An integrated modular group-controlled air compressor optimization system

Abstract

The present invention proposes an integrated modular group-controlled air compressor optimization system, which belongs to the field of air compression and includes: a control management device, a main control device, a field device, a network A, a network B and a compressed air main pipe; the control management device is connected to the main control device through the network A and the network B respectively, the main control device is connected to the field device through the network A and the network B respectively, and the field device is connected to the compressed air main pipe; the present invention can integrate and modularize the original air compressor system on a large scale, and optimize the original air compressor system. The optimized air compressor system can achieve energy-saving goals, reduce costs, and be unmanned. The integrated modular group-controlled air compressor optimization system product has very little modification to the original air compressor system and has very strong expansibility, and is suitable for modifications to different air compressor systems.

Description

Technical Field

[0001] The invention belongs to the field of air compression, and in particular relates to an integrated modular group-controlled air compressor optimization system. Background Art

[0002] Compressed air is an important power source. Compared with other energy sources, it has the following obvious characteristics: clear and transparent, easy to transport, no special harmful properties, no fire hazard, not afraid of overload, can work in many adverse environments, air is everywhere on the ground and is inexhaustible.

[0003] With the continuous development of air compression technology, many enterprises in my country have begun to pay attention to energy-saving and environmentally friendly air compression devices and systems. Due to the different scales of enterprises, different air compression devices, different on-site environments, and different cost requirements, the demand for integrated modularization of air compression systems is very urgent. Enterprises are eager for a set of air compression systems with high portability, strong scalability, unattended operation, energy saving and environmental protection, low cost, and little modification to the original on-site environment. There is no air compression system on the market that combines all the above advantages, and many existing air compression technologies are based on the transformation of frequency conversion technology, which has great limitations in scalability, and due to the high cost brought by scale expansion, it is not suitable for the technical transformation of large-scale enterprises. Summary of the invention

[0004] Based on the above technical problems, the present invention proposes an integrated modular group-controlled air compressor optimization system, including: a control management device, a main control device, a field device, a network A, a network B and a compressed air main pipe;

[0005] The control management device is connected to the main control device through network A and network B respectively, the main control device is connected to the field device through network A and network B respectively, and the field device is connected to the compressed air main pipe;

[0006] The control management device is located in the control room, issues control instructions to the main control device, collects historical operation records, and provides summary reports for managers;

[0007] The main control device is located in the electronic room, receives the control instructions issued by the control management device, and transmits them to the field devices, so that the field devices operate according to the control instructions;

[0008] The field device is located in the field area, receives the control instruction transmitted by the main control device, and transmits it to the air compressor to be optimized, so that the air compressor to be optimized operates according to the control instruction. If the factory to be optimized has several field areas, each field area includes a set of field devices;

[0009] The compressed air main pipe collects all compressed air outputted by the optimized air compressors to the compressed air main pipe, and the compressed air main pipe provides compressed air to the gas users;

[0010] Network A and Network B are communication networks, and switching between Network A and Network B is performed according to the backup network usage rules;

[0011] The backup network usage rule is: when network A fails and communication is impossible, switch to network B, otherwise use network A for communication;

[0012] The control and management equipment specifically includes: an engineer station, an operation station, and a printer;

[0013] The main control device includes a main control cabinet;

[0014] The field equipment specifically includes: at least one air compressor cabinet, at least one communication interface device, a remote cabinet, and field instruments;

[0015] The field instrument is connected to the remote cabinet, the remote cabinet is connected to the communication interface device through the communication cable, and the communication interface device is connected to the air compressor cabinet through the communication cable; the remote cabinet is connected to the first switch through the network A, the remote cabinet is connected to the second switch through the network B, the first switch is connected to the main control cabinet through the network A, the second switch is connected to the main control cabinet through the network B, the first switch is connected to the engineer station, the operation station, and the printer through the network A, and the second switch is connected to the engineer station, the operation station, and the printer through the network B; the compressed air main pipe is connected to the air compressor cabinet;

[0016] The field instrument is a device for detecting various parameters of the integrated modular group-controlled air compressor optimization system on site, and sending the detected parameter signals to the communication interface device;

[0017] The equipment for measuring various parameters of the integrated modular group-controlled air compressor optimization system specifically includes: pressure measuring equipment, temperature measuring equipment, flow measuring equipment, air compressor current signal measuring equipment, and air compressor voltage signal measuring equipment; wherein the pressure measuring equipment measures the pressure value in the compressed air main pipe; the temperature measuring equipment measures the temperature value in the compressed air main pipe; the flow measuring equipment measures the flow value in the compressed air main pipe; the air compressor current signal measuring equipment measures the current value of each air compressor; the air compressor voltage signal measuring equipment measures the voltage value of each air compressor;

[0018] The measurement signals of field instruments are all 4-20mA. The measurement signals are connected to the I / O modules in the remote cabinet through cables. The I / O modules convert the measurement signals into digital signals.

[0019] The air compressor cabinet contains an air compressor to be tested and an air compressor control module. The air compressor to be tested is connected to the air compressor control module. The air compressor control module is used to control the start and stop of the air compressor by adjusting parameters.

[0020] The communication interface device reads various parameters of the air compressor to be tested from the field instrument, reads the control signal of the air compressor to be tested from the remote cabinet, and transmits the control signal to the air compressor to be tested in the air compressor cabinet;

[0021] The various parameters of the air compressor to be tested are read, including: the running state of each air compressor, the stopping state of each air compressor, the loading state of each air compressor, the unloading state of each air compressor, the current of each air compressor, the outlet pressure of each air compressor, and the temperature alarm of each air compressor;

[0022] The control signal of the air compressor to be tested includes: a start control signal of the air compressor, a stop control signal of the air compressor, a loading control signal of the air compressor, and an unloading control signal of the air compressor;

[0023] The communication interface device is connected to the communication interface configured on the air compressor in the air compressor cabinet, and communicates through Modus communication. Each air compressor is configured with a communication interface device. If there are N air compressors on site, N communication interface devices are configured accordingly.

[0024] The remote cabinet acts as a signal relay between the field instrument and the control cabinet, reading various parameter signals of the field instrument, reading various parameter signals of the air compressor through the communication interface device, and sending all the read signals to the main control cabinet;

[0025] The remote cabinet includes: an I / O module, a communication module, a power module and a remote cabinet cabinet;

[0026] Power module: connected to the I / O module and communication module respectively to provide power for the I / O module and communication module;

[0027] I / O module: realizes bidirectional conversion between digital and analog signals. According to the needs, it is set to convert analog signals into digital signals, digital signals into analog signals, switch signals into digital signals, or digital signals into switch signals. Specifically, it is set as needed: convert analog signals transmitted from communication interface equipment into digital signals; convert analog signals transmitted from field instruments into digital signals; convert switch signals transmitted from field instruments into digital signals; or according to the needs, it is set to convert digital signals transmitted from communication interface equipment into analog signals; convert digital signals transmitted from field instruments into analog signals; convert digital signals transmitted from field instruments into switch signals;

[0028] Communication module: connected to the communication interface device to realize the communication between the remote cabinet and the communication interface device;

[0029] Remote cabinet cabinet: The outer shell of the remote cabinet protects the internal components;

[0030] Network A: The first switch is the communication network between the remote cabinet, the main control cabinet, the engineer station, the operation room, and the printer. It switches between network A and network B according to the backup network usage rules;

[0031] Network B: The communication network between the second switch and the remote cabinet, main control cabinet, engineer station, operation room, and printer is a backup network. It switches between network A and network B according to the backup network usage rules;

[0032] The backup network usage rule is: when network A fails and communication is impossible, switch to network B, otherwise use network A for communication;

[0033] The communication medium between network A and network B is RJ45 network cable;

[0034] Main control cabinet: All signals transmitted in real time from the remote cabinet are calculated by the air compressor optimization software in the main control cabinet controller to obtain the air compressor control signal, and then the control signal is transmitted to the remote cabinet;

[0035] The main control cabinet comprises: a main control cabinet power module, a controller, a main control cabinet communication module, a first switch, a second switch, and a main control cabinet cabinet;

[0036] The main control cabinet power supply module is respectively connected to the controller, the main control cabinet communication module, the first switch and the second switch to provide power for the controller, the main control cabinet communication module, the first switch and the second switch;

[0037] The controller stores the air compressor control software, calculates all the signals transmitted from the remote cabinet in real time, obtains the air compressor control signal, and transmits the air compressor control signal to the remote cabinet;

[0038] The main control cabinet communication module completes the communication between the main control cabinet and the remote cabinet;

[0039] Main control cabinet cabinet, the outer shell of the main control cabinet, plays the role of protecting the internal components;

[0040] The first switch is used to form a star topology network structure with the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer; the first switch is an intermediate medium for data transmission and exchange between the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer;

[0041] The second switch is used to connect the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer to form a star topology network structure; the second switch is the intermediate medium for data transmission and exchange between the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer;

[0042] The engineer station is equipped with a first industrial computer, a first display, a first mouse and a first keyboard, and the air compressor control signals are organized into an air compressor control database in chronological order, and the database historical data, data trends, and alarm information reports are obtained; the air compressor operation status monitoring screen is obtained through the display;

[0043] The operation station includes a second industrial computer, a second display, a second mouse and a second keyboard; the second industrial computer sends the air compressor control signal and obtains the air compressor operation status monitoring screen through the display;

[0044] Printer, print database historical data, data trends, alarm information reports;

[0045] If the air compressor factory to be optimized has an original monitoring system, recorded as a SIS system, the first switch is connected to the monitoring system through network A, and the second switch is connected to the monitoring system through network B. This monitoring system can only monitor and cannot perform any operations on other hardware and software.

[0046] Further, the engineer edits and compiles the air compressor optimization software. After the compilation is completed, the air compressor control software is downloaded to the main control cabinet controller; the air compressor control software includes: a compressed air main pipe pressure calculation and setting module, a compressed air main pipe flow calculation module, a compressed air main pipe pressure open-loop regulation mode module, a compressed air main pipe pressure closed-loop regulation mode module, a pressure regulation algorithm selection module, an automatic start and stop air compressor control module, an air compressor sequence and priority selection module, an automatic loading and unloading air compressor control module, a compressed air main pipe pressure manual and automatic control selection module, and a manual control air compressor module;

[0047] The compressed air main pipe pressure calculation and setting module is connected to the compressed air main pipe pressure manual and automatic control selection module, the compressed air main pipe pressure manual and automatic control selection module is respectively connected to the pressure regulation algorithm selection module, the air compressor sequence and priority selection module and the manual control air compressor module, the manual control air compressor module is respectively connected to the air compressor start and stop and loading and unloading control module of each air compressor, the air compressor sequence and priority selection module is connected to the automatic start and stop air compressor control module, the automatic start and stop air compressor control module is connected to the automatic loading and unloading air compressor control module, the pressure regulation algorithm selection module is respectively connected to the compressed air main pipe pressure open-loop regulation mode module and the compressed air main pipe pressure closed-loop regulation mode module, the compressed air main pipe pressure open-loop regulation mode module and the compressed air main pipe pressure closed-loop regulation mode module are respectively connected to the automatic start and stop air compressor control module, and the compressed air main pipe flow calculation module is connected to the compressed air main pipe pressure open-loop regulation mode module;

[0048] The compressed air main pipe pressure calculation and setting module, the pressure measuring device collects the compressed air main pipe pressure value, and transmits it to the main control cabinet through the remote cabinet. The number of the pressure measuring devices is 1 to 3. According to the requirements of the work to be optimized, one of the following three algorithms is selected and set in the compressed air main pipe pressure calculation and setting module, namely, the single value algorithm, the mean value algorithm or the three-mid algorithm, to calculate and obtain the final compressed air main pipe real-time pressure value, and transmit the final compressed air main pipe real-time pressure value to the compressed air main pipe pressure open-loop regulation mode module or the compressed air main pipe pressure closed-loop regulation mode module;

[0049] The single value algorithm is to specify and select a certain pressure measuring device and take the compressed air main pipe pressure value collected by it; the average value algorithm is to specify and select two certain pressure measuring devices and take the average value of the compressed air main pipe pressure values ​​collected by the two; the three-way algorithm is to take the middle value of the compressed air main pipe pressure values ​​collected by the three pressure measuring devices;

[0050] The compressed air main pipe flow calculation module, the flow measurement device measures the flow value in the compressed air main pipe, and transmits it to the main control cabinet through the remote cabinet, takes the flow value in the compressed air main pipe as the feedforward quantity, and transmits it to the compressed air main pipe pressure open-loop regulation mode module and the compressed air main pipe pressure closed-loop regulation mode module;

[0051] The compressed air main pipe pressure open-loop regulation mode module manually sets the main pipe pressure upper and lower limits, and compares the calculated compressed air main pipe real-time pressure value with the manually set main pipe pressure upper and lower limits. If the compressed air main pipe real-time pressure value exceeds the manually set main pipe pressure upper limit, the compressed air main pipe pressure open-loop regulation mode module outputs the unloading control instruction to the automatic start and stop air compressor control module, and then transmits it to the automatic loading and unloading air compressor control module to automatically unload K air compressors; if the compressed air main pipe real-time pressure value is lower than the manually set main pipe pressure lower limit, the compressed air The main pipe pressure open-loop regulation mode module outputs a start-up loading control instruction to the automatic start-stop air compressor control module to start loading K standby air compressors; the specific process of starting loading K air compressors is as follows: if it is detected that the standby air compressor is in a standby state, the automatic loading and unloading air compressor control module is used to output a loading control instruction to directly load the standby air compressor; if it is detected that the standby air compressor is in a stopped state, the automatic start-stop air compressor control module is first used to output a start-up control instruction to start the standby air compressor, and then the automatic loading and unloading air compressor control module is used to output a loading control instruction to load the standby air compressor;

[0052] The compressed air main pipe pressure closed-loop regulation mode module, if the absolute value of the difference between the real-time pressure of the compressed air main pipe and the manually set main pipe pressure value is greater than the difference threshold, the closed-loop control mode is used to adjust the actuator of the running compressor, so that the real-time pressure of the compressed air main pipe continues to approach the manually set main pipe pressure value; if the real-time pressure of the compressed air main pipe exceeds the manually set high alarm value, the compressed air main pipe pressure closed-loop regulation mode module sends a stop control instruction to the automatic start-stop air compressor control module, and then stops K running air compressors; if the real-time pressure of the compressed air main pipe is lower than the manually set low alarm value, the compressed air main pipe pressure closed-loop regulation mode module sends a start-load control instruction to the automatic start-stop air compressor control module, and then starts loading K spare air compressors. The specific process of starting to load K air compressors is as follows: if it is detected that the standby air compressor is in a standby state, the automatic loading and unloading air compressor control module is used to output a loading control instruction to directly load the standby air compressor; if it is detected that the standby air compressor is in a stopped state, the automatic start-stop air compressor control module is first used to output a starting control instruction to start the standby air compressor, and then the automatic loading and unloading air compressor control module is used to output a loading control instruction to load the standby air compressor;

[0053] The pressure regulation algorithm selection module is used for manual setting according to whether the air intake volume of the air compressor configured by the factory is adjustable. If the air intake volume of the air compressor is not adjustable, the open-loop regulation mode module is used to control the mother pipe pressure; if the air intake volume of the air compressor is adjustable, the closed-loop regulation mode module is used to control the mother pipe pressure;

[0054] The air compressor sequence and priority selection module, for the air compressors controlled by the control optimization system, manually formulates the start or stop, load or unload sequence of n sets of related compressors according to the start or stop, load or unload sequence and switching requirements of the related air compressors in the factory, so that the air compressor optimization software program can execute automatically;

[0055] The automatic start-stop air compressor control module, according to the control instructions transmitted by the compressed air main pipe pressure open-loop regulation mode module, the compressed air main pipe pressure closed-loop regulation mode module, and the air compressor sequence and priority selection module, if the control instruction is to start loading, the following process is performed: if it is detected that the standby air compressor is in the standby state, the loading control instruction is transmitted to the automatic loading and unloading air compressor control module, and the loading control instruction is output to directly load the standby air compressor; if it is detected that the standby air compressor is in the stopped state, the automatic start-stop air compressor control module is first used to output the start control instruction to start the standby air compressor, and then the loading control instruction is output through the automatic loading and unloading air compressor control module to load the standby air compressor; if the control instruction is a stop instruction, the stop control instruction is output through the automatic start-stop air compressor control module to stop the corresponding air compressor; if the control instruction is a loading or unloading instruction, the loading or unloading instruction is output to the automatic loading and unloading air compressor control module;

[0056] The automatic loading and unloading air compressor control module performs loading or unloading air compressor operations according to the loading and unloading control instructions transmitted by the automatic start and stop air compressor control module;

[0057] Compressed air main pipe pressure manual and automatic control selection module, select manual input or automatic control of the air compressor main pipe pressure value;

[0058] Manual control of air compressor module: if the compressed air main pipe pressure automatic control is not required, this module is used to manually control a single air compressor under the optimization system. Manual control is achieved through the operation station to start / stop a single air compressor and manually set the loading pressure and unloading pressure of a single air compressor.

[0059] The air compressor start / stop and load / unload control module receives the signals of the automatic air compressor and the manual air compressor from the manual air compressor module, and directly drives the start / stop or load / unload of the air compressor;

[0060] If the integrated modular group-controlled air compressor optimization system encounters a data transmission abnormality fault, the following actions will occur depending on the fault type:

[0061] If the communication interface fails, the air compressor corresponding to the failed communication interface will automatically switch to local control;

[0062] If a remote station fails, all air compressors corresponding to the failed remote station interface will automatically switch to local control;

[0063] If the main control cabinet fails, all air compressors will be switched to local control;

[0064] Both network A and network B fail, and all air compressors are switched to local control.

[0065] Beneficial technical effects:

[0066] The present invention proposes an integrated modular group-controlled air compressor optimization system, which can integrate and modularize the original air compressor system on a large scale and optimize the original air compressor system. The optimized air compressor system can achieve energy-saving goals, reduce costs, and be unmanned. This integrated modular group-controlled air compressor optimization system product has very little modification to the original air compressor system and has very strong scalability, and is suitable for the modification of different air compressor systems. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Figure 1 A block diagram of an integrated modular group-controlled air compressor optimization system according to an embodiment of the present invention;

[0068] Figure 2 This is a software block diagram for optimizing the air compressor according to an embodiment of the present invention. DETAILED DESCRIPTION

[0069] The invention is further described below in conjunction with the accompanying drawings and specific implementation examples. The hardware system structure of the air compressor control optimization system is shown in the attached drawings. Figure 1 As shown. A set of control system is selected to form all the required hardware equipment. This system structure is configured because the number of air compressor equipment in the factory is generally large, and the air compressors are generally distributed in multiple workshops, but it is also suitable for the situation where they are concentrated in one workshop. In this system structure, an air compressor workshop is defined as one field area. The functions and roles of each hardware in this system structure are described as follows.

[0070] The present invention proposes an integrated modular group-controlled air compressor optimization system, such as Figure 1 As shown, it includes: control management equipment, main control equipment, field equipment, network A, network B and compressed air main pipe;

[0071] The control management device is connected to the main control device through network A and network B respectively, the main control device is connected to the field device through network A and network B respectively, and the field device is connected to the compressed air main pipe;

[0072] The control management device is located in the control room, issues control instructions to the main control device, collects historical operation records, and provides summary reports for managers;

[0073] The main control device is located in the electronic room, receives the control instructions issued by the control management device, and transmits them to the field devices, so that the field devices operate according to the control instructions;

[0074] The field device is located in the field area, receives the control instruction transmitted by the main control device, and transmits it to the air compressor to be optimized, so that the air compressor to be optimized operates according to the control instruction. If the factory to be optimized has several field areas, each field area includes a set of field devices;

[0075] The compressed air main pipe collects all compressed air outputted by the optimized air compressors to the compressed air main pipe, and the compressed air main pipe provides compressed air to the gas users;

[0076] Network A and Network B are communication networks, and switching between Network A and Network B is performed according to the backup network usage rules;

[0077] The backup network usage rule is: when network A fails and communication is impossible, switch to network B, otherwise use network A for communication;

[0078] The control and management equipment specifically includes: an engineer station, an operation station, and a printer;

[0079] The main control device includes a main control cabinet;

[0080] The field equipment specifically includes: at least one air compressor cabinet, at least one communication interface device, a remote cabinet, and field instruments;

[0081] The field instrument is connected to the remote cabinet, the remote cabinet is connected to the communication interface device through the communication cable, and the communication interface device is connected to the air compressor cabinet through the communication cable; the remote cabinet is connected to the first switch through the network A, the remote cabinet is connected to the second switch through the network B, the first switch is connected to the main control cabinet through the network A, the second switch is connected to the main control cabinet through the network B, the first switch is connected to the engineer station, the operation station, and the printer through the network A, and the second switch is connected to the engineer station, the operation station, and the printer through the network B; the compressed air main pipe is connected to the air compressor cabinet;

[0082] Field instruments are devices that detect various parameters of the integrated modular group-controlled air compressor optimization system on site, and send the detected parameter signals to the communication interface device;

[0083] The equipment for measuring various parameters of the integrated modular group-controlled air compressor optimization system specifically includes: pressure measuring equipment, temperature measuring equipment, flow measuring equipment, air compressor current signal measuring equipment, and air compressor voltage signal measuring equipment; wherein the pressure measuring equipment measures the pressure value in the compressed air main pipe; the temperature measuring equipment measures the temperature value in the compressed air main pipe; the flow measuring equipment measures the flow value in the compressed air main pipe; the air compressor current signal measuring equipment measures the current value of each air compressor; the air compressor voltage signal measuring equipment measures the voltage value of each air compressor;

[0084] The measurement signals of field instruments are all 4-20mA. The measurement signals are connected to the I / O modules in the remote cabinet through cables. The I / O modules convert the measurement signals into digital signals.

[0085] The air compressor to be tested and the air compressor control module are placed in the air compressor cabinet. The air compressor to be tested is connected to the air compressor control module. The air compressor control module is used to control the start and stop operation of the air compressor by adjusting parameters.

[0086] The communication interface device reads various parameters of the air compressor to be tested from the on-site instruments, reads the control signal of the air compressor to be tested from the remote cabinet, and transmits the control signal to the air compressor to be tested in the air compressor cabinet;

[0087] The various parameters of the air compressor to be tested are read, including: the running state of each air compressor, the stopping state of each air compressor, the loading state of each air compressor, the unloading state of each air compressor, the current of each air compressor, the outlet pressure of each air compressor, and the temperature alarm of each air compressor;

[0088] The control signal of the air compressor to be tested includes: a start control signal of the air compressor, a stop control signal of the air compressor, a loading control signal of the air compressor, and an unloading control signal of the air compressor;

[0089] The communication interface device is connected to the communication interface configured on the air compressor in the air compressor cabinet, and communicates through Modus communication. Each air compressor is configured with a communication interface device. If there are N air compressors on site, N communication interface devices are configured accordingly.

[0090] The remote cabinet acts as a signal relay between the field instrument and the control cabinet, reading various parameter signals of the field instrument, reading various parameter signals of the air compressor through the communication interface device, and sending all the read signals to the main control cabinet;

[0091] Since the distance between the air compressor plant and the control room is generally far, a remote control cabinet is required to receive / send the control information of the air compressor in the plant and receive the signals of the field instruments near the plant. This is its main function. One set of this equipment is configured in one air compressor plant and arranged in the air compressor plant.

[0092] The remote cabinet includes: an I / O module, a communication module, a power module and a remote cabinet cabinet;

[0093] Power module: connected to the I / O module and communication module respectively to provide power for the I / O module and communication module;

[0094] I / O module: realizes bidirectional conversion between digital and analog signals. According to the needs, it is set to convert analog signals into digital signals, digital signals into analog signals, switch signals into digital signals, or digital signals into switch signals. Specifically, it is set as needed: convert analog signals transmitted from communication interface equipment into digital signals; convert analog signals transmitted from field instruments into digital signals; convert switch signals transmitted from field instruments into digital signals; or according to the needs, it is set to convert digital signals transmitted from communication interface equipment into analog signals; convert digital signals transmitted from field instruments into analog signals; convert digital signals transmitted from field instruments into switch signals;

[0095] Communication module: connected to the communication interface device to realize the communication between the remote cabinet and the communication interface device;

[0096] Remote cabinet cabinet: The outer shell of the remote cabinet protects the internal components;

[0097] Network A: The first switch is the communication network between the remote cabinet, the main control cabinet, the engineer station, the operation room, and the printer. It switches between network A and network B according to the backup network usage rules;

[0098] Network B: The communication network between the second switch and the remote cabinet, main control cabinet, engineer station, operation room, and printer is a backup network. It switches between network A and network B according to the backup network usage rules;

[0099] The backup network usage rule is: when network A fails and communication is impossible, switch to network B, otherwise use network A for communication;

[0100] The communication medium between network A and network B is RJ45 network cable;

[0101] Main control cabinet: All signals transmitted in real time from the remote cabinet are calculated by the air compressor optimization software in the main control cabinet controller to obtain the air compressor control signal, and then the control signal is transmitted to the remote cabinet;

[0102] The main control cabinet comprises: a main control cabinet power module, a controller, a main control cabinet communication module, a first switch, a second switch, and a main control cabinet cabinet;

[0103] The main control cabinet power supply module is respectively connected to the controller, the main control cabinet communication module, the first switch and the second switch to provide power for the controller, the main control cabinet communication module, the first switch and the second switch;

[0104] The controller stores the air compressor control software, calculates all the signals transmitted from the remote cabinet in real time, obtains the air compressor control signal, and transmits the air compressor control signal to the remote cabinet;

[0105] The main control cabinet communication module completes the communication between the main control cabinet and the remote cabinet;

[0106] Main control cabinet cabinet, the outer shell of the main control cabinet, plays the role of protecting the internal components;

[0107] The first switch is used to form a star topology network structure with the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer; the first switch is an intermediate medium for data transmission and exchange between the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer;

[0108] The second switch is used to connect the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer to form a star topology network structure; the second switch is the intermediate medium for data transmission and exchange between the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer;

[0109] The engineer station is equipped with a first industrial computer, a first display, a first mouse and a first keyboard, and the air compressor control signals are organized into an air compressor control database in chronological order, and the database historical data, data trends, and alarm information reports are obtained; the air compressor operation status monitoring screen is obtained through the display;

[0110] The operation station includes a second industrial computer, a second display, a second mouse and a second keyboard; the second industrial computer sends the air compressor control signal and obtains the air compressor operation status monitoring screen through the display;

[0111] Printer, print database historical data, data trends, alarm information reports;

[0112] If the air compressor factory to be optimized has an original monitoring system, recorded as SIS system, the first switch is connected to the monitoring system through network A, and the second switch is connected to the monitoring system through network B. This monitoring system can only monitor and cannot perform any operations on other hardware and software. Figure 1 The SIS system shown in the figure. The monitoring screen of the air compressor optimization system can be connected to the plant-level monitoring SIS system to provide a window for air compressor equipment management and monitoring for plant-level managers. This is an optional option. And the SIS system can only monitor, not operate.

[0113] The air compressor models of the present invention are: IngersollRand: 350ML; CompAir: L375; CompAir: L250; Sullair: TS-32S;

[0114] Controller model: Siemens brand: a) Hardware: S7-1200, S7-1500, S7-300, S7-400; b) Programming and development software: TIA Portal, STEP7, PCS7; Schneider brand: a) Hardware: Quantum PLC (140), Premium PLC (TSX 57); b) Programming and development software: Concept, Unity;

[0115] Host computer monitoring software: Siemens brand: WINCC; GE brand: IFIX;

[0116] Those skilled in the art can easily ensure the normal operation of the air compressor optimization system through the software and hardware configuration of the above models;

[0117] Further, the engineer edits and compiles the air compressor control software. After the compilation is completed, the air compressor control software is downloaded to the main control cabinet controller; the air compressor control software includes: a compressed air main pipe pressure calculation and setting module, a compressed air main pipe flow calculation module, a compressed air main pipe pressure open-loop regulation mode module, a compressed air main pipe pressure closed-loop regulation mode module, a pressure regulation algorithm selection module, an automatic start and stop air compressor control module, an air compressor sequence and priority selection module, an automatic loading and unloading air compressor control module, a compressed air main pipe pressure manual and automatic control selection module, and a manual control air compressor module;

[0118] The compressed air main pipe pressure calculation and setting module is connected to the compressed air main pipe pressure manual and automatic control selection module, the compressed air main pipe pressure manual and automatic control selection module is respectively connected to the pressure regulation algorithm selection module, the air compressor sequence and priority selection module and the manual control air compressor module, the manual control air compressor module is respectively connected to the air compressor start and stop and loading and unloading control module of each air compressor, the air compressor sequence and priority selection module is connected to the automatic start and stop air compressor control module, the automatic start and stop air compressor control module is connected to the automatic loading and unloading air compressor control module, the pressure regulation algorithm selection module is respectively connected to the compressed air main pipe pressure open-loop regulation mode module and the compressed air main pipe pressure closed-loop regulation mode module, the compressed air main pipe pressure open-loop regulation mode module and the compressed air main pipe pressure closed-loop regulation mode module are respectively connected to the automatic start and stop air compressor control module, and the compressed air main pipe flow calculation module is connected to the compressed air main pipe pressure open-loop regulation mode module; Figure 2 shown.

[0119] The compressed air main pipe pressure calculation and setting module, the pressure measuring device collects the compressed air main pipe pressure value, and transmits it to the main control cabinet through the remote cabinet. The number of the pressure measuring devices is 1 to 3. According to the requirements of the work to be optimized, one of the following three algorithms is selected and set in the compressed air main pipe pressure calculation and setting module, namely, the single value algorithm, the mean value algorithm or the three-mid algorithm, to calculate and obtain the final compressed air main pipe real-time pressure value, and transmit the final compressed air main pipe real-time pressure value to the compressed air main pipe pressure open-loop regulation mode module or the compressed air main pipe pressure closed-loop regulation mode module;

[0120] The single value algorithm is to specify and select a certain pressure measuring device and take the compressed air main pipe pressure value collected by it; the average value algorithm is to specify and select two certain pressure measuring devices and take the average value of the compressed air main pipe pressure values ​​collected by the two; the three-way algorithm is to take the middle value of the compressed air main pipe pressure values ​​collected by the three pressure measuring devices;

[0121] The compressed air main pipe flow calculation module, the flow measurement device measures the flow value in the compressed air main pipe, and transmits it to the main control cabinet through the remote cabinet. The flow value in the compressed air main pipe is used as the feedforward quantity, and is transmitted to the compressed air main pipe pressure open-loop regulation mode module and the compressed air main pipe pressure closed-loop regulation mode module; an important reason for the change in factory compressed air pressure is the change in compressed air flow at the user end, so the change in flow can be used as an auxiliary means of compressed air main pipe pressure regulation. Here, the on-site compressed air flow is collected to the system by the remote cabinet, and a standard calculation is performed as a feedforward quantity for compressed air main pipe pressure control.

[0122] The compressed air main pipe pressure open-loop regulation mode module manually sets the main pipe pressure upper and lower limits, and compares the calculated compressed air main pipe real-time pressure value with the manually set main pipe pressure upper and lower limits. If the compressed air main pipe real-time pressure value exceeds the manually set main pipe pressure upper limit, the compressed air main pipe pressure open-loop regulation mode module outputs the unloading control instruction to the automatic start and stop air compressor control module, and then transmits it to the automatic loading and unloading air compressor control module to automatically unload K air compressors; if the compressed air main pipe real-time pressure value is lower than the manually set main pipe pressure lower limit, the compressed air The main pipe pressure open-loop regulation mode module outputs a start-up loading control instruction to the automatic start-stop air compressor control module to start loading K standby air compressors; the specific process of starting loading K air compressors is as follows: if it is detected that the standby air compressor is in a standby state, the automatic loading and unloading air compressor control module is used to output a loading control instruction to directly load the standby air compressor; if it is detected that the standby air compressor is in a stopped state, the automatic start-stop air compressor control module is first used to output a start-up control instruction to start the standby air compressor, and then the automatic loading and unloading air compressor control module is used to output a loading control instruction to load the standby air compressor;

[0123] The compressed air main pipe pressure closed-loop regulation mode module, if the absolute value of the difference between the real-time pressure of the compressed air main pipe and the manually set main pipe pressure value is greater than the difference threshold, the closed-loop control mode is used to adjust the actuator of the running compressor, so that the real-time pressure of the compressed air main pipe continues to approach the manually set main pipe pressure value; if the real-time pressure of the compressed air main pipe exceeds the manually set high alarm value, the compressed air main pipe pressure closed-loop regulation mode module sends a stop control instruction to the automatic start-stop air compressor control module, and then stops K running air compressors; if the real-time pressure of the compressed air main pipe is lower than the manually set low alarm value, the compressed air main pipe pressure closed-loop regulation mode module sends a start-load control instruction to the automatic start-stop air compressor control module, and then starts loading K spare air compressors. The specific process of starting to load K air compressors is as follows: if it is detected that the standby air compressor is in a standby state, the automatic loading and unloading air compressor control module is used to output a loading control instruction to directly load the standby air compressor; if it is detected that the standby air compressor is in a stopped state, the automatic start-stop air compressor control module is first used to output a starting control instruction to start the standby air compressor, and then the automatic loading and unloading air compressor control module is used to output a loading control instruction to load the standby air compressor;

[0124] The pressure regulation algorithm selection module is used for manual setting according to whether the air intake volume of the air compressor configured by the factory is adjustable. If the air intake volume of the air compressor is not adjustable, the open-loop regulation mode module is used to control the mother pipe pressure; if the air intake volume of the air compressor is adjustable, the closed-loop regulation mode module is used to control the mother pipe pressure;

[0125] The air compressor sequence and priority selection module, for the air compressors controlled by the control optimization system, manually formulates the start or stop, load or unload sequence of n sets of related compressors according to the start or stop, load or unload sequence and switching requirements of the related air compressors in the factory, so that the air compressor optimization software program can execute automatically;

[0126] The automatic start-stop air compressor control module, according to the control instructions transmitted by the compressed air main pipe pressure open-loop regulation mode module, the compressed air main pipe pressure closed-loop regulation mode module, and the air compressor sequence and priority selection module, if the control instruction is to start loading, the following process is performed: if it is detected that the standby air compressor is in the standby state, the loading control instruction is transmitted to the automatic loading and unloading air compressor control module, and the loading control instruction is output to directly load the standby air compressor; if it is detected that the standby air compressor is in the stopped state, the automatic start-stop air compressor control module is first used to output the start control instruction to start the standby air compressor, and then the loading control instruction is output through the automatic loading and unloading air compressor control module to load the standby air compressor; if the control instruction is a stop instruction, the stop control instruction is output through the automatic start-stop air compressor control module to stop the corresponding air compressor; if the control instruction is a loading or unloading instruction, the loading or unloading instruction is output to the automatic loading and unloading air compressor control module;

[0127] The automatic loading and unloading air compressor control module performs loading or unloading air compressor operations according to the loading and unloading control instructions transmitted by the automatic start and stop air compressor control module;

[0128] Compressed air main pipe pressure manual and automatic control selection module, select manual input or automatic control of the air compressor main pipe pressure value;

[0129] Manual control of air compressor module: if the compressed air main pipe pressure automatic control is not required, this module is used to manually control a single air compressor under the optimization system. Manual control is achieved through the operation station to start / stop a single air compressor and manually set the loading pressure and unloading pressure of a single air compressor.

[0130] The air compressor start / stop and load / unload control module receives the signals of the automatic air compressor and the manual air compressor from the manual air compressor module, and directly drives the start / stop or load / unload of the air compressor;

[0131] If the integrated modular group-controlled air compressor optimization system encounters a data transmission abnormality fault, the following actions will occur depending on the fault type:

[0132] If the communication interface fails, the air compressor corresponding to the failed communication interface will automatically switch to local control;

[0133] If a remote station fails, all air compressors corresponding to the failed remote station interface will automatically switch to local control;

[0134] If the main control cabinet fails, all air compressors will be switched to local control;

[0135] Both network A and network B fail, and all air compressors are switched to local control.

[0136] A list of specifications and models of main components of an integrated modular group-controlled air compressor optimization system is shown in Table 1:

[0137] Table 1 List of main component specifications

[0138]

[0139] The design advantages of the present invention are:

[0140] (1) Reduce the use of cables and save users money. The distance between the air compressor site and the main control room and the electronic room of the factory is generally more than 500 meters. If all the hardware is arranged in the electronic room, the relevant instrument signals and communication signals on site need to be laid over long distances. A large number of cables are required, which will result in high cable costs. Therefore, a remote cabinet is designed in each air compressor room. The instrument signals and communication signals on the nearest site can be transmitted to the remote cabinet through a very short cable, which can save a lot of money on cable purchases and save costs for users.

[0141] (2) Both the control network and the local area network use redundant networks to ensure the safe and stable operation of the control optimization system. The communication equipment and communication media of the control network and the local area network are designed as A and B dual redundancy, which run synchronously and are mutually redundant. If a single network fails, it will not affect the operation of the control optimization system. When any network fails, there will be an alarm prompting the maintenance personnel to handle the inspection and treatment in time to ensure the timely elimination of the fault. Therefore, the redundant network design of the control network and the local area network provides a strong guarantee for the safe and stable operation of the control optimization system.

Claims

1. An integrated modular group-controlled air compressor optimization system, It is characterized in that include: Control management equipment, main control equipment, field equipment, network A, network B and compressed air main pipe; The control management device is connected to the main control device through network A and network B respectively, the main control device is connected to the field device through network A and network B respectively, and the field device is connected to the compressed air main pipe; The control management device is located in the control room, issues control instructions to the main control device, collects historical operation records, and provides summary reports for managers; The main control device is located in the electronic room, receives the control instructions issued by the control management device, and transmits them to the field devices, so that the field devices operate according to the control instructions; The field device is located in the field area, receives the control instruction transmitted by the main control device, and transmits it to the air compressor to be optimized, so that the air compressor to be optimized operates according to the control instruction. If the factory to be optimized has several field areas, each field area includes a set of field devices; The compressed air main pipe collects all compressed air outputted by the optimized air compressors to the compressed air main pipe, and the compressed air main pipe provides compressed air to the gas users; Network A and Network B are communication networks, and switching between Network A and Network B is performed according to the backup network usage rules; The backup network usage rule is: when network A fails and communication is impossible, switch to network B, otherwise use network A for communication; The control and management equipment specifically includes: an engineer station, an operation station, and a printer; The main control device includes a main control cabinet; The field equipment specifically includes: at least one air compressor cabinet, at least one communication interface device, a remote cabinet, and field instruments; The field instrument is connected to the remote cabinet, the remote cabinet is connected to the communication interface device through the communication cable, and the communication interface device is connected to the air compressor cabinet through the communication cable; the remote cabinet is connected to the first switch through the network A, the remote cabinet is connected to the second switch through the network B, the first switch is connected to the main control cabinet through the network A, the second switch is connected to the main control cabinet through the network B, the first switch is connected to the engineer station, the operation station, and the printer through the network A, and the second switch is connected to the engineer station, the operation station, and the printer through the network B; the compressed air main pipe is connected to the air compressor cabinet; The field instrument is a device for detecting various parameters of the integrated modular group-controlled air compressor optimization system on site, and sending the detected parameter signals to the communication interface device; The air compressor cabinet contains an air compressor to be tested and an air compressor control module. The air compressor to be tested is connected to the air compressor control module. The air compressor control module is used to control the start and stop of the air compressor by adjusting parameters. The communication interface device reads various parameters of the air compressor to be tested from the field instrument, reads the control signal of the air compressor to be tested from the remote cabinet, and transmits the control signal to the air compressor to be tested in the air compressor cabinet; The communication interface device is connected to the communication interface configured on the air compressor in the air compressor cabinet, and communicates via Modus communication. Each air compressor is configured with one communication interface device. If there are N air compressors on site, N communication interface devices are configured accordingly. The remote cabinet acts as a signal relay between the field instrument and the control cabinet, reading various parameter signals of the field instrument, reading various parameter signals of the air compressor through the communication interface device, and sending all the read signals to the main control cabinet; The remote cabinet includes: an I / O module, a communication module, a power module and a remote cabinet cabinet; Power module: connected to the I / O module and communication module respectively to provide power for the I / O module and communication module; I / O module: realizes bidirectional conversion between digital and analog signals. According to the needs, it is set to convert analog signals into digital signals, digital signals into analog signals, switch signals into digital signals, or digital signals into switch signals. Specifically, it is set as needed: convert analog signals transmitted from communication interface equipment into digital signals; convert analog signals transmitted from field instruments into digital signals; convert switch signals transmitted from field instruments into digital signals; or according to the needs, it is set to convert digital signals transmitted from communication interface equipment into analog signals; convert digital signals transmitted from field instruments into analog signals; convert digital signals transmitted from field instruments into switch signals; Communication module: connected to the communication interface device to realize the communication between the remote cabinet and the communication interface device; Remote cabinet cabinet: The outer shell of the remote cabinet protects the internal components; Network A: The first switch is the communication network between the remote cabinet, the main control cabinet, the engineer station, the operation room, and the printer. It switches between network A and network B according to the backup network usage rules. Network B: The communication network between the second switch and the remote cabinet, main control cabinet, engineer station, operation room, and printer is a backup network. It switches between network A and network B according to the backup network usage rules; Main control cabinet: All signals transmitted in real time from the remote cabinet are calculated by the air compressor optimization software in the main control cabinet controller to obtain the air compressor control signal, and then the control signal is transmitted to the remote cabinet; The main control cabinet includes: a main control cabinet power module, a controller, a main control cabinet communication module, a first switch, a second switch, and a main control cabinet cabinet; The main control cabinet power supply module is respectively connected to the controller, the main control cabinet communication module, the first switch and the second switch to provide power for the controller, the main control cabinet communication module, the first switch and the second switch; The controller stores the air compressor control software, calculates all the signals transmitted from the remote cabinet in real time, obtains the air compressor control signal, and transmits the air compressor control signal to the remote cabinet; The main control cabinet communication module completes the communication between the main control cabinet and the remote cabinet; Main control cabinet cabinet, the outer shell of the main control cabinet, plays the role of protecting the internal components; The first switch is used to connect the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer to form a star topology network structure; the first switch is an intermediate medium for data transmission and exchange between the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer; The second switch is used to connect the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer to form a star topology network structure; the second switch is the intermediate medium for data transmission and exchange between the remote cabinet, the main control cabinet, the engineer station, the operation station, and the printer; The engineer station is equipped with the first industrial computer, the first display, the first mouse and the first keyboard, and the air compressor control software is downloaded to the main control cabinet controller; the air compressor control signals are organized into an air compressor control database in chronological order, and the database historical data, data trends, and alarm information reports are obtained; the air compressor operation status monitoring screen is obtained through the display; The operation station includes a second industrial computer, a second display, a second mouse and a second keyboard; the second industrial computer sends the air compressor control signal and obtains the air compressor operation status monitoring screen through the display; Printer, print database historical data, data trends, alarm information reports; The equipment for measuring various parameters of the integrated modular group-controlled air compressor optimization system specifically includes: pressure measuring equipment, temperature measuring equipment, flow measuring equipment, air compressor current signal measuring equipment, and air compressor voltage signal measuring equipment; wherein the pressure measuring equipment measures the pressure value in the compressed air main pipe; the temperature measuring equipment measures the temperature value in the compressed air main pipe; the flow measuring equipment measures the flow value in the compressed air main pipe; the air compressor current signal measuring equipment measures the current value of each air compressor; the air compressor voltage signal measuring equipment measures the voltage value of each air compressor; The measurement signals of field instruments are all 4-20mA. The measurement signals are connected to the I / O modules in the remote cabinet through cables. The I / O modules convert the measurement signals into digital signals. The various parameters of the air compressor to be tested are read, including: the running state of each air compressor, the stopping state of each air compressor, the loading state of each air compressor, the unloading state of each air compressor, the current of each air compressor, the outlet pressure of each air compressor, and the temperature alarm of each air compressor; The control signal of the air compressor to be tested includes: a start control signal of the air compressor, a stop control signal of the air compressor, a loading control signal of the air compressor, and an unloading control signal of the air compressor.

2. According to the integrated modular group-controlled air compressor optimization system of claim 1, It is characterized in that The communication medium between network A and network B is RJ45 network cable.

3. According to the integrated modular group-controlled air compressor optimization system of claim 1, It is characterized in that If the air compressor factory to be optimized has an original monitoring system, recorded as a SIS system, the first switch is connected to the monitoring system through network A, and the second switch is connected to the monitoring system through network B. This monitoring system can only monitor and cannot perform any operations on other hardware and software.

Images