Air compression station safe energy-saving power utilization system driven by air floating shaft

Abstract

The invention discloses a safe and energy-saving power utilization system of an air compression station driven by an air floating shaft, and relates to the technical field of air compression stations, operating parameters of all equipment in the air compression station are monitored in real time through a data acquisition module, the operating state of an air compressor can be adjusted through a variable frequency driving module according to the real-time air utilization requirement, unnecessary energy consumption is avoided, and the power utilization efficiency of the air compression station is improved. The pressure of a pipe network is monitored through a pressure sensor, the output air pressure of an air compressor is controlled within the optimal range, and energy waste caused by too high pressure is avoided; waste heat generated in the operation process of the air compressor is recycled through the energy recycling module, and the energy requirements of other links are reduced; when the multiple air compressors operate through the linkage control module, the system automatically distributes loads, it is ensured that each device operates in an efficient interval, and the loads are balanced; a protection mechanism is automatically triggered through the safety protection module under an abnormal condition, so that the safety of equipment and personnel is effectively ensured; and the control strategy of the control center ensures that the air compression station equipment is always kept stable in the operation process.

Description

Technical Field

[0001] The present invention relates to the technical field of air compressor stations, and particularly to a safe and energy-saving power consumption system for an air compressor station driven by an air floating shaft. Background Art

[0002] Compressed air, as the most environmentally friendly power source in industrial production, is widely used in various industries such as medicine, food, machinery, and electronics. Compared with voltage and oil pressure, air pressure has its unique advantages. It is inexhaustible and basically every factory will be equipped with an air compressor station; and an air compressor station driven by an air floating shaft is an air compression station that adopts air floating bearing technology. Since there is no mechanical contact during the operation of the air floating main shaft, the wear degree is extremely low, which can ensure that the accuracy always remains stable, and it has the advantages of no friction, high precision, and long life.

[0003] In the existing air compressor stations driven by air floating shafts, since the air compressor generates a large amount of heat during operation, there are safety hazards in manual inspection, resulting in the inability to directly monitor the operating status of the equipment in the air compressor station. It is necessary to collect the working parameters of the air compressor equipment through electrical equipment for monitoring. Moreover, multiple air compressor equipment are set in the air compressor station. How to evenly allocate the work of multiple air compressors to achieve energy conservation and consumption reduction while meeting the actual use requirements is also an urgent problem for those skilled in the art to solve. Summary of the Invention

[0004] To solve the above problems, the present invention provides a safe and energy-saving power consumption system for an air compressor station driven by an air floating shaft, which replaces traditional manual on-site work monitoring of air compressor equipment, not only realizes the even allocation of the work of multiple air compressors, but also realizes the purpose of energy conservation and consumption reduction.

[0005] To achieve the above object, the technical solution adopted by the present invention is: a safe and energy-saving power consumption system for an air compressor station driven by an air floating shaft; including: A control center, the control center is respectively connected to a monitoring and management module and a control subsystem. The control subsystem includes a variable frequency drive module, a data acquisition module, an energy recovery module, a safety protection module, and a linkage control module. The control subsystem is connected to multiple air compressors in the air compressor station; The control center includes a programmable logic controller PLC, which is used to monitor the operating status of the air compressor station in real time and automatically adjust the start-stop and load of the air compressor according to the gas consumption demand to avoid no-load or overload operation; The variable frequency drive module includes a variable frequency drive VFD, which is used to adjust the output power according to the actual gas consumption, reduce the motor speed at low load, and reduce power consumption; The data acquisition module is used to collect the pipeline pressure, flow rate, and operating status data of the air compressor station in real time; The energy recovery module is used to convert the waste heat generated during the operation of the air compressor into hot water or steam, which can be reused in other production processes; The safety protection module is used to control the automatic shutdown of the equipment in the air compressor station in case of abnormalities, automatically switch the system to the standby equipment, and send out alarm signals to avoid accidents; The linkage control module is used to automatically start and stop or switch the air compressors according to the gas consumption demand, optimize the load distribution, and ensure that all equipment in the air compressor station operates in the efficient range and avoid single equipment running at high load for a long time.

[0006] Preferably, the monitoring and management module realizes remote monitoring through Internet of Things (IoT) technology, can view the operating status and energy consumption data of each equipment in the air compressor station in real time, realizes remote warning and remote diagnosis, and improves the maintenance efficiency; the monitoring and management module is also connected to the cloud platform to upload the operating data of the equipment in the air compressor station to the cloud platform for storage.

[0007] Preferably, the control center analyzes the current gas consumption demand according to the data collected by the data acquisition module according to the preset control strategy, judges whether to start or stop the air compressor, and sends start-stop or speed regulation commands to each air compressor; when receiving the signal sent by the safety protection module, automatically switch the faulty equipment to the standby equipment and send out an alarm signal.

[0008] More preferably, the control strategy specifically includes: By setting a target pressure range; when the pressure of the air compressor station pipeline network is lower than the lower limit, start one or more air compressors; when the pipeline network pressure reaches the upper limit, stop some air compressors; Set a priority for each air compressor and start and stop in sequence, specifically start the air compressor with a shorter running time first to balance the wear of each equipment; When multiple air compressors are running, dynamically adjust the load of each equipment to ensure that all equipment operates in the efficient range; For the air compressor equipped with a frequency converter, adjust the motor speed according to the gas consumption demand, increase the motor speed at high load and decrease the motor speed at low load to reduce power consumption and achieve precise gas supply.

[0009] Preferably, the data acquisition module includes a pressure sensor, a flow sensor, a current sensor, a humidity sensor and a timer, which are used to collect the pipeline network pressure of the air compressor station, the air flow in the pipeline network, the real-time current of the air compressor equipment and the humidity of the nearby working environment in real time, and collect the running time of the air compressor equipment, and send the data to the control center.

[0010] Preferably, the safety protection module monitors the operating status of the air compressor to ensure the stable operation of the system; The specific steps include: By collecting the working current and voltage of the air compressor in real time and comparing them with the rated working current and voltage, when the real-time working current is greater than the rated working current or the real-time working voltage is greater than the rated working voltage and the running time is greater than the preset time t, it is determined that the running state of the current air compressor equipment is in an overload state; When the real-time working current is much greater than the rated working current and the real-time working voltage is much less than the rated working voltage and the running time is greater than the preset time t, it is determined that the running state of the current air compressor equipment is in a short-circuit state; When it is determined that the current equipment has a fault, a signal is sent to the control center.

[0011] Preferably, the linkage control module designates one air compressor as the main machine and the others as slave machines. The main machine controls the start and stop of the slave machines according to the gas consumption demand. The linkage control module evenly wears the equipment by regularly rotating the master-slave roles of each air compressor; When multiple air compressors are running simultaneously, in cooperation with the control center, the master-slave roles of each device are dynamically adjusted according to the total gas consumption demand to balance the load.

[0012] More preferably, the regular rotation of the master-slave roles of each air compressor includes: Combining multiple factors such as time, load, and fault status, the dynamic adjustment of the rotation strategy specifically includes collecting data and real-time status to predict the best rotation timing.

[0013] More preferably, the calculation method of the best rotation timing is as follows:

[0014] Among them, T represents the time for the device to rotate to the main machine next time, N represents the annual average workload of the device, T B represents the number of days the device is shut down due to faults, T b represents the number of days the device is not scheduled to work, X represents the number of days the device works as the main machine, M represents the workload of the device when it last worked as the main machine, and η represents the average working efficiency of the device.

[0015] Preferably, by setting a PID controller, the output of the air compressor is adjusted by adjusting the frequency converter VFD in real time. The specific steps include: Collect the current pressure of the air compressor station pipe network through a pressure sensor: Subsequently, calculate the deviation between the current pressure and the expected output pressure; Calculate the control output u(t) according to the PID ratio and the deviation; The variable frequency drive module adjusts the motor speed or start-stop state of the air compressor according to u(t); Continuously monitor the pipe network pressure and repeat the above steps to ensure stable pressure output.

[0016] The beneficial effects of the present invention are as follows: Through a safe and energy-saving power consumption system for an air compressor station driven by an air floating shaft according to the present invention, the operating parameters of each device in the air compressor station are monitored in real time through a data acquisition module, and the operating state of the air compressor can be adjusted according to the real-time gas consumption demand, avoiding unnecessary energy consumption. Among them, the pipeline pressure is monitored through a pressure sensor, and the output of the air compressor is controlled by PID to control the air pressure of the air compressor within the optimal range, avoiding energy waste caused by excessive pressure; the waste heat generated during the operation of the air compressor is recovered and utilized through an energy recovery module, reducing the energy demand in other links; through a linkage control module, when multiple air compressors are operating, the system automatically distributes the load to ensure that each device operates in an efficient range, achieving load balance; through a safety protection module, a protection mechanism is automatically triggered in case of an abnormality, effectively ensuring the safety of the device and personnel; the control strategy of the control center can effectively ensure the effective operation of each device in the air compressor station, ensure that the device always remains stable during operation, and at the same time can avoid a certain device malfunctioning and affecting other devices, thereby affecting the overall operating performance of the air compressor station. Brief Description of the Drawings

[0017] Figure 1 It is a block diagram of a safe and energy-saving power consumption system for an air compressor station driven by an air floating shaft according to the present invention. Detailed Embodiments

[0018] Please refer to Figure 1 As shown, the present invention relates to a safe and energy-saving power consumption system for an air compressor station driven by an air floating shaft as follows: It includes a control center, the control center is respectively connected to a monitoring and management module and a control subsystem, the control subsystem includes a variable frequency drive module, a data acquisition module, an energy recovery module, a safety protection module and a linkage control module, and the control subsystem is connected to multiple air compressors in the air compressor station; The control center includes a programmable logic controller PLC, which is used to monitor the operating state of the air compressor station in real time and automatically adjust the start-stop and load of the air compressor according to the gas consumption demand, avoiding no-load or over-load operation; The data acquisition module is used to collect the pipeline pressure, flow rate, and operating state data of the air compressor in the air compressor station in real time; The programmable logic controller (PLC), as the core control unit, coordinates the operation of multiple air compressors through a preset program. Each air compressor is connected to the main controller via an industrial bus or Ethernet to achieve data exchange and instruction transmission. Each air compressor is also equipped with a data acquisition module, including a pressure sensor, a flow sensor, a current sensor, a humidity sensor, and a timer, which are used to collect the pressure of the air compressor station pipeline network, the air flow rate in the pipeline network, the real-time current of the air compressor equipment, the humidity of the nearby working environment, and the operating time of the air compressor equipment in real time, and send the data to the control center via wireless communication.

[0019] Based on the data collected by the data acquisition module, the control center analyzes the current gas consumption demand according to the preset control strategy, determines whether to start or stop the air compressors, and sends start / stop or speed regulation instructions to each air compressor; when receiving the signal sent by the safety protection module, it automatically switches the faulty equipment to the standby equipment and sends an alarm signal.

[0020] The control strategy specifically includes: By setting a target pressure range; when the pressure of the air compressor station pipeline network is lower than the lower limit (insufficient output), start one or more air compressors; when the pipeline network pressure reaches the upper limit (excessive output), stop some air compressors; Combining multiple factors such as time, load, and fault status, dynamically adjust the rotation strategy, set priorities for each air compressor, and start and stop in sequence. Specifically, give priority to starting the air compressor with a shorter operating time to balance the wear of each device; When multiple air compressors are running, dynamically adjust the load of each device to ensure that all devices operate in the high-efficiency range; ensure that each air compressor is within the rated working range and does not operate overloaded.

[0021] For air compressors equipped with frequency converters, adjust the motor speed according to the gas consumption demand, increase the motor speed under high load, and decrease the motor speed under low load to reduce power consumption and achieve precise air supply.

[0022] The variable frequency drive module includes a variable frequency drive (VFD), which is used to adjust the output power according to the actual gas consumption, reduce the motor speed under low load, and reduce power consumption; Since a pressure sensor is set at the pipeline network, it can effectively measure the output of the air compressor. By comparing the real-time output P 实际 of the air compressor with the expected output P 目标 a deviation is obtained: Deviation e(t) = P 目标 - P 实际 Subsequently, calculate the control output u(t) according to the PID control formula;

[0023] wherein K p、 K i、 K d respectively represent the proportional, integral, and differential coefficients. Subsequently, the variable frequency drive module adjusts the motor speed or start / stop state of the air compressor according to u(t).

[0024] Assume that the target pressure of the pipeline network in a certain air compressor station is 0.7 MPa, the current pressure is 0.65 MPa, and the PID parameters are as follows: = 2; = 0.1; = 0.5, Calculate the deviation e(t) = 0.7 - 0.65 = 0.05, Calculate the PID output Assume: The historical cumulative value of the integral term is 0.02.

[0025] The differential term (rate of change of deviation) is -0.01.

[0026] Then: u(t)=2⋅0.05 + 0.1⋅0.02 + 0.5⋅(−0.01)=0.1 + 0.002−0.005 = 0.097, If u(t) = 0.097 is positive, it means that the output of the air compressor needs to be increased.

[0027] Assume that the control output range is from 0 to 1, corresponding to the motor speed from 0% to 100%.

[0028] Adjust the motor speed to 9.7% of the current speed.

[0029] Continuously monitor the pressure of the pipeline network through the pressure sensor, and repeat the above calculations and adjustments until the pressure stabilizes at 0.7 MPa.

[0030] The energy recovery module is used to convert the waste heat generated during the operation of the air compressor into hot water or steam, which can be reused in other production processes; Since a large amount of heat is generated during the operation of the air compressor, a heat energy recovery heat exchanger is equipped at the outlet of the compressor. The heat of the compressor exhaust is recovered through water circulation, or heat exchange is carried out with the cold water to be heated through the heat exchanger to heat the cold water to a certain temperature for heating or domestic water use; or the water is turned into steam through the heat exchanger, and the steam is sent to a steam power generation unit for power generation.

[0031] The setting of the energy recovery module can improve the energy utilization efficiency and convert waste heat into useful electrical energy.

[0032] When the air compressor is working and the heat discharged is higher than the ambient temperature and higher than a preset threshold, calculate T in real time out represents the outlet water temperature of the heat exchanger, T in represents the inlet water temperature of the heat exchanger:

[0033] Among them, represents the designed water temperature difference flowing through the heat exchanger, W re represents the minimum proportion of the heat exchanger in the operating energy cost of the air compressor. The first water volume W generated by the air compressor due to compressed air 1， the second water volume W2 discharged from the air storage tank, represents the waste heat design coefficient and can be obtained according to the actual test results. T represents the ambient temperature. When T out is greater than the first threshold, the heat exchanger exchanges heat with the cold water to be heated, heating the cold water to a certain temperature for heating or domestic water use; when T out is greater than the second threshold, excess heat energy is generated through the heat exchanger, turning water into steam and sending the steam into a steam power generation unit for power generation.

[0034] The safety protection module is used to control the automatic shutdown of the equipment in the air compressor station in case of abnormalities, automatically switch the system to standby equipment, and send out an alarm signal to avoid accidents; The safety protection module monitors the operating status of the air compressor to ensure the stable operation of the system; The specific steps include: By collecting the working current and voltage of the air compressor in real time and comparing them with the rated working current and voltage, when the real-time working current is greater than the rated working current or the real-time working voltage is greater than the rated working voltage and the running time is greater than the preset t time, it is judged that the running status of the current air compressor equipment is in an overload state; When the real-time working current is much greater than the rated working current and the real-time working voltage is much less than the rated working voltage and the running time is greater than the preset t time, it is judged that the running status of the current air compressor equipment is in a short-circuit state; Let the current working voltage be , the rated working voltage be , the working current be , the rated working current be , by setting the interval range and , When the difference between them is within and the difference between and , when the running time is greater than the preset time t, it is determined that the current operating state of the air compressor equipment is an overload state; When The difference between is greater than 0 and much greater than I b When, U d is close to the power supply voltage, it is determined that the current operating state of the air compressor equipment is a short - circuit state. In addition, when a certain bearing of the equipment has a wear failure, its vibration frequency and amplitude will show a specific change law, and its current harmonics will be abnormal:

[0035] Among them, represents the correlation degree of the current harmonic disturbance signal, U(t) represents the decomposition result of the harmonic disturbance signal, t is the running time length of the equipment, k represents the vibration amplitude, z represents the vibration frequency, I k represents the energy coefficient of the current harmonic disturbance signal; When the rotor is unbalanced, abnormalities appear in its vibration spectrum:

[0036] Among them, f r represents the actual rotation frequency of the motor, n represents the motor speed, represents the vibration severity factor coefficient, d represents the diameter of the electronic rotor, represents the time required for the rotor to rotate one week.

[0037] When the correlation degree of the current harmonic disturbance signal is greater than the preset threshold, it is determined that the current equipment bearing is worn and needs to be replaced. When the vibration severity factor coefficient is greater than the preset threshold, it is determined that the current equipment rotor is unbalanced.

[0038] When it is determined that the current equipment has a fault, the equipment is immediately stopped, and a signal is sent to the control center. If the air compressor is the main machine, the next main machine is enabled according to the order of the control strategy. If the air compressor is a slave machine, a standby air compressor (also acting as a slave machine role) is enabled to avoid affecting the normal operation of the air compressor station.

[0039] The abnormal vibration mode of the equipment is detected. Once potential fault signs are detected, the operation and maintenance team can be notified in time to take measures, reducing the unexpected downtime.

[0040] The linkage control module is used to automatically start, stop or switch the air compressors according to the gas consumption demand, optimize the load distribution, and ensure that each equipment in the air compressor station operates in the efficient range and avoid long - term high - load operation of a single equipment.

[0041] The linkage control module designates one air compressor as the main unit and the others as slave units. The main unit controls the start and stop of the slave units according to the air consumption demand. The linkage control module balances equipment wear by regularly rotating the master-slave roles of each air compressor. When multiple air compressors are running simultaneously, in cooperation with the control center, it dynamically adjusts the master-slave roles of each device according to the total air consumption demand to balance the load.

[0042] Regularly rotating the master-slave roles of each air compressor includes: Combining multiple factors such as time, load, and fault status, dynamically adjusting the rotation strategy specifically includes collecting data and real-time status to predict the best rotation timing.

[0043] In actual operation, there are also the following rotation methods. 1. Time rotation Set an operating time threshold for each air compressor, such as 8 hours. When the operating time of the main control air compressor reaches the threshold, the system automatically switches to the next air compressor.

[0044] 2. Load rotation Monitor the load of each air compressor. When the load of a certain device is too high, switch to a device with a lower load.

[0045] In load rotation, by combining PID control, dynamically adjust the operating state of the air compressor and adjust its speed.

[0046] 3. Fault-priority rotation Monitor the operating state of each air compressor, including temperature, vibration, fault records, etc. When rotating, give priority to selecting the air compressor with the best state.

[0047] The rotation steps are as follows: First, it is necessary to collect the operating data of each air compressor in the air compressor station, including operating time, load, status, temperature, vibration, fault records, etc.; then, according to the selected rotation strategy, select the next air compressor as the output main unit, gradually reduce the load of the current main control device, and at the same time start the next output main unit device, continuously monitor the state of each air compressor device in the air compressor station to ensure a smooth switching process, and finally record the rotation historical data to optimize the rotation strategy.

[0048] The calculation method of the best rotation timing of the present invention is as follows:

[0049] Among them, T represents the time when the device will be rotated to the main unit next time, N represents the annual average workload of the device, T B represents the number of days when the device stops due to faults, T bIt represents the number of days when the device is not scheduled for work, X represents the number of days when the device works as the main host, M represents the workload of the device when it last worked as the main host, η represents the average working efficiency of the device, 1.442 is the deviation coefficient, which is used to adjust the deviation based on working hours of the air compressor as the main host under high load and overtime duration, and 0.225 is the adjustment parameter, which is used to adjust and compensate for the high load operation duration of the air compressor as the main host.

[0050] By calculating the time when each air compressor in the air compressor station will rotate to be the output main host next time, and arranging them as the output main host in ascending order of time.

[0051] The calculation method of the optimal rotation timing provided by the present invention can accurately calculate the time when each air compressor will rotate to be the main host (main output) next time, can balance the operation time, reduce the wear of a single device, and effectively extend the service life of the device; through the rotation operation, it can effectively ensure that each device is in good condition, balance the wear, reduce the failure rate, and reduce the maintenance requirements and costs.

[0052] The present invention is also provided with a monitoring and management module, which realizes remote monitoring through the Internet of Things (IoT) technology. Through remote monitoring, the operation status and energy consumption data of each device in the air compressor station can be viewed in real time, and remote warning and remote diagnosis can be realized to improve the maintenance efficiency; in a feasible implementation manner, the management personnel can change the output of the air compressor or manually change the master-slave role of each air compressor in the remote control center through the monitoring and management module. Among them, the monitoring and management module is also connected to the cloud platform, and uploads the operation data of the devices in the air compressor station to the cloud platform for permanent storage.

[0053] The above formulas are all calculated by removing the dimension and taking their numerical values. The formulas are obtained by collecting a large amount of data for software simulation to get a formula closest to the real situation. The preset parameters and preset thresholds in the formulas are set by those skilled in the art according to the actual situation or obtained by simulating a large amount of data.

[0054] Those skilled in the art can clearly understand that, for the convenience and brevity of description, only the above-mentioned division of each functional unit and module is used as an example. In actual applications, the above functions can be allocated to different functional units and modules according to needs, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above. Each functional unit and module in the embodiments can be integrated into a processing unit, or each unit can exist physically alone, or two or more units can be integrated into one unit. The above integrated unit can be implemented in the form of hardware or in the form of a software functional unit. In addition, the specific names of each functional unit and module are only for the convenience of mutual distinction and do not limit the protection scope of this application. The specific working processes of the units and modules in the above system can refer to the corresponding processes in the foregoing method embodiments and will not be elaborated herein.

[0055] In the above embodiments, the descriptions of the respective embodiments have their own emphases. For the parts not detailed or recorded in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0056] Those of ordinary skill in the art can realize that the units and algorithm steps of each example described in combination with the embodiments disclosed herein can be implemented by electronic hardware, or by a combination of computer software and electronic hardware. Whether these functions are executed in the form of hardware or software depends on the specific application and design constraints of the technical solution. Professionals can use different methods to implement the described functions for each specific application, but such implementation should not be considered to exceed the scope of the present invention.

[0057] In the embodiments provided by the present invention, it should be understood that the disclosed device / terminal device and method can be implemented in other ways. For example, the device / terminal device embodiments described above are merely illustrative. For example, the division of modules or units is only a logical functional division. In actual implementation, there can be other division methods. For example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the displayed or discussed couplings or direct couplings or communication connections to each other can be through some interfaces. The indirect couplings or communication connections of the device or unit can be in electrical, mechanical or other forms.

[0058] The units described as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units, that is, they can be located in one place or distributed to multiple network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0059] In addition, in each embodiment of the present invention, each functional unit can be integrated into one processing unit, or each unit can exist physically alone, or two or more units can be integrated into one unit. The above-mentioned integrated unit can be implemented in the form of hardware or in the form of a software functional unit.

[0060] If the integrated module / unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on such an understanding, to implement all or part of the processes in the above-mentioned embodiment methods of the present invention, it can also be completed by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium. When the computer program is executed by a processor, the steps of the above-mentioned various method embodiments can be implemented. Among them, the computer program includes computer program code, and the computer program code can be in the form of source code, object code, executable file or some intermediate form, etc. The computer-readable medium can include: any entity or device that can carry the computer program code, recording medium, USB flash drive, mobile hard disk, magnetic disk, optical disc, computer memory, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), electrical carrier signal, telecommunication signal, and software distribution medium, etc. It should be noted that the content included in the computer-readable medium can be appropriately increased or decreased according to the requirements of legislation and patent practice in the jurisdiction. For example, in some jurisdictions, according to legislation and patent practice, the computer-readable medium does not include electrical carrier signals and telecommunication signals.

[0061] 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 foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the various embodiments of the present invention, and should all be included in the protection scope of the present invention.

[0062] The above are only the preferred implementation cases of the present disclosure. Although the present disclosure has been described in conjunction with the accompanying drawings, the purpose is not to limit the present disclosure. For those skilled in the art, the present disclosure can have various changes and modifications. Any modifications, replacements, improvements, etc. made within the spirit and principle of the present disclosure should all be included in the protection scope of the present disclosure.

Claims

1. An air flotation shaft-driven safety and energy-saving power consumption system for an air compressor station, characterized in that, Including: A control center, which is respectively connected to a monitoring and management module and a control subsystem. The control subsystem includes a variable-frequency drive module, a data acquisition module, an energy recovery module, a safety protection module and a linkage control module. The control subsystem is connected to multiple air compressors in the air compressor station; The control center includes a programmable logic controller (PLC), which is used to monitor the operating status of the air compressor station in real time and automatically adjust the start, stop and load of the air compressors according to the gas consumption demand, so as to avoid no-load or overload operation; The variable-frequency drive module includes a variable-frequency drive (VFD), which is used to adjust the output power according to the actual gas consumption and reduce the motor speed at low load; The data acquisition module is used to collect the air pressure, flow rate and operating status data of the air compressor station pipeline network in real time; The energy recovery module is used to convert the waste heat generated during the operation of the air compressor into hot water or steam and transfer it to other production links; The safety protection module is used to control the automatic shutdown of the equipment in the air compressor station in case of abnormality, automatically switch the system to standby equipment, and send an alarm signal to avoid accidents; The linkage control module is used to automatically start, stop or switch the air compressors according to the gas consumption demand, optimize the load distribution, and ensure that each equipment in the air compressor station operates in the efficient range and avoid long-term high-load operation of a single equipment.

2. The air compressor station safety and energy-saving power consumption system driven by an air floating shaft according to claim 1, wherein The monitoring and management module realizes remote monitoring through Internet of Things (IoT) technology, and can view the operating status and energy consumption data of each equipment in the air compressor station in real time; the monitoring and management module is also connected to the cloud platform to upload the operating data of the equipment in the air compressor station to the cloud platform for storage.

3. The air compressor station safety and energy-saving power consumption system driven by an air-floating shaft according to claim 1, characterized in that, The control center analyzes the current gas consumption demand according to the data collected by the data acquisition module, judges whether it is necessary to start or stop the air compressors according to the preset control strategy, and sends start-stop or speed regulation commands to each air compressor; when receiving the signal sent by the safety protection module, automatically switch the faulty equipment to the standby equipment and send an alarm signal.

4. The air-bearing spindle-driven air compressor station safety and energy-saving power consumption system according to claim 3, characterized in that, The control strategy specifically includes: By setting a target pressure range; when the air pressure in the air compressor station pipeline network is lower than the lower limit, start one or more air compressors; when the pipeline network pressure reaches the upper limit, stop some air compressors; Set a priority for each air compressor and start and stop in sequence. Specifically, give priority to starting the air compressor with a shorter running time to balance the wear of each equipment; When multiple air compressors are running, dynamically adjust the load of each equipment to ensure that all equipment operates in the efficient range; For the air compressors equipped with variable-frequency drives, adjust the motor speed according to the gas consumption demand, increase the motor speed at high load and reduce the motor speed at low load.

5. The air flotation shaft-driven air compressor station safety and energy-saving power consumption system according to claim 1, wherein, The data acquisition module includes a pressure sensor, a flow sensor, a current sensor, a humidity sensor and a timer, which are used to collect the air pressure in the air compressor station pipeline network, the air flow rate in the pipeline network, the real-time current of the air compressor equipment and the humidity of the nearby working environment in real time, and collect the running time of the air compressor equipment, and send the data to the control center.

6. The air flotation shaft-driven air compressor station safety and energy-saving power consumption system according to claim 1, characterized in that, The safety protection module monitors the operating status of the air compressors to ensure the stable operation of the system; The specific steps include: By collecting the working current and voltage of the air compressor in real time and comparing them with the rated working current and voltage, when the real-time working current is greater than the rated working current or the real-time working voltage is greater than the rated working voltage and the running time is greater than the preset time t, it is determined that the running state of the current air compressor equipment is an overload state; When the real-time working current is much greater than the rated working current and the real-time working voltage is much less than the rated working voltage and the running time is greater than the preset time t, it is determined that the running state of the current air compressor equipment is a short-circuit state; When it is determined that the current equipment has a fault, a signal is sent to the control center.

7. An air compressor station safety and energy-saving power consumption system driven by an air floating shaft according to claim 1, characterized in that, The linkage control module designates one air compressor as the host and the others as slaves. The host controls the start and stop of the slaves according to the gas demand. The linkage control module evenly wears the equipment by regularly rotating the master-slave roles of each air compressor; When multiple air compressors are running simultaneously, in cooperation with the control center, the master-slave roles of each device are dynamically adjusted according to the total gas demand to balance the load.

8. The air flotation shaft-driven air compressor station safety and energy-saving power consumption system according to claim 7, characterized in that The regular rotation of the master-slave roles of each air compressor includes: Combining multiple factors such as time, load, and fault status, dynamically adjusting the rotation strategy specifically includes collecting data and real-time status to predict the best rotation time.

9. The air flotation shaft-driven air compressor station safety and energy-saving power consumption system according to claim 8, characterized in that, The calculation method of the best rotation time is as follows: Among them, T represents the time when the device will be rotated as the host next time, N represents the average annual workload of the device, and T B Indicates the number of days the equipment is down due to failure, T b represents the number of days that the device is not scheduled to work, X represents the number of days that the device works as a host, M represents the workload of the device when it worked as a host last time, and η represents the average working efficiency of the device.

10. An air flotation shaft-driven air compressor station safety and energy-saving power consumption system according to claim 1, characterized in that, By setting a PID controller, the output of the air compressor is adjusted by adjusting the frequency converter VFD in real time. The specific steps include: Collect the current pressure of the air compressor station pipe network through a pressure sensor: Subsequently, calculate the deviation between the current pressure and the expected output pressure; Calculate the control output u(t) according to the PID ratio and the deviation; The variable frequency drive module adjusts the motor speed or start-stop state of the air compressor according to u(t); Continuously monitor the pipe network pressure and repeat the above steps to ensure stable pressure output.

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