Method and system for automatically starting and stopping compressed air source

Abstract

The invention relates to the technical field of compressed air, in particular to a method and system for automatically starting and stopping a compressed air source, and the method comprises the steps: monitoring an air pressure value in real time through an intelligent monitoring module, and timely responding to the air pressure change; the air pressure value data collected by the intelligent monitoring module is compared with a preset limit value, and starting and stopping of the compressor are intelligently decided; the air pressure in the air storage tank is judged in real time through the automatic starting and stopping compressed air source system, and the compressor is controlled to be automatically started and stopped; the automatic control level of the control system is integrated and improved through coordination control of compressed air; by adding the air source purification module, the water removal, oil removal and dust removal effects of the drying machine are enhanced, and the air source quality is improved; and the operation time of the compressor is optimized according to historical data and real-time requirements. The method has the beneficial effects that the compressor is automatically started or stopped according to the actual air pressure requirement, energy consumption is reduced, automatic starting and stopping of the compressor are achieved, and continuity and stability of air source supply under different air using requirements are ensured.

Description

Technical Field

[0001] The invention relates to the technical field of compressed air, and in particular to a method and system for automatically starting and stopping a compressed air source. Background Art

[0002] In the field of contemporary industrial manufacturing and automation, compressed air is widely used as a key power source to drive and perform various mechanical movements due to its clean, safe and easy-to-control characteristics. It plays an indispensable role in automated production lines, pneumatic tools, pneumatic control systems and many process flows. A reliable and efficient compressed air supply system has a significant impact on ensuring the continuity of the production process, improving production efficiency and ensuring product quality.

[0003] However, traditional compressed air supply systems often rely on manual operation or simple time-based automation control strategies. These methods often lack the ability to respond to actual air pressure needs in real time, causing the compressor to frequently switch between full load and no-load, or continue to run when not needed, resulting in energy waste. In addition, manual control makes it difficult to achieve precise air pressure regulation, which may affect the performance of pneumatic equipment and the processing quality of products. Against the backdrop of increasing environmental awareness and rising energy costs, these systems can no longer meet the stringent requirements of modern industry for energy efficiency and cost control. Summary of the invention

[0004] In view of the above problems or problems existing in the prior art, the present invention is proposed.

[0005] Therefore, the purpose of the present invention is to provide a method for automatically starting and stopping a compressed air source, which can solve the problem of energy waste and low production efficiency caused by the lack of real-time demand response and precise control capabilities in traditional compressed air supply systems.

[0006] In order to solve the above technical problems, the present invention provides the following technical solutions: a method for automatically starting and stopping a compressed air source, which includes real-time monitoring of air pressure values ​​through an intelligent monitoring module and timely response to air pressure changes;

[0007] The air pressure data collected by the intelligent monitoring module is compared with the preset limit value to intelligently decide whether to start or stop the compressor;

[0008] The air pressure in the air storage tank is judged in real time through the automatic start-stop compressed air source system to control the automatic start-stop of the compressor;

[0009] Through the coordinated control of compressed air, the automation control level of the control system is integrated and improved;

[0010] By adding an air source purification module, the dryer can enhance its water, oil and dust removal effects and improve the air source quality.

[0011] Optimize compressor operating time based on historical data and real-time demand.

[0012] As a preferred solution of the method for automatically starting and stopping a compressed gas source of the present invention, a pressure sensor is installed inside a gas storage tank to monitor the air pressure changes in the gas storage tank in real time, and the data of the pressure sensor is transmitted to an intelligent monitoring module via wired or wireless means.

[0013] As a preferred solution of the method for automatically starting and stopping a compressed air source of the present invention, the intelligent monitoring module has built-in logic judgment, which compares the real-time value of the air pressure with the preset minimum and maximum limits to intelligently decide whether to start or stop the compressor.

[0014] As a preferred solution of the method for automatically starting and stopping a compressed gas source of the present invention, the intelligent monitoring module makes a real-time judgment on the air pressure in the gas tank. When the air pressure in the gas tank drops to a preset minimum limit, the compressor is controlled to start, so that it starts working and increases the air pressure; when the air pressure rises to a preset maximum limit, the compressor is controlled to stop.

[0015] As a preferred solution of the method for automatically starting and stopping a compressed air source of the present invention, the coordinated control includes setting up multiple air compressors to operate in parallel, and when one air compressor is started and reaches full load, the standby air compressor is automatically started.

[0016] As a preferred solution of the method for automatically starting and stopping a compressed air source of the present invention, the air source purification module includes an air-water separator and an automatic drainer installed in the outlet pipe of the dryer, the air-water separator is used to remove moisture and impurities in the compressed air; the automatic drainer automatically discharges the moisture in the separator when it accumulates to a certain level.

[0017] To solve the above technical problems, the present invention also provides the following technical solutions: an automatic start-stop compressed air source system, comprising an intelligent monitoring module, a start-stop module connected to the intelligent monitoring module, an air source purification module connected to the start-stop module, an optimization module connected to the intelligent monitoring module, and an interaction module connected to the optimization module.

[0018] As a preferred solution of the non-stop power-off detection current transformer secondary circuit opening system of the present invention, the intelligent monitoring module includes a pressure sensor and a central controller; the start-stop module includes an electric butterfly valve and a compressor; the air source purification module includes an air-water separator and an automatic drainer; the optimization module includes an energy consumption monitor and a multi-device interlocking control strategy; and the interactive module includes an operation panel.

[0019] As a preferred solution of the current transformer secondary circuit opening system for non-power-off detection of the present invention, the electric butterfly valve automatically opens or closes according to the command of the central controller to control the air flow into the air storage tank; the compressor automatically starts and stops according to the air pressure conditions to maintain the air pressure within the set range.

[0020] As a preferred solution of the current transformer secondary circuit opening detection system without power outage of the present invention, the operation panel includes display of air pressure data, system status and manual control options, so that the operator can monitor and adjust the system operation.

[0021] Beneficial effects of the present invention: The present invention monitors the air pressure value in the air tank in real time, maintains the air pressure between the preset minimum and maximum limits, improves the accuracy of air pressure control, and automatically starts or stops the compressor according to the actual air pressure demand, reduces unnecessary no-load operation and frequent loading and unloading states, effectively reduces energy consumption, and realizes automatic start and stop of the compressor through the intelligent control system, ensuring the continuity and stability of the air supply under different gas demands. At the same time, the present invention also reduces manual operation of personnel, reduces the labor intensity of operators, and improves the level of automation control of the air compressor. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. Among them:

[0023] Figure 1 The figure is a flow chart of the method for automatically starting and stopping a compressed gas source.

[0024] Figure 2 This is a schematic diagram of the overall application of the automatic start and stop compressed air source system.

[0025] Figure 3 It is a schematic diagram of a first implementation method of an automatic start and stop compressed air source system.

[0026] Figure 4 It is a schematic diagram of a second implementation method of the automatic start and stop compressed air source system. DETAILED DESCRIPTION

[0027] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0028] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0029] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0030] Example 1

[0031] Reference Figure 1 , which is the first embodiment of the present invention, provides a method for automatically starting and stopping a compressed air source, which can solve the problem of energy waste and low production efficiency caused by the lack of real-time demand response and precise control capabilities in traditional compressed air supply systems.

[0032] Specifically, the air pressure value is monitored in real time through the intelligent monitoring module, and the air pressure changes are responded to promptly;

[0033] The air pressure data collected by the intelligent monitoring module is compared with the preset limit value to intelligently decide whether to start or stop the compressor;

[0034] The air pressure in the air storage tank is judged in real time through the automatic start-stop compressed air source system to control the automatic start-stop of the compressor;

[0035] Through the coordinated control of compressed air, the automation control level of the control system is integrated and improved;

[0036] By adding an air source purification module, the dryer can enhance its water, oil and dust removal effects and improve the air source quality.

[0037] Optimize compressor operating time based on historical data and real-time demand.

[0038] Specifically, the real-time monitoring and response of the intelligent monitoring module includes: the intelligent monitoring module is equipped with high-precision pressure sensors, which are installed at key positions of the gas tank to monitor the air pressure value in real time. The pressure sensor data is transmitted to the intelligent monitoring module through a high-speed communication network. The module can respond quickly to small changes in air pressure to ensure that the system can adjust the operating status of the compressor in time to cope with fluctuations in air pressure; the start and stop of the intelligent decision-making compressor includes: the intelligent monitoring module not only collects air pressure values, but also contains control algorithms, namely, PID control algorithms, threshold trigger algorithms, fuzzy logic control algorithms, and predictive control algorithms. These algorithms compare the real-time air pressure value with the preset safety and efficiency limits. When the air pressure is lower than the minimum limit, the system automatically starts the compressor to replenish the air pressure; when the air pressure rises to the maximum limit, the system stops the compressor to avoid over-compression and energy waste; the automatic start and stop compressed air source system includes, The air pressure in the air tank is judged in real time through the intelligent monitoring module. This real-time judgment is based on the logic control strategy and can accurately control the automatic start and stop of the compressor. For example, the compressor is automatically started when the air pressure drops to a certain threshold, and the compressor is stopped when the air pressure rises to another threshold, thereby maintaining the stability of the air pressure; the coordinated control of compressed air includes that the system integrates the work of multiple compressors through the optimization module to improve the automation control level of the control system. This coordinated control ensures a rapid response during high-demand periods and reduces the number of running compressors during low-demand periods to achieve optimal energy efficiency. At the same time, the system uses big data analysis technology to predict future gas usage patterns based on historical data and real-time demand. This prediction allows the system to optimize the operating time of the compressor to match actual demand and reduce unnecessary energy consumption. For example, before high gas demand is predicted, the compressor is started in advance, or the number of running compressors is reduced during low-demand periods.

[0039] In summary, the present invention monitors the air pressure value in the air storage tank in real time, maintains the air pressure between the preset minimum and maximum limits, improves the accuracy of air pressure control, and automatically starts or stops the compressor according to the actual air pressure demand, thereby reducing unnecessary no-load operation and frequent loading and unloading states, effectively reducing energy consumption, and realizing automatic start and stop of the compressor through the intelligent control system, ensuring the continuity and stability of the air supply under different gas demands. At the same time, the present invention also reduces manual operation of personnel, reduces the labor intensity of operators, and improves the level of automation control of the air compressor.

[0040] Example 2

[0041] Reference Figure 1 , which is the second embodiment of the present invention, provides a method for automatically starting and stopping a compressed air source, which can solve the problem of energy waste and low production efficiency caused by the lack of real-time demand response and precise control capabilities in traditional compressed air supply systems.

[0042] Specifically, the pressure sensor is installed inside the gas tank to monitor the air pressure changes in the gas tank in real time, and the data of the pressure sensor is transmitted to the intelligent monitoring module via wired or wireless means.

[0043] Furthermore, the intelligent monitoring module has built-in logical judgment, which compares the real-time value of the air pressure with the preset minimum and maximum limits, and makes intelligent decisions on starting and stopping the compressor.

[0044] It should be noted that the intelligent monitoring module not only collects air pressure values, but also includes control algorithms, namely, PID control algorithm, threshold trigger algorithm, fuzzy logic control algorithm and predictive control algorithm. The PID control algorithm includes: Proportional (P), the controller output is proportional to the current error. The larger the error, the stronger the control action; Integral (I), the controller accumulates past errors to eliminate steady-state errors and enable the system to reach a more accurate set point; Differential (D), the controller predicts the future trend of the error to make adjustments in advance and reduce the dynamic response time of the system. The formula is as follows:

[0045]

[0046] Where, u(t) is the controller output (controls the start and stop of the compressor); K p is the proportional gain; K i is the integral gain; K d is the differential gain; e(t) is the error, that is, the difference between the current air pressure value and the set air pressure value; τ is the time variable of the integration.

[0047] The threshold trigger algorithm determines the control action by comparing the current air pressure value with the preset threshold value. Its parameters include the air pressure threshold P for starting the compressor. low , the upper pressure threshold P for stopping the compressor high .

[0048] The fuzzy logic control algorithm determines the control action through a fuzzy rule base. These rules are based on fuzzy sets and fuzzy operations of input variables (such as error and error change rate). The parameters include:

[0049] Fuzzy sets: Fuzzy sets that define input and output variables, such as "high", "medium", "low";

[0050] Fuzzy rules: Define fuzzy relationships between inputs and outputs, such as "if the error is large and the rate of change of the error increases, then reduce the compressor output."

[0051] Predictive control algorithms use a dynamic model of the system to predict future errors and calculate current control actions to optimize future performance, as follows:

[0052]

[0053] Where u is the control input, e(k) is the error within the prediction range, and N is the prediction range.

[0054] Furthermore, the intelligent monitoring module makes real-time judgment on the air pressure in the gas tank. When the air pressure in the gas tank drops to a preset minimum limit, the compressor is controlled to start, so that it starts working and increases the air pressure; when the air pressure rises to a preset maximum limit, the compressor is controlled to stop.

[0055] It should be noted that the minimum limit is set at 0.5MPa to ensure that when the air pressure is lower than this value, the system can start the compressor in time to replenish the air pressure; the maximum limit is set at 0.8MPa to avoid excessive air pressure causing the air tank to operate at overpressure, thereby ensuring system safety.

[0056] Furthermore, the coordinated control includes setting up multiple air compressors to operate in parallel, and when one air compressor is started and reaches full load, the standby air compressor is automatically started.

[0057] Furthermore, the air source purification module includes an air-water separator and an automatic drainer installed in the outlet pipe of the dryer. The air-water separator is used to remove moisture and impurities in the compressed air; the automatic drainer automatically discharges the moisture in the separator when it accumulates to a certain level.

[0058] In summary, the present invention monitors the air pressure value in the air storage tank in real time, maintains the air pressure between the preset minimum and maximum limits, improves the accuracy of air pressure control, and automatically starts or stops the compressor according to the actual air pressure demand, thereby reducing unnecessary no-load operation and frequent loading and unloading states, effectively reducing energy consumption, and realizing automatic start and stop of the compressor through the intelligent control system, ensuring the continuity and stability of the air supply under different gas demands. At the same time, the present invention also reduces manual operation of personnel, reduces the labor intensity of operators, and improves the level of automation control of the air compressor.

[0059] Example 3

[0060] Reference Figure 2 to Figure 4 , which is the third embodiment of the present invention, provides a method for automatically starting and stopping a compressed air source, which can solve the problem of energy waste and low production efficiency caused by the lack of real-time demand response and precise control capabilities in traditional compressed air supply systems.

[0061] Specifically, the intelligent monitoring module 100, the start-stop module 200 connected to the intelligent monitoring module 100, the air source purification module 300 connected to the start-stop, the optimization module 400 connected to the intelligent monitoring module 100, and the interaction module 500 connected to the optimization module 400.

[0062] Furthermore, the intelligent monitoring module 100 includes a pressure sensor 101 and a central controller 102; the start-stop module 200 includes an electric butterfly valve and a compressor 202; the air source purification module 300 includes an air-water separator 301 and an automatic drainer 302; the optimization module 400 includes an energy consumption monitor and a multi-device interlocking control strategy 402; and the interaction module 500 includes an operation panel 501.

[0063] It should be noted that the central controller 102, as the control center of the system, receives air pressure data from the pressure sensor 101, and controls the start and stop of the electric butterfly valve and the compressor 202 according to the preset air pressure limit. The central controller 102 is also responsible for coordinating the interlocking mode between multiple compressors 202 to achieve coordinated control of compressed air.

[0064] Furthermore, the electric butterfly valve is automatically opened or closed according to the instruction of the central controller 102 to control the air flow into the air storage tank; the compressor 202 is automatically started and stopped according to the air pressure to maintain the air pressure within a set range.

[0065] It should be noted that the electric butterfly valve is installed at the compressed air outlet of the compressor 202 and is linked to the pressure sensor 101. The pressure sensor 101 monitors the air pressure in the air tank in real time and sends a signal to the central controller 102 according to the change in air pressure. The central controller 102 controls the opening and closing of the electric butterfly valve according to the signal.

[0066] Furthermore, the operation panel 501 includes display of air pressure data, system status and manual control options, allowing the operator to monitor and adjust system operation.

[0067] It should be noted that the air pressure monitoring and judgment includes the pressure sensor 101 monitoring the air pressure value in the air tank in real time. When the air pressure is lower than 0.5MPa, the controller automatically starts the compressor 202; when the air pressure reaches 0.8MPa, the controller automatically stops the operation of the compressor 202; when the air pressure in the air tank is lower than 0.5MPa and the main compressor 202 has been started, the system judges and starts the backup air compressor by itself through the optimization logic to cope with the situation of large-scale use of compressed air and ensure the stable operation of the air source system. In addition, the increase in gas purity and automatic discharge function includes the separation of moisture in the compressed air through the gas-water separator 301, reducing the humidity in the gas and improving the gas purity. When the moisture in the gas-water separator 301 accumulates to a certain level, the automatic drain 302 automatically opens to discharge the separated moisture out of the system to reduce manual maintenance. The comparison before and after the improvement is shown in the following table:

[0068] index Prior art Improved technology Gas humidity 80％ 30％ Number of air compressor starts frequently 30% reduction power consumption high 20% reduction Maintenance costs high 40% reduction

[0069] Comparison table of indicators before and after improvement

[0070] When in use, after the system is powered on, the pressure sensor 101 starts to monitor the air pressure in the gas tank, and the controller enters standby mode. Further, according to the air pressure value, the controller instructs the electric butterfly valve and the compressor 202 to start and stop operations to maintain the air pressure between 0.5MPa and 0.8MPa. At this time, the compressed air is separated from the water by the air-water separator 301, and the automatic drainer 302 discharges the water to improve the purity of the gas. At the same time, in the case of multiple air compressors, the controller coordinates the operation of each air compressor according to the air pressure and load conditions to achieve high efficiency and energy saving.

[0071] In summary, the present invention improves the accuracy of air pressure control by monitoring the air pressure value in the air tank in real time, maintaining the air pressure between the preset minimum and maximum limits, and automatically starting or stopping the compressor 202 according to the actual air pressure demand, thereby reducing unnecessary no-load operation and frequent loading and unloading states, effectively reducing energy consumption, and realizing automatic start and stop of the compressor 202 through the intelligent control system, thereby ensuring the continuity and stability of the air supply under different gas demands. At the same time, the present invention also reduces manual operation of personnel, reduces the labor intensity of operators, and improves the level of automation control of the air compressor.

[0072] Importantly, it should be noted that the construction and arrangement of the present application shown in a plurality of different exemplary embodiments are only exemplary. Although only a few embodiments are described in detail in this disclosure, it should be readily understood by those who refer to this disclosure that many modifications are possible without substantially departing from the novel teachings and advantages of the subject matter described in the application (e.g., mounting arrangements, use of materials, color, changes in orientation, etc.). For example, the element shown as integrally formed may be composed of a plurality of parts or elements, the position of the element may be inverted or otherwise changed, and the nature or number or position of the discrete element may be altered or changed. Therefore, all such modifications are intended to be included within the scope of the present invention. The order or sequence of any process or method steps may be changed or reordered according to an alternative embodiment. In the claims, any "bracket plus function" clause is intended to cover the structure of the execution function described herein, and is not only structurally equivalent but also equivalent structure. Without departing from the scope of the present invention, other replacements, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments. Therefore, the present invention is not limited to a specific embodiment, but extends to a variety of modifications that still fall within the scope of the appended claims.

[0073] Additionally, in an effort to provide a concise description of example embodiments, all features of an actual implementation may not be described.

[0074] It should be understood that in the development of any actual implementation, as in any engineering or design project, numerous implementation-specific decisions may be made. Such a development effort may be complex and time-consuming, but for those of ordinary skill having the benefit of this disclosure, the development effort will be a routine task of design, fabrication, and production without undue experimentation.

[0075] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A method for automatically starting and stopping a compressed air source, characterized in that: include, The intelligent monitoring module monitors the air pressure in real time and responds promptly to changes in air pressure; The air pressure data collected by the intelligent monitoring module is compared with the preset limit value to intelligently decide whether to start or stop the compressor; The air pressure in the air storage tank is judged in real time through the automatic start-stop compressed air source system to control the automatic start-stop of the compressor; Through the coordinated control of compressed air, the automation control level of the control system is integrated and improved; By adding an air source purification module, the dryer can enhance its water, oil and dust removal effects and improve the air source quality. Optimize compressor operating time based on historical data and real-time demand.

2. The method for automatically starting and stopping a compressed air source according to claim 1, characterized in that: The pressure sensor is installed inside the gas storage tank to monitor the air pressure changes in the gas storage tank in real time, and the data of the pressure sensor is transmitted to the intelligent monitoring module via wired or wireless means.

3. The method for automatically starting and stopping a compressed air source according to claim 2, characterized in that: The intelligent monitoring module has built-in logic judgment, which compares the real-time value of the air pressure with the preset minimum and maximum limits, and makes intelligent decisions on starting and stopping the compressor.

4. The method for automatically starting and stopping a compressed air source according to claim 3, characterized in that: The intelligent monitoring module makes a real-time judgment on the air pressure in the air tank. When the air pressure in the air tank drops to a preset minimum limit, the compressor is controlled to start, so that it starts working and increases the air pressure; when the air pressure rises to a preset maximum limit, the compressor is controlled to stop.

5. The method for automatically starting and stopping a compressed air source according to claim 4, characterized in that: The coordinated control includes setting up multiple air compressors to run in parallel, and when one air compressor is started and reaches full load, the standby air compressor is automatically started.

6. The method for automatically starting and stopping a compressed air source according to claim 5, characterized in that: The air source purification module includes an air-water separator and an automatic drainer installed in the outlet pipe of the desiccant. The air-water separator is used to remove moisture and impurities in the compressed air; the automatic drainer automatically discharges the moisture in the separator when it accumulates to a certain level.

7. An automatic start-stop compressed air source system, used in the automatic start-stop compressed air source method, characterized in that: include, An intelligent monitoring module (100), a start-stop module (200) connected to the intelligent monitoring module (100), an air source purification module (300) connected to the start-stop module, an optimization module (400) connected to the intelligent monitoring module (100), and an interaction module (500) connected to the optimization module (400).

8. The automatic start-stop compressed air source system according to claim 7, characterized in that: The intelligent monitoring module (100) comprises a pressure sensor (101) and a central controller (102); the start-stop module (200) comprises an electric butterfly valve and a compressor (202); the air source purification module (300) comprises an air-water separator (301) and an automatic drainer (302); the optimization module (400) comprises an energy consumption monitor and a multi-device interlocking control strategy (402); and the interaction module (500) comprises an operation panel (501).

9. The automatic start-stop compressed air source system according to claim 8, characterized in that: The electric butterfly valve is automatically opened or closed according to the instruction of the central controller (102) to control the air flow into the air storage tank; the compressor (202) is automatically started and stopped according to the air pressure to maintain the air pressure within a set range.

10. The automatic start-stop compressed air source system according to claim 9, characterized in that: The operation panel (501) includes display of air pressure data, system status and manual control options, allowing operators to monitor and adjust system operation.

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