A condensate monitoring and management system

Abstract

The present invention provides a condensate monitoring and management system for monitoring and managing the condensate in an air compression system; it includes a condensate monitoring manager and a terminal management platform; the condensate monitoring manager includes a Hall sensor flow valve and a PCB management module; the Hall sensor flow valve is installed at the condensate discharge port of the air compression system; the Hall sensor flow valve is connected to the PCB management module; the PCB management module is connected to the terminal management platform. The condensate monitoring and management system of the present invention is applicable to general compressed air systems with condensate discharge, can detect the condensate discharge situation in real time, can quickly and effectively discover and troubleshoot problems in the condensate discharge process, reduce the energy loss of the compressed air system, and prevent the damage of the compressed air system caused by untimely condensate discharge.

Description

Technical Field

[0001] The present invention relates to the technical field of compressed air systems, and particularly to a condensate monitoring and management system in a compressed air system. Background Art

[0002] A compressed air system generally includes an air compressor, a gas storage tank, and a dryer; the air compressor compresses air and stores it in the gas storage tank, and a common air compressor is a screw compressor; the dryer dries the compressed air in the gas storage tank and supplies it to the gas-using port, and a common dryer is a refrigerated dryer.

[0003] There are a large number of condensate discharge ports in the compressed air system, such as condensate discharge ports are provided on both the gas storage tank and the refrigerated dryer. It is found in the actual use process that these condensate discharge ports lack a monitoring and management system, causing a lot of inconvenience; for example: (1) It is impossible to timely detect a blocked condensate discharge port and manual inspection is required; (2) If not discharged for a long time, liquid water escapes into the gas storage tank, causing pipeline water hammer and high water content at the end; it will accelerate the corrosion or bursting of the refrigerated dryer, and the water hammer causes irreversible early wear of the air compressor; (3) It is impossible to timely detect which condensate discharge port is leaking during long-term discharge, or the manual discharge is not tightly closed, resulting in a large amount of energy waste; (4) The condensate discharge cannot be digitalized and there is no data for management. Summary of the Invention

[0004] The purpose of the present invention is to provide a condensate monitoring and management system to solve the above technical problems.

[0005] To achieve the above purpose, a condensate monitoring and management system of the present invention is used for the condensate monitoring and management of an air compression system; it includes a condensate monitoring manager and a terminal management platform;

[0006] The condensate monitoring manager includes a Hall sensor flow valve and a PCB management module; the Hall sensor flow valve is installed on the condensate discharge port of the air compression system; the Hall sensor flow valve is connected to the PCB management module; the PCB management module is connected to the terminal management platform;

[0007] The Hall sensor flow valve is used to detect the discharge of condensate; and outputs a signal using the Hall effect;

[0008] The PCB management module receives the output signal of the Hall sensor flow valve, judges the drainage state of the condensate according to the output signal, receiving the output signal indicates that the condensate is discharged normally; not receiving the output signal indicates that the condensate is not discharged;

[0009] The single condensate discharge amount, discharge total time, cumulative discharge total times, and cumulative discharge total time are recorded in real time;

[0010] Set the time threshold for continuously receiving the output signal, that is, the continuous emission time threshold, and issue a long-time emission alarm when the continuous emission time threshold is exceeded;

[0011] Set the time threshold for the interval between two discontinuous receptions of the output signal, that is, the interval time threshold between two emissions, and issue a long-time non-emission alarm when the interval time threshold between two emissions is exceeded;

[0012] The terminal management platform visually displays the total cumulative emission times and total cumulative emission time detected by the PCB management module, as well as the long-time emission alarm and long-time non-emission alarm status.

[0013] Further, the Hall sensor flow valve includes a valve body; a liquid inlet interface and a liquid outlet interface are provided on the valve body; the liquid inlet interface is connected to the condensate discharge port of the air compression system; an impeller is installed inside the valve body; a permanent magnet is installed on the central shaft of the impeller; an installation box connected to the valve body is provided at the top of the permanent magnet; a Hall sensor is provided inside the installation box;

[0014] Further, the PCB management module includes a housing; a core board is installed inside the housing; a single condensate emission amount recording and detection function module, a single condensate emission total time recording and detection function module, a total cumulative emission times recording and detection function module, a total cumulative emission time recording and detection function module, a long-time emission alarm module, and a long-time non-emission alarm module are provided on the core board;

[0015] Further, the housing is fixed on the Hall sensor flow valve through a connecting plate; the connecting plate is arranged at the upper end of the installation box; the connecting plate, the installation box, and the valve body are fixed by bolts;

[0016] Further, a normal state indicator light and an alarm state indicator light are provided on the housing; when working normally, the normal state indicator light is on; when a long-time emission alarm or a long-time non-emission alarm occurs, the alarm state indicator light is on;

[0017] Further, a display screen is installed on the housing; it is used to display the single condensate emission amount, the total emission time, the total cumulative emission times, and the total cumulative emission time.

[0018] Further, a setting button is provided on the housing, which is used to set the continuous emission time threshold and the interval time threshold between two emissions;

[0019] Further, a power connection socket is provided on the housing for connecting the power supply;

[0020] Further, the core board is connected to the MD communication module; MODBUS terminals are provided on the MD communication module to connect to the terminal management platform.

[0021] Preferably, the model of the core board is stm32F103R8C6.

[0022] Beneficial effects: The condensate monitoring and management system of the present invention is applicable to general compressed air systems with condensate discharge, can detect the condensate discharge situation in real time, quickly and effectively discover and troubleshoot problems during the condensate discharge process, reduce the energy loss of the compressed air system, and prevent the damage of the compressed air system caused by untimely condensate discharge. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is the logic block diagram of the condensate monitoring and management system of the present invention;

[0024] Figure 2 is the structural schematic diagram of the condensate monitoring manager of the present invention;

[0025] Figure 3 is the structural schematic diagram of the Hall sensor flow valve of the present invention; DETAILED DESCRIPTION OF THE EMBODIMENTS

[0026] To make the objectives, technical solutions and advantages of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention. Unless otherwise defined, the technical terms or scientific terms used herein shall have the ordinary meaning as understood by those of ordinary skill in the art in the field to which the present invention belongs. The words such as "including" used herein mean that the elements or objects appearing before the word cover the elements or objects listed after the word and their equivalents, without excluding other elements or objects.

[0027] In view of the problems existing in the prior art, the embodiments of the present invention provide a condensate monitoring and management system.

[0028] Embodiment

[0029] As Figures 1 to 3 shown, a condensate monitoring and management system for the condensate monitoring and management of an air compression system; includes a condensate monitoring manager and a terminal management platform;

[0030] The condensate monitoring manager includes a Hall sensor flow valve 1 and a PCB management module 2; the Hall sensor flow valve 1 is installed at the condensate discharge port of the air compression system; the Hall sensor flow valve 1 is connected to the PCB management module 2; the PCB management module 2 is connected to the terminal management platform;

[0031] The Hall sensor flow valve 1 is used to detect the discharge of condensate; and outputs a signal using the Hall effect;

[0032] The PCB management module 2 receives the output signal of the Hall sensor flow valve 1, determines the drainage state of the condensate based on the output signal. Receiving the output signal indicates normal drainage of the condensate; not receiving the output signal indicates that the condensate has not been drained.

[0033] Record in real time the single condensate discharge volume, the total discharge time, the total cumulative discharge times, and the total cumulative discharge time.

[0034] Set the time threshold for continuously receiving the output signal, that is, the continuous discharge time threshold. When the continuous discharge time threshold is exceeded, a long-time discharge alarm is issued.

[0035] Set the time threshold for the interval between two discontinuous receptions of the output signal, that is, the interval time threshold between two discharges. When the interval time threshold between two discharges is exceeded, a long-time non-discharge alarm is issued.

[0036] The terminal management platform visually displays the total cumulative discharge times, the total cumulative discharge time, the long-time discharge alarm, and the long-time non-discharge alarm status recorded and detected by the PCB management module 2.

[0037] The Hall sensor flow valve 1 includes a valve body 1-1; a liquid inlet interface and a liquid outlet interface are provided on the valve body 1-1; the liquid inlet interface is connected to the condensate discharge port of the air compression system; an impeller 1-2 is installed inside the valve body 1-1; a permanent magnet 1-3 is installed on the central axis of the impeller 1-2; an installation box 1-4 connected to the valve body 1-1 is provided at the top of the permanent magnet 1-3; a Hall sensor 1-5 is provided inside the installation box 1-4.

[0038] The PCB management module 2 includes a housing 2-1; a core board is installed inside the housing 2-1; the model of the core board is stm32F103R8C6; a single condensate discharge volume record detection function module, a single condensate discharge total time record detection function module, a total cumulative discharge times record detection function module, a total cumulative discharge time record detection function module, a long-time discharge alarm module, and a long-time non-discharge alarm module are provided on the core board.

[0039] The housing 2-1 is fixed on the Hall sensor flow valve 1 through a connecting plate 3; the connecting plate 3 is arranged at the upper end of the installation box 1-4; the connecting plate 3, the installation box 1-4, and the valve body 2-1 are fixed by bolts.

[0040] The housing 2-1 is provided with a normal state indicator light 2-2 and an alarm state indicator light 2-3; during normal operation, the normal state indicator light is on; when a long-time discharge alarm or a long-time non-discharge alarm occurs, the alarm state indicator light is on.

[0041] A display screen 2-4 is installed on the housing 2-1; it is used to display the single condensate discharge volume, the discharge total time, the total cumulative discharge times, and the total cumulative discharge time.

[0042] The housing 2-1 is provided with a setting button 2-5 for setting the continuous discharge time threshold and the time threshold between two discharges;

[0043] The housing 2-1 is provided with a power connection socket 2-6 for connecting the power supply;

[0044] The core board is connected to the MD communication module; the MD communication module is provided with a MODBUS terminal block 2-7 for connecting to the terminal management platform.

[0045] Although the embodiments of the present invention have been described in detail above, it is obvious to those skilled in the art that various modifications and changes can be made to these embodiments. However, it should be understood that such modifications and changes are all within the scope and spirit of the present invention described in the claims. Moreover, the present invention described herein can have other embodiments and can be implemented or realized in various ways.

Claims

1. A condensate monitoring and management system for monitoring and managing the condensate in an air compression system; Characterized in that, It includes a condensate monitoring manager and a terminal management platform; The condensate monitoring manager includes a Hall sensor flow valve and a PCB management module; The Hall sensor flow valve is installed at the condensate discharge port of the air compression system; The Hall sensor flow valve is connected to the PCB management module; The PCB management module is connected to the terminal management platform; The Hall sensor flow valve is used to detect the discharge of condensate; And output a signal using the Hall effect; The PCB management module receives the output signal of the Hall sensor flow valve, judges the drainage state of the condensate according to the output signal, and receiving the output signal indicates normal discharge of the condensate; Not receiving the output signal indicates that the condensate is not discharged; Record the single condensate discharge amount, discharge total time, cumulative discharge total times and cumulative discharge total time detected in real time; Set the continuous receiving output signal time threshold, that is, the continuous discharge time threshold, and issue a long-time discharge alarm when the continuous discharge time threshold is exceeded; Set the interval time threshold for two non-consecutive receiving output signals, that is, the interval time threshold for two discharges, and issue a long-time non-discharge alarm when the interval time threshold for two discharges is exceeded; The terminal management platform visually displays the cumulative discharge total times, cumulative discharge total time, long-time discharge alarm and long-time non-discharge alarm status recorded and detected by the PCB management module; The Hall sensor flow valve includes a valve body; The valve body is provided with a liquid inlet interface and a liquid outlet interface; The liquid inlet interface is connected to the condensate discharge port of the air compression system; An impeller is installed in the valve body; A permanent magnet is installed on the central axis of the impeller; An installation box connected to the valve body is provided at the top of the permanent magnet; A Hall sensor is provided in the installation box; The PCB management module includes a housing; A core board is installed in the housing; The core board is provided with a single condensate discharge amount record detection function module, a single condensate discharge total time record detection function module, a cumulative discharge total times record detection function module, a cumulative discharge total time record detection function module, a long-time discharge alarm module and a long-time non-discharge alarm module.

2. A condensate monitoring and management system according to claim 1, wherein the housing is fixed on the Hall sensor flow valve through a connecting plate; The connecting plate is arranged at the upper end of the installation box; The connecting plate, the installation box and the valve body are fixed by bolts.

3. A condensate monitoring and management system according to claim 2, wherein the housing is provided with a normal state indicator light and an alarm state indicator light; When working normally, the normal state indicator light is on; When there is a long-time discharge alarm or a long-time non-discharge alarm, the alarm state indicator light is on.

4. A condensate monitoring and management system according to claim 3, wherein a display screen is installed on the housing; It is used to display the single condensate discharge amount, discharge total time, cumulative discharge total times and cumulative discharge total time.

5. A condensate monitoring and management system according to claim 4, wherein the housing is provided with a setting button for setting the continuous discharge time threshold and the interval time threshold for two discharges.

6. A condensate monitoring and management system according to claim 5, wherein the housing is provided with a power connection socket for connecting the power supply.

7. A condensate monitoring and management system according to claim 6, wherein the core board is connected to the MD communication module; the MD communication module is provided with a MODBUS terminal block for connecting to the terminal management platform.

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