An automatic multi-bladder full-flow clearance multi-stage adjustment system for reciprocating compressors

Abstract

The present invention relates to an automatic multi-bag full-flow clearance multi-stage adjustment system for a reciprocating compressor, which obtains different clearance volumes by controlling the switch combination of different volume airbags on the shaft side and the cover side of the cylinder, and correspondingly controls the different exhaust volumes of the compressor, and can realize 0% to 100% full-flow multi-stage precise numerical control adjustment of the reciprocating compressor. The driving mode can be pneumatic or hydraulic, which will be one of the simplest and most energy-saving methods in the air volume adjustment method of the reciprocating compressor.

Description

Technical Field

[0001] The utility model relates to the field of reciprocating compressors, in particular to an automatic multi-bladder full-flow clearance multi-stage regulating system for reciprocating compressors. Background Art

[0002] Since reciprocating piston compressors are usually customized according to the maximum operating flow rate, and the actual operating flow rate required is usually less than the design flow rate, a large number of compressors waste energy. Multi-bladder clearance multi-stage adjustment of reciprocating compressors is an energy-saving flow regulation method for reciprocating piston compressors. The working principle is to install a multi-bladder actuator on the cover side of each cylinder of the compressor. The multi-bladder actuator obtains different clearance volumes through a combination of multiple airbags with different volumes. According to the compressor flow demand, each airbag is controlled to switch to obtain the clearance volume corresponding to the required flow, thereby controlling the flow on the compressor cylinder head side.

[0003] The current clearance adjustment actuator is only installed on the compressor cylinder head side and can only adjust the air volume on the compressor cylinder head side, with the following shortcomings: the air volume adjustment range is generally 50% to 100% of the rated flow rate, and the adjustment range is small. The compressor cannot be adjusted to 0% to 100% full flow or the air volume below 50% of the rated flow rate, and cannot meet the requirements of maximum energy saving; at the same time, because only the air volume on the compressor cover side is adjusted, under some working conditions, it will have an adverse effect on the force of the unit, causing problems such as accelerated wear of the crosshead pin due to a too small reverse angle; in some devices, because the air volume on the cover side is much smaller than the air volume on the shaft side, the difference in air volume on both sides will increase the pulsation of the compressor pipeline, which may cause problems such as device vibration. Utility Model Content

[0004] The purpose of the utility model is to improve the deficiencies of the current existing technology and to provide an automatic multi-bladder full-flow clearance multi-stage adjustment system for a reciprocating compressor.

[0005] The technical scheme adopted by the utility model is: an automatic multi-bag full-flow clearance multi-stage adjustment system for a reciprocating compressor, including: a control system, and its technical key points are: it also includes a power system, a signal transmission system, a power valve, a power pipeline, a cover-side multi-bag air volume adjustment actuator, a special air and a shaft-side multi-bag air volume adjustment actuator, the power system, the power valve and the power pipeline are connected, the control system realizes signal transmission with the power valve through the signal transmission system, the special cylinder is a double-acting cylinder, which is divided into two working chambers by the compressor piston, and the two working chambers are respectively arranged on the cylinder head side and the crankcase side, the cover-side multi-bag air volume adjustment actuator is installed on the cylinder head side of the special cylinder, the shaft-side multi-bag air volume adjustment actuator is installed on the crankcase side of the special cylinder, and the shaft-side working chamber of the special cylinder is provided with one or more docking ports, the docking ports are communicated with the air bag channel of the shaft-side multi-bag air volume adjustment actuator, and are provided with an installation positioning structure.

[0006] The advantages and beneficial effects of the utility model are as follows: due to the use of the reciprocating compressor automatic multi-bladder full-flow clearance multi-stage adjustment system, the compressor double-acting cylinder head side gas volume and shaft side gas volume can be adjusted and controlled, which is conducive to optimizing the compressor unit stress by adjusting the shaft cover side gas volume ratio in the design stage, so that the original smaller load adjustment range of 50% to 100% is increased to 0% to 100% of the full flow. The increase in the adjustment range greatly improves the application scope of the multi-bladder clearance adjustment system and has better energy-saving effect. Through the precise control of the flow on both sides of the compressor cylinder, the risk of component damage caused by unbalanced force and the risk of pulsation and vibration caused by unbalanced flow can be effectively reduced. The system has low requirements for the power system and control system, high basic configuration flexibility, and little public engineering consumption. General factories can conveniently use the utility model, which is also applicable to remote areas with scarce resources. The fully automated control method can effectively reduce labor consumption and effectively improve production efficiency and safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In order to more clearly illustrate the embodiments of the utility model or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0008] Figure 1 It is a schematic diagram of the system structure of the utility model;

[0009] Figure 2 This is a schematic diagram of the structure of the multi-capsule actuator of the utility model;

[0010] Figure 3 It is a schematic diagram of the cross section of a special cylinder;

[0011] The serial numbers in the figure are explained as follows: 1 control system, 2 power system, 3 signal transmission system, 4 power valve, 5 power pipeline, 6 cover side multi-bag gas volume adjustment actuator, 7 special cylinder, 8 shaft side multi-bag gas volume adjustment actuator, 9 docking port of special cylinder. DETAILED DESCRIPTION

[0012] In order to make the above-mentioned purposes, features and advantages of the present invention more obvious and easy to understand, the following is a brief description of the present invention in conjunction with the attached drawings. Figure 1 , Figure 2 , Figure 3 The utility model is further described in detail with specific embodiments. A reciprocating compressor automatic multi-bag full-flow clearance multi-stage adjustment system includes: a control system 1, characterized in that it also includes a power system 2, a signal transmission system 3, a power valve 4, a power pipeline 5, a cover-side multi-bag air volume adjustment actuator 6, a special cylinder 7 and a shaft-side multi-bag air volume adjustment actuator 8, the power system 2, the power valve 4 and the power pipeline are connected, the control system 1 realizes signal transmission with the power valve 4 through the signal transmission system 3, the special cylinder 7 is a double-acting cylinder, which is divided into two working chambers by the compressor piston, and the two working chambers are respectively arranged on the cylinder head side and the crankcase side, the cover-side multi-bag air volume adjustment actuator 6 is installed on the cylinder head side of the special cylinder 7, the shaft-side multi-bag air volume adjustment actuator 8 is installed on the crankcase side of the special cylinder 7, and the shaft-side working chamber of the special cylinder 7 is provided with one or more docking ports, which are connected to the airbag channel of the shaft-side multi-bag air volume adjustment actuator 8, and are provided with an installation positioning structure.

[0013] Furthermore, the control system 1 is a PLC system or a DCS system, and the control system 1 controls the switching state of the power valve 4 through the signal transmission system 3, and the power valve 4 controls the on-off state of the power pipeline 5, and the on-off state of the power pipeline 5 controls the connection or closing state of each airbag chamber in the cover-side multi-bag air volume adjustment actuator 6 and the shaft-side multi-bag air volume adjustment actuator 8 installed on the special cylinder 7 with the cover-side and shaft-side working chambers of the special cylinder 7.

[0014] The utility model protects an automatic multi-bag full-flow clearance multi-stage adjustment system for a double-acting cylinder reciprocating compressor, which includes a control system 1, a power system 2, a signal transmission system 3, a power valve 4, a power pipeline 5, a cover-side multi-bag air volume adjustment actuator 6, a special cylinder 7 and a shaft-side multi-bag air volume adjustment actuator 8. The specific number of each component is configured according to the air volume adjustment function required by the compressor. The flow adjustment range can be 0% to 100% full-flow multi-stage precise CNC adjustment with a minimum flow of 0% and a maximum flow of 100%, or it can be a certain flow section or multiple flow sections within the flow range of 0% to 100% multi-stage precise CNC adjustment.

[0015] The control system 1 included in the utility model can be a PLC system or a DCS system, and configuration programming is performed in the system. The configuration program is set according to the volume of each airbag chamber in the cover-side multi-bag air volume adjustment actuator 6 and the shaft-side multi-bag air volume adjustment actuator 8 and considering the overall stress condition of the unit.

[0016] The power system 2 can be a pneumatic system or a hydraulic system. Specifically, the pneumatic system is a system driven by gases such as compressed air, nitrogen or compressor medium gas as a power source. Specifically, the hydraulic system is a system driven by liquid media such as a hydraulic oil system or a water pressure system as a power source.

[0017] The signal transmission system 3 is used to control the transmission of signals between the system 1 and the power valve 4, which can be wired transmission or wireless transmission.

[0018] The power valve 4 can be controlled by the control system 1 through an electrical signal, and can be an automatically controllable valve such as a solenoid valve, a proportional valve, a regulating valve, a stop valve, a needle valve, etc. It is not limited to an electric valve, and can also be a pneumatic or hydraulic valve.

[0019] The power pipeline 5 is used to connect the power system 2, the cover-side multi-bag gas volume adjustment actuator 6 and the shaft-side multi-bag gas volume adjustment actuator 8, provide external power for the actuator, and is responsible for power transmission and recovery. The power pipeline 5 is a pipeline used to transport the power source medium. Different types of pipelines are selected according to the different characteristics of the required power medium.

[0020] The control system 1 controls the switching state of the power valve 4 through the signal transmission system 3, and the power valve 4 controls the on-off state of the power pipeline 5. The on-off state of the power pipeline 5 controls the connection or closing state of each airbag chamber in the cover-side multi-bag air volume adjustment actuator 6 and the shaft-side multi-bag air volume adjustment actuator 8 installed on the special cylinder 7 with the cover-side and shaft-side working chambers of the special cylinder 7. After the volumes of each airbag chamber are combined, a series of different clearance volumes can be obtained. After the different clearance volumes of this series are connected with the working chamber, the compressor cylinder has the ability of multi-stage adjustable air volume. This regulation system can adjust the flow on the compressor cylinder cover side, and can also adjust the flow on the compressor cylinder shaft side, that is, it realizes the full flow regulation function of the compressor.

[0021] The special cylinder 7 is a double-acting ordinary cylinder of a reciprocating compressor with one or more docking ports on the axial side of the working chamber. Figure 2 and Figure 3This docking port is connected to the shaft-side multi-bag gas volume adjustment actuator 8. This docking port needs to avoid the position of the gas valve and its channel, and reserve a wall thickness of sufficient strength. At the same time, a threaded connection position is reserved outside the docking port, and a stopper is set for the installation and positioning of the shaft-side multi-bag gas volume adjustment actuator 8 to facilitate installation. Different from the current conventional cylinders, the special cylinder 7 has 1 to 2 interfaces dedicated to multi-bag gas volume adjustment on the upper side of the shaft, similar to the valve interface.

[0022] The cover-side multi-bag gas volume regulating actuator 6 and the shaft-side multi-bag gas volume regulating actuator 8 are pneumatically or hydraulically controlled multi-valve multi-cavity structures, usually composed of multiple gas bags with volume ratios in geometric progression. Specifically, the volume of the second (or group) gas bag is twice the volume of the first (or group) gas bag, the volume of the third (or group) gas bag is four times the volume of the first (or group) gas bag, and the volume of the fourth (or group) gas bag is eight times the volume of the first (or group) gas bag, and so on. Each cavity is equipped with one or more switch valves, which are controlled by the actuator piston, and the actuator piston is controlled by the power delivered by the power pipeline 5. The combination of different clearance volumes in a series is usually arranged in an arithmetic progression. The values ​​of these volume combinations can make each level of the gas volume of each compressor cylinder uniformly distributed. According to the actual gas volume requirements, only part of the volume values ​​in the series can be used in actual applications, and not all of them are necessarily used. In special cases, the arrangement in an arithmetic progression may not be used.

[0023] Working method: Figure 1 As shown, the cover-side multi-bag gas volume regulating actuator 6 is installed on the cylinder head side (i.e., the cover side) of the special cylinder 7, and the shaft-side multi-bag gas volume regulating actuator 8 is installed on the crankcase side (i.e., the shaft side) of the special cylinder 7. The power system 2, the power valve 4, the cover-side multi-bag gas volume regulating actuator 6 and the shaft-side multi-bag gas volume regulating actuator 8 are connected together through the power pipeline 5, and the power system 2 continuously provides power. The control system 1 controls the switch state of the power valve 4 through the signal transmission system 3, and the power valve 4 controls the connection or closing state of each airbag chamber in the cover-side multi-bag gas volume regulating actuator 6 and the shaft-side multi-bag gas volume regulating actuator 8 with the cover-side and shaft-side working chambers of the special cylinder 7, that is, the clearance volume of the compressor cylinder is controlled by the switch state of the power valve 4, that is, the purpose of regulating the full flow of the compressor by the control system 1 is achieved. According to the characteristics of the compressed medium and the requirements of the on-site environment, the automatic multi-bag full-flow clearance multi-stage adjustment system of the reciprocating compressor may need to add supporting systems such as the venting system, the nitrogen filling replacement system, and the leakage monitoring system.

[0024] Embodiment 1: A factory needs to add a two-row two-stage air compressor with full flow regulation requirements, and installs the utility model. The control system 1 uses a PLC system, the power system 2 uses 0.6MPa compressed air, the signal transmission system 3 uses a multi-core shielded cable, the power valve 4 uses a solenoid valve, the power pipeline 5 uses a stainless steel tube, the docking port of the special cylinder 7 is located just above the shaft side, and the first and second level cover side multi-bag air volume regulation actuator 6 and the first and second level shaft side multi-bag air volume regulation actuator 8 have five air bags. The compressor needs to be equipped with 2 cover-side multi-bag air volume regulating actuators 6, 2 shaft-side multi-bag air volume regulating actuators 8 and 2 special cylinders 7, so that each cover-side multi-bag air volume regulating actuator 6 and shaft-side multi-bag air volume regulating actuator 8 can adjust the flow rate by about 50% at most. At this time, the total air bag volume required by the cover-side multi-bag air volume regulating actuator 6 and the shaft-side multi-bag air volume regulating actuator 8 is 31L, of which the first air bag volume of each actuator is 1L, the second air bag volume is 2L, and the third air bag volume is 1L. The volume of the first airbag is 4L, the volume of the fourth airbag is 8L, and the volume of the fifth airbag is 16L. Through the switch combination of the airbags on the cover side and the shaft side, a total of 63 volume series arranged in an arithmetic progression are formed (including the case of 0L when all are closed), as shown in Table 1. The flow control accuracy of each actuator is about 1.6%. After the hydrogen compressor is installed with the utility model, the flow can be automatically controlled by the PLC system. The control accuracy of each level of regulation is 1.6%, and the flow adjustment range is 0% to 100% load.

[0025] Table 1

[0026]

[0027] Embodiment 2: The existing compressor is a two-row two-stage high-pressure hydrogen compressor used in a chemical plant, with a load flow regulation requirement of 40% to 100%. The utility model is installed, requiring the reduction of air bags as much as possible and a control accuracy of 2%. The control system 1 adopts the DCS system, the power system 2 adopts the 15MPa hydraulic system, the signal transmission system 3 adopts the multi-core shielded cable, the power valve 4 adopts the two-position two-way solenoid valve, the power pipeline 5 adopts the stainless steel tube, the docking port of the newly added special cylinder 7 is located in the horizontal direction of the shaft side and replaces the original cylinder, the first and second stage multi-bag gas volume adjustment actuators are five groups of air bags, and the total air bag volume required for each level is 30L, among which each cylinder head side actuator is equipped with three groups of air bags numbered 1#, 2#, and 3#, and each cylinder shaft side actuator is equipped with two groups of air bags numbered 4# and 5#. The volume of the first group of air bags is 1L, the volume of the second group of air bags is 4L, the volume of the third group of air bags is 15L, the volume of the fourth group of air bags is 2L, and the volume of the fifth group of air bags is 8L. Figure 3As shown. Through the switch combination of each airbag, a total of 31 volume series arranged in an arithmetic progression are formed (including the case of 0L when all are closed), see Table 2. After the installation of the utility model, the hydrogen compressor automatically controls the flow through the DCS system, the control accuracy of each level of regulation is 2%, and the flow adjustment range is 40% to 100% load. Since the medium of this compressor is hydrogen, the instrument needs to be configured according to the on-site explosion-proof requirements, and the actuator needs to be equipped with a cooling system, a venting system, a nitrogen filling replacement system, and a leakage monitoring system.

[0028] Table 2

[0029]

[0030]

[0031]

Claims

1. An automatic multi-bladder full-flow clearance multi-stage adjustment system for a reciprocating compressor, comprising: The control system (1) is characterized in that it also includes a power system (2), a signal transmission system (3), a power valve (4), a power pipeline (5), a head-side multi-bag gas volume adjustment actuator (6), a special cylinder (7) and a shaft-side multi-bag gas volume adjustment actuator (8). The power system (2), the power valve (4) and the power pipeline (5) are connected. The control system (1) realizes signal transmission with the power valve (4) through the signal transmission system (3). The special cylinder (7) is a double-acting cylinder, which is divided into two working chambers by a compressor piston. The two working chambers are respectively arranged on the cylinder head side and the crankcase side. The head-side multi-bag gas volume adjustment actuator (6) is installed on the cylinder head side of the special cylinder (7). The shaft-side multi-bag gas volume adjustment actuator (8) is installed on the crankcase side of the special cylinder (7). The shaft-side working chamber of the special cylinder (7) is provided with one or more docking ports, which are connected to the airbag channel of the shaft-side multi-bag gas volume adjustment actuator (8) and are provided with an installation positioning structure.

2. The automatic multi-bladder full-flow clearance multi-stage adjustment system for a reciprocating compressor according to claim 1, characterized in that: The control system (1) is a PLC system or a DCS system. The control system (1) controls the on / off state of the power valve (4) through the signal transmission system (3). The power valve (4) controls the on / off state of the power pipeline (5). The on / off state of the power pipeline (5) controls the connection or closing state of each airbag chamber in the cover-side multi-bag air volume adjustment actuator (6) and the shaft-side multi-bag air volume adjustment actuator (8) installed on the special cylinder (7) with the cover-side and shaft-side working chambers of the special cylinder (7).

3. The automatic multi-bladder full-flow clearance multi-stage adjustment system for a reciprocating compressor according to claim 2, characterized in that: The power system (2) is a pneumatic system or a hydraulic system.

4. The automatic multi-bladder full-flow clearance multi-stage adjustment system for a reciprocating compressor according to claim 3, characterized in that: The cover-side multi-bag air volume regulating actuator (6) and the shaft-side multi-bag air volume regulating actuator (8) are composed of a plurality of air bags whose volume ratios are in a geometric progression, i.e., the volume of the second air bag is twice the volume of the first air bag, the volume of the third air bag is four times the volume of the first air bag, the volume of the fourth air bag is eight times the volume of the first air bag, and so on.

5. The automatic multi-bladder full-flow clearance multi-stage adjustment system for a reciprocating compressor according to claim 4, characterized in that: The power pipeline (5) is used to connect the power system (2), the cover-side multi-bag gas volume regulating actuator (6) and the shaft-side multi-bag gas volume regulating actuator (8), and the power pipeline (5) is a pipeline for transporting a power source medium.

6. The automatic multi-bladder full-flow clearance multi-stage adjustment system for a reciprocating compressor according to claim 1, characterized in that: The signal transmission system (3) is used to transmit signals between the control system (1) and the power valve (4), and the transmission method is wired transmission or wireless transmission.

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