marking the standard weight of the air compressor as ZT; calculating to obtain a scale weight ratio ZD by using a formula ZD ═ Z1-ZT)/ZT multiplied by mu, wherein mu is a compensation factor and takes a value of 1.37;

whether scale deposits exist on the inner wall of the air compressor is preliminarily detected through the infrared scanning probe, and when the scale deposits exist on the inner wall of the air compressor, the thickness of the center of the scale area is obtained through the infrared distance meter and marked as the scale thickness;

acquiring real-time image information of the inner wall of the air compressor through an image detection unit; acquiring standard image information of the inner wall of the air compressor from a database, and comparing the real-time image information with the standard image information; obtaining the area of the scale area and the distribution number of the scale area; and dividing the area of the scale by the area of the inner wall of the air compressor to obtain the area ratio of the scale.

5. The operation protection system of the intelligent air compression station as claimed in claim 1, wherein in step V1, the air compression machine is subjected to startup detection, and the specific steps are as follows:

acquiring current working parameters of the air compressor when the air compressor is started, if the temperature of the air compressor is less than or equal to 85 ℃, continuing to observe the operation of the air compressor, and judging whether the operation of the air compressor is interrupted for 5 mins; if the air compressor is interrupted, the air compressor stops running, and workers are prompted to overhaul the air compressor;

if the temperature of the air compressor is higher than 85 ℃, judging whether the air pressure of the air cylinder is larger than or equal to 1.1 Mpa; if the air pressure of the air cylinder is larger than or equal to 1.1Mpa, the air compressor is not started, and the operation protection module controls the heat dissipation module to cool and dissipate heat of the air compressor.

6. The operation protection system of the intelligent air compression station as claimed in claim 1, wherein in step V2, the air compressor is subjected to protection adjustment according to real-time working parameters, specifically:

acquiring the air pressure of an air compressor, if the air pressure of the air compressor is less than 0.85Mpa, judging whether the temperature of the air compressor is greater than 110 ℃, and if the temperature of the air compressor is less than or equal to 110 ℃, inflating the air compressor to 1.02 Mpa; if the temperature of the air compressor is more than 110 ℃, delaying the time of 25s for stopping the air compressor;

and acquiring the air displacement of the air compressor, and if the air displacement is greater than a preset air displacement threshold, controlling and adjusting the working frequency of the air compressor by the operation protection module.

7. The operation protection system of the intelligent air compressor station is characterized by further comprising a gas leakage detection module, wherein the gas leakage detection module is used for detecting whether gas leakage exists in the operation process of the air compressor; when detecting that the air compressor has gas leakage, generate gas leakage signal and send it to the controller, the controller receives gas leakage signal back control air compressor machine shut down to the suggestion staff overhauls the air compressor machine.

8. The operation protection system of an intelligent air compressor station as claimed in claim 7, wherein the gas leakage detection module comprises a pressure sensor and a gas flow rate sensor distributed on the surface of the air compressor.

Technical Field

The invention relates to the technical field of air compressors, in particular to an operation protection system of an intelligent air compression station.

Background

The air compression station is a compressed air station and consists of an air compressor, an air storage tank (divided into a first-stage air storage tank and a second-stage air storage tank), air treatment and purification equipment and a cold dryer.

An air compressor is a device for compressing gas. The air compressor is constructed similarly to a water pump. Most air compressors are of the reciprocating piston type, rotating vane or rotating screw type; in order to ensure that the air compressor can normally and reliably run and the service life of the unit is ensured, a detailed maintenance plan needs to be made, and the air compressor unit is kept clean, free of oil and dirt by performing personnel operation, regular maintenance and regular inspection and maintenance;

the currently used air compressor is not monitored in real time, the temperature and the air displacement of the compressor cannot be monitored in real time, the compressor can be blocked by water scale due to long-term operation, and if the compressor is impacted by external force, a pressure switch fails or the ambient temperature of the compressor is changed too fast, the air compression station can explode.

Disclosure of Invention

In order to solve the problems existing in the scheme, the invention provides an operation protection system of an intelligent air compression station.

The purpose of the invention can be realized by the following technical scheme:

an operation protection system of an intelligent air compression station comprises a database, a scale monitoring module, a controller, a cleaning module, an information acquisition module, an operation protection module and a heat dissipation module;

scale monitoring module: the water quality monitoring device is connected with the air compressor and is used for detecting whether the air compressor has scale or not after the air compressor is stopped or before the air compressor is started and judging whether the air compressor needs to be cleaned or not according to the blocking condition of the scale;

a cleaning module: the air compressor cleaning device is used for cleaning the air compressor by workers;

the information acquisition module: the system comprises an operation protection module, a real-time working parameter acquisition module and a real-time working parameter acquisition module, wherein the real-time working parameter acquisition module is used for acquiring the real-time working parameter of the air compressor and sending the real-time working parameter to the operation protection module; the operation protection module: the method is used for protecting and adjusting the air compressor according to real-time working parameters of the air compressor, and comprises the following specific steps:

v1: powering on the air compressor, and performing starting detection on the air compressor;

v2: after starting up detection, the air compressor is normally started and stopped, real-time working parameters of the air compressor are collected, and the air compressor is protected and adjusted according to the real-time working parameters;

a heat dissipation module: the air compressor cooling device is used for cooling and radiating the air compressor.

Further, the database stores standard parameter information and standard image information of the air compressor; the standard parameter information comprises standard weight, model, length, width and height; the real-time working parameters comprise the real-time temperature of the air compressor, the air pressure of the air cylinder and the air displacement.

Further, the incrustation scale monitoring module includes weight detecting element, image detecting element and infrared scanning probe, and concrete work step is as follows:

acquiring the weight ratio of scale, the number of scale areas, the area ratio of scale and the thickness of scale of the air compressor; if the weight ratio of the water scale is larger than or equal to the ratio threshold, generating a cleaning signal;

evaluating the cleaning coefficient of the air compressor according to the distribution quantity of the scale areas, the area ratio of the scale areas and the thickness of the scale; if the cleaning coefficient is larger than or equal to a preset coefficient threshold value, generating a cleaning signal;

the scale monitoring module is used for transmitting the cleaning signal to the controller, and the controller is used for sending reminding information to the cleaning module after receiving the cleaning signal.

Further, the method for acquiring the scale weight ratio, the scale area distribution number, the scale area ratio and the scale thickness of the air compressor comprises the following steps:

monitoring the weight of the air compressor in real time through a weight detection unit, and marking as Z1;

acquiring standard parameter information of the air compressor from a database, and marking the standard weight of the air compressor as ZT; calculating to obtain a scale weight ratio ZD by using a formula ZD ═ Z1-ZT)/ZT × μ, wherein μ is a compensation factor, for example, μ takes a value of 1.37;

whether scale deposits exist on the inner wall of the air compressor is preliminarily detected through the infrared scanning probe, and when the scale deposits exist on the inner wall of the air compressor, the thickness of the center of the scale area is obtained through the infrared distance meter and marked as the scale thickness;

acquiring real-time image information of the inner wall of the air compressor through an image detection unit; acquiring standard image information of the inner wall of the air compressor from a database, and comparing the real-time image information with the standard image information; obtaining the area of the scale area and the distribution number of the scale area; and dividing the area of the scale by the area of the inner wall of the air compressor to obtain the area ratio of the scale.

Further, in step V1, the air compressor is subjected to start-up detection, and the specific steps are as follows:

acquiring current working parameters of the air compressor when the air compressor is started, if the temperature of the air compressor is less than or equal to 85 ℃, continuing to observe the operation of the air compressor, and judging whether the operation of the air compressor is interrupted for 5 mins; if the air compressor is interrupted, the air compressor stops running, and workers are prompted to overhaul the air compressor;

if the temperature of the air compressor is higher than 85 ℃, judging whether the air pressure of the air cylinder is larger than or equal to 1.1 Mpa; if the air pressure of the air cylinder is larger than or equal to 1.1Mpa, the air compressor is not started, and the operation protection module controls the heat dissipation module to cool and dissipate heat of the air compressor.

Further, in step V2, performing protection adjustment on the air compressor according to the real-time working parameters, specifically:

acquiring the air pressure of an air compressor, if the air pressure of the air compressor is less than 0.85Mpa, judging whether the temperature of the air compressor is greater than 110 ℃, and if the temperature of the air compressor is less than or equal to 110 ℃, inflating the air compressor to 1.02 Mpa; if the temperature of the air compressor is more than 110 ℃, delaying the time of 25s for stopping the air compressor;

and acquiring the air displacement of the air compressor, and if the air displacement is greater than a preset air displacement threshold, controlling and adjusting the working frequency of the air compressor by the operation protection module.

Further, the system also comprises a gas leakage detection module for detecting whether gas leakage exists in the operation process of the air compressor; when detecting that the air compressor has gas leakage, generate gas leakage signal and send it to the controller, the controller receives gas leakage signal back control air compressor machine shut down to the suggestion staff overhauls the air compressor machine.

Further, the gas leakage detection module comprises a pressure sensor and a gas flow rate sensor which are distributed on the surface of the air compressor.

Compared with the prior art, the invention has the beneficial effects that:

1. after the air compressor is shut down or before the air compressor is started, the scale monitoring module is used for detecting whether the air compressor is blocked by scale or not, and judging whether the air compressor needs to be cleaned or not according to the blocking condition of the scale; the problem that the air compressor is blocked by water scale due to long-term operation to cause resource loss is avoided; the working efficiency of the air compressor is improved;

2. the operation protection module is used for protecting and adjusting the air compressor according to real-time working parameters of the air compressor; firstly, electrifying an air compressor, carrying out starting detection on the air compressor, judging whether the air compressor can be normally started or stopped, and inflating or stopping the air compressor in a delayed manner according to the temperature of the air compressor and the air pressure of an air cylinder after starting detection so as to protect the air compressor and prevent explosion danger; the gas leakage detection module is used for detecting whether gas leakage exists in the operation process of the air compressor; and prompt the staff in time to overhaul the air compressor, effectively improve the operation safety of air compressor machine.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.

Fig. 1 is a schematic block diagram of an operation protection system of an intelligent air compression station according to the present invention.

Detailed Description

The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

As shown in fig. 1, an operation protection system of an intelligent air compression station includes a database, a scale monitoring module, a controller, a cleaning module, an information acquisition module, an operation protection module, and a heat dissipation module;

the database stores standard parameter information and standard image information of the air compressor; the standard parameter information comprises standard weight, model, length, width and height;

the scale monitoring module is connected with the air compressor, and is used for detecting whether the air compressor is blocked by scale or not after the air compressor is stopped or before the air compressor is started, and judging whether the air compressor needs to be cleaned or not according to the blocking condition of the scale; the method specifically comprises the following steps:

s1: acquiring the weight ratio of scale, the number of scale areas, the area ratio of scale and the thickness of scale of the air compressor; the method specifically comprises the following steps:

monitoring the weight of the air compressor in real time through a weight detection unit, and marking as Z1;

acquiring standard parameter information of the air compressor from a database, and marking the standard weight of the air compressor as ZT; calculating to obtain a weight ratio ZD of the scale according to Z1 and ZT, wherein the specific calculation formula is as follows:

ZD＝(Z1-ZT)/ZT×μ

in the formula, mu is a compensation factor; for example, μ takes the value 1.37; for example, the abrasion of the air compressor in the operation process or the corrosion of the air compressor caused by the external environment can reduce or increase the weight of the air compressor, and at the moment, a compensation factor is introduced to eliminate the influence of the external factors;

whether scale deposits exist on the inner wall of the air compressor is preliminarily detected through the infrared scanning probe, and when the infrared scanning probe detects that the scale deposits exist on the inner wall of the air compressor, the thickness of the center of a scale area is obtained through the infrared distance meter and marked as scale thickness ZS;

acquiring real-time image information of the inner wall of the air compressor through an image detection unit; acquiring standard image information of the inner wall of the air compressor from a database, and comparing the real-time image information with the standard image information; obtaining the area of the scale area;

counting the distribution number of the scale areas as C1, summing the areas of the scale areas to obtain a total scale area, and dividing the total scale area by the inner wall area of the air compressor to obtain a scale area ratio and marking as ZM;

s2: comparing the weight proportion of the scale with a proportion threshold value;

if the weight ratio of the water scale is larger than or equal to the ratio threshold, generating a cleaning signal;

s3: evaluating the cleaning coefficient of the air compressor according to the distribution quantity of the scale areas, the area ratio of the scale areas and the thickness of the scale;

comparing the cleaning coefficient with a preset coefficient threshold;

if the cleaning coefficient is larger than or equal to a preset coefficient threshold value, generating a cleaning signal;

the scale monitoring module is used for transmitting the cleaning signal to the controller, the controller is used for sending reminding information to the cleaning module after receiving the cleaning signal, and the reminding information is used for reminding a worker to clean the air compressor to remove scale;

the cleaning module is used for cleaning the air compressor by workers;

the scale monitoring module comprises a weight detection unit, an image detection unit and an infrared scanning probe, wherein the weight detection unit is used for detecting the weight of the air compressor in real time; the infrared scanning probe is used for preliminarily detecting whether obvious scale accumulation exists in the air compressor or not; when the infrared scanning probe detects that scale deposits exist in the air compressor, the image detection unit is used for acquiring real-time image information in the air compressor;

the information acquisition module is used for acquiring real-time working parameters of the air compressor and transmitting the real-time working parameters to the operation protection module, and the operation protection module is used for protecting and adjusting the air compressor according to the real-time working parameters of the air compressor; the real-time working parameters comprise the real-time temperature of the air compressor, the air pressure of the air cylinder and the air displacement;

the information acquisition module comprises a temperature sensor, an air pressure sensor and an exhaust detector, wherein the temperature sensor is used for acquiring the real-time temperature of the air compressor, the air pressure sensor is used for acquiring the air pressure of an air cylinder, and the exhaust detector is used for acquiring the exhaust volume of the air compressor;

the specific steps of the operation protection module for carrying out protection adjustment on the air compressor are as follows:

v1: the air compressor machine circular telegram carries out the start-up detection to the air compressor machine, specifically is:

acquiring current working parameters of the air compressor when the air compressor is started, and judging whether the temperature of the air compressor is higher than 85 ℃; if the temperature of the air compressor is less than or equal to 85 ℃, continuing to observe the operation of the air compressor, judging whether the operation of the air compressor is interrupted for 5mins, if so, stopping the operation of the air compressor, and prompting a worker to overhaul the air compressor;

if the temperature of the air compressor is higher than 85 ℃, judging whether the air pressure of the air cylinder is larger than or equal to 1.1 Mpa; if the air pressure of the air cylinder is more than or equal to 1.1Mpa, the air compressor is not started, and the operation protection module controls the heat dissipation module to cool and dissipate heat of the air compressor;

v2: after starting up detection, normally starting and stopping the air compressor, and acquiring real-time working parameters of the air compressor;

acquiring the air pressure of an air compressor, and judging whether the air pressure of the air compressor is less than 0.85Mpa or not;

if the air pressure of the air cylinder is less than 0.85Mpa, judging whether the temperature of the air compressor is more than 110 ℃, and if the temperature of the air compressor is less than or equal to 110 ℃, inflating the air compressor to 1.02 Mpa; if the temperature of the air compressor is more than 110 ℃, the air compressor is delayed for 25s and is stopped, and the air compressor is protected to prevent explosion danger;

acquiring the air displacement of the air compressor, and judging whether the air displacement is greater than a preset air displacement threshold value or not;

if the air displacement is larger than a preset air exhaust threshold value, the operation protection module controls and adjusts the working frequency of the air compressor;

the system also comprises a gas leakage detection module for detecting whether gas leakage exists in the operation process of the air compressor; the gas leakage detection module comprises a pressure sensor and a gas flow velocity sensor which are distributed on the surface of the air compressor; when detecting that the air compressor machine has gas leakage, generate gas leakage signal and send it to the controller, the controller receives gas leakage signal control air compressor machine and shuts down to the suggestion staff overhauls the air compressor machine.

The above formulas are all calculated by removing dimensions and taking numerical values thereof, the formula is a formula which is obtained by acquiring a large amount of data and performing software simulation to obtain the closest real situation, and the preset parameters and the preset threshold value in the formula are set by the technical personnel in the field according to the actual situation or obtained by simulating a large amount of data.

The working principle of the invention is as follows:

when the operation protection system of the intelligent air compression station works, after an air compressor is shut down or before the air compressor is started, whether the air compressor is blocked by scale or not is detected through a scale monitoring module, and whether the air compressor needs to be cleaned or not is judged according to the blocking condition of the scale; acquiring the weight proportion of scale, the number of scale regions, the area proportion of scale and the thickness of scale of the air compressor, evaluating the cleaning coefficient of the air compressor according to the number of scale regions, the area proportion of scale and the thickness of scale, and generating a cleaning signal when the weight proportion of scale is not less than the proportion threshold value or the cleaning coefficient is not less than the preset coefficient threshold value, so as to prompt a worker to clean the air compressor and remove scale; the problem that the air compressor is blocked by water scale due to long-term operation to cause resource loss is avoided, and the working efficiency of the air compressor is improved;

the operation protection module is used for protecting and adjusting the air compressor according to real-time working parameters of the air compressor; firstly, electrifying an air compressor, carrying out starting detection on the air compressor, judging whether the air compressor can be normally started or stopped, normally starting and stopping the air compressor after starting detection, inflating or stopping the air compressor in a delayed manner according to the temperature of the air compressor and the air pressure of an air cylinder, protecting the air compressor, and preventing explosion danger; the gas leakage detection module is used for detecting whether gas leakage exists in the running process of the air compressor or not and timely prompting workers to overhaul the air compressor.

In the description herein, references to the description of "one embodiment," "an example," "a specific example" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

The preferred embodiments of the invention disclosed above are intended to be illustrative only. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best utilize the invention. The invention is limited only by the claims and their full scope and equivalents.