Remote control system and method for air compressor of pressure impregnation device

Abstract

The application discloses a kind of pressure impregnation paint device's air compressor remote control system, including control unit, multiple air compressors, multiple pressurizing switches, starting switch and stop switch, each pressurizing switch is one-to-one corresponding with each impregnation tank and is one-to-one corresponding connection with the input end of control unit, and the input end of the starting switch and stop switch is connected with control unit;The starting control end and the stop end of each air compressor are one-to-one corresponding connection with the output end of control unit;Any pressurizing switch is connected after input control unit corresponding input end low voltage, triggers the output end of control unit to output starting signal to control corresponding air compressor start;Each air compressor is automatically cyclically alternately operated.The application has the advantages of simple structure, simple control process, high reliability and the like.

Description

Technical Field

[0001] This invention mainly relates to the field of motor coil impregnation technology, specifically to a remote control system and method for an air compressor of a pressure impregnation device. Background Technology

[0002] The insulation treatment of motor coils largely employs pressure impregnation, with the pressurized gas for the impregnation device sourced from an air compressor. The air compressor is turned on during impregnation pressurization, quickly reaches the required pressure, and then shuts off. Multiple impregnation units are matched with two air compressors, necessitating frequent manual switching of the compressors from a distant machine room. This solution presents two significant problems: 1) Forgetting to turn the blower on or off. Forgetting to turn it on results in low air pressure and slow pressurization, leading to low impregnation efficiency. Forgetting to turn it off wastes a significant amount of electrical energy. 2) Uneven usage between the two air compressors leads to one being overused while the other is underutilized, hindering equipment maintenance and upkeep.

[0003] Another conventional air compressor remote control technology is similar to the utility model patent "An Air Compressor Remote Control Device," specifically including a host computer and a PLC control system. The host computer and the PLC control system are communicatively connected. The digital output module of the PLC control system outputs signals to an intermediate relay. The normally open contact of the intermediate relay is connected in series in the air compressor start / stop circuit. The host computer uses WICC monitoring software to send instructions to the PLC control system. The signal output by the digital input / output module SM323 controls the intermediate relay, causing the intermediate relay coil KA to close. Its normally open contact connects the start / stop control terminals (35, 36) of the air compressor, sending a pulse signal to the air compressor start control circuit. By connecting or disconnecting terminals 35 and 36, the remote start / stop control process of the air compressor is realized, ensuring that the air compressor operates under a reliable constant pressure state. The remote start / stop of the air compressor is achieved through digital control.

[0004] The aforementioned utility model patent only relates to a simple single circuit connection principle, and does not solve the following problems:

[0005] 1) Multiple or one impregnation unit automatically remotely controls one or more air compressors.

[0006] 2) The paint impregnation control room can manually and remotely control one or more air compressors.

[0007] 3) The air compressor automatically switches and is used in a cycle.

[0008] 4) PLC technology solves the above three combined problems.

[0009] 5) The relay controlling the air compressor is integrated with the PLC. Summary of the Invention

[0010] The technical problem to be solved by this invention is: in view of the problems existing in the prior art, this invention provides a remote control system and method for an air compressor of a pressure impregnation device that is simple in structure, simple in control process, and highly reliable.

[0011] To solve the above-mentioned technical problems, the technical solution proposed by this invention is as follows:

[0012] A remote control system for an air compressor in a pressure impregnation device includes a control unit, multiple air compressors, multiple pressurization switches, a start switch, and a stop switch. Each pressurization switch corresponds one-to-one with each impregnation tank and is connected to an input terminal of the control unit. The start and stop switches are both connected to the input terminals of the control unit. The start and stop terminals of each air compressor are connected one-to-one with the output terminals of the control unit. When any pressurization switch is turned on, a low voltage is input to the corresponding input terminal of the control unit, triggering the control unit to output a start signal to control the corresponding air compressor to start. The air compressors automatically cycle and alternate between each other.

[0013] As a further improvement to the above technical solution:

[0014] The control unit is a PLC.

[0015] The number of air compressors is two, namely air compressor #1 and air compressor #2; the input terminals X1, X2, and X3 of the PLC are connected to the pressurization valves of the control rooms of impregnation tanks #1, #2, and #3, respectively; the output Y0 of the PLC is connected to the start control terminal of air compressor #1, the output Y1 of the PLC is connected to the stop control terminal of air compressor #1, the output Y2 of the PLC is connected to the start control terminal of air compressor #2, and the output Y3 of the PLC is connected to the stop control terminal of air compressor #2; the X4 and X5 terminals of the PLC are connected to the start switch and stop switch of the air compressor, respectively.

[0016] This invention also discloses a control method for a remote control system of an air compressor based on the pressure impregnation device described above, including an automatic remote control start-up method, specifically: when any of the pressurization valves of tanks #1, #2, and #3 is turned on, a low level is input to any of the corresponding X1, X2, and X3 terminals, triggering the PLC, and the Y0 terminal outputs an on signal to air compressor #1, thus starting air compressor #1; if the system has been switched to air compressor #2, a low level is input to any of X1, X2, and X3 terminals, triggering the PLC, and the Y2 terminal outputs an on signal to air compressor #2, thus starting air compressor #2.

[0017] As a further improvement to the above technical solution:

[0018] The automatic remote control shutdown method is as follows: When all impregnation tanks have been pressurized and entered the pressure holding phase, the pressurization valve in the control room closes. The output signal of the last pressurization valve in tanks #1, #2, and #3 that has been closed becomes low level, and the corresponding X1, X2, and X3 terminals input low level. The Y1 terminal of the PLC outputs a stop signal to the running air compressor #1, shutting down air compressor #1. If air compressor #2 has been switched to operation, a low level input at any of the X1, X2, and X3 terminals triggers the PLC, and Y3 outputs a 1-second stop signal to air compressor #2, shutting down air compressor #2.

[0019] The method includes manual remote start and stop of the air compressor, specifically: when the air compressor start switch is turned on, the corresponding X4 terminal inputs a low level, triggering the PLC's Y0 terminal to output a start signal to air compressor #1, thus starting air compressor #1; when the air compressor stop switch is turned on, the corresponding X5 terminal inputs a low level, triggering the PLC's Y1 terminal to output a stop signal to air compressor #1, thus stopping air compressor #1; if air compressor #2 has been switched to operation, the Y2 and Y3 terminals output signals to air compressor #2, remotely starting or stopping air compressor #2.

[0020] It also includes an air compressor interaction method, specifically: the automatic switching time between air compressor #1 and air compressor #2 is set to 0 when the PLC is powered on. By default, the Y0 terminal outputs an on signal first, and air compressor #1 starts running. When the predetermined time is reached, the Y1 terminal outputs a stop signal, and air compressor #1 stops running. The Y2 terminal outputs an on signal, and air compressor #2 starts running. When the predetermined time is reached, the Y3 terminal outputs a stop signal, and air compressor #2 stops running. This cycle continues, with air compressors #1 and #2 running alternately.

[0021] The scheduled time is 20 to 30 hours.

[0022] Compared with the prior art, the advantages of the present invention are as follows:

[0023] The invention features a simple circuit structure, a simple control process, and high reliability. It enables automatic control of the air compressor's start and stop according to the pressure and holding requirements of the impregnation process, improving the efficiency of automated impregnation production and avoiding waste of equipment, energy, and products caused by human error. It also allows for manual remote control of the air compressor's start and stop from the impregnation control room, facilitating operation. Furthermore, it enables automatic switching between two air compressors based on their operating time, allowing for cyclical use and avoiding equipment wear caused by uneven usage, thus reducing maintenance costs. Attached Figure Description

[0024] Figure 1 A control block diagram of an air compressor in the prior art.

[0025] Figure 2 This is a schematic diagram of the process control of the control system of the present invention in an embodiment.

[0026] Figure 3 This is a wiring diagram of the control system of the present invention in an embodiment. Detailed Implementation

[0027] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0028] like Figure 2 and Figure 3 As shown, the remote control system for the air compressor of the pressure impregnation device in this embodiment includes a control unit (such as a PLC), multiple air compressors, multiple pressurization switches, start switches, and stop switches. Each pressurization switch corresponds one-to-one with each impregnation tank and is connected to the input terminal of the control unit. The start and stop switches are both connected to the input terminal of the control unit. The start control terminal and stop terminal of each air compressor are connected one-to-one with the output terminal of the control unit. When any pressurization switch is turned on, a low voltage is input to the corresponding input terminal of the control unit, triggering the output terminal of the control unit to output a start signal to control the corresponding air compressor to start. The air compressors automatically cycle and alternate.

[0029] In one specific embodiment, such as Figure 3 As shown, there are two air compressors, namely air compressor #1 and air compressor #2. The input terminals X1, X2, and X3 of the PLC are connected to the pressurization valves of the control rooms of impregnation tanks #1, #2, and #3, respectively. The output Y0 of the PLC is connected to the start control terminal of air compressor #1, the output Y1 is connected to the stop control terminal of air compressor #1, the output Y2 is connected to the start control terminal of air compressor #2, and the output Y3 is connected to the stop control terminal of air compressor #2. The X4 and X5 terminals of the PLC are connected to the start switch and stop switch of the air compressor, respectively.

[0030] This invention also discloses a control method for a remote control system of an air compressor based on the pressure impregnation device described above, including: an automatic remote control start-up method for the air compressor, such as... Figure 1 As shown, when any one of the impregnation tanks (#1, #2, and #3) requires pressurization, or both simultaneously, the impregnation unit automatically and remotely starts air compressor #1 or air compressor #2. Specifically, when any pressurization valve of tanks #1, #2, or #3 is closed, a low-level input is sent to any of the corresponding X1, X2, or X3 terminals, triggering the PLC. The Y0 terminal then outputs a 1-second connection signal to air compressor #1, starting it. If the system has switched to air compressor #2, a low-level input is sent to any of the X1, X2, or X3 terminals, triggering the PLC. The Y2 terminal then outputs a 1-second connection signal to air compressor #2, starting it.

[0031] In one specific embodiment, an automatic remote control shutdown method for the air compressor is also included, such as... Figure 1As shown, once all impregnation tanks (tanks #1, #2, and #3) have been pressurized and entered the pressure holding stage, the impregnation unit automatically and remotely shuts down either air compressor #1 or air compressor #2. Specifically, when all impregnation tanks have been pressurized and entered the pressure holding stage, the pressurization valve in the control room closes. The output signal of the last pressurization valve in tanks #1, #2, and #3 that has been closed becomes low, corresponding to low-level inputs at terminals X1, X2, and X3. The PLC's Y1 terminal outputs a 1-second stop signal to the running air compressor #1, shutting it down. If the system has switched to air compressor #2, a low-level input at any of terminals X1, X2, or X3 triggers the PLC, and Y3 outputs a 1-second stop signal to air compressor #2, shutting it down.

[0032] In one specific embodiment, a method for manually and remotely starting and stopping the air compressor is also included, such as... Figure 1 As shown, when it is necessary to start air compressor #1 or #2 separately, they can be manually started remotely from the paint impregnation control room; similarly, when it is necessary to shut down air compressor #1 or #2 separately, they can be manually shut down remotely from the paint impregnation control room, enabling the operation of starting or stopping air compressors locally. Specifically, when the air compressor start switch is turned on, the corresponding X4 terminal inputs a low level, triggering the PLC's Y terminal 0 to output a 1-second start signal to air compressor #1, starting it. When the air compressor stop switch is turned on, the corresponding X5 terminal inputs a low level, triggering the PLC's Y1 terminal to output a 1-second stop signal to air compressor #1, shutting it down. If air compressor #2 has already been switched to operation, the Y2 and Y3 terminals output signals to air compressor #2, remotely starting or stopping it.

[0033] In one specific embodiment, an interactive control method for air compressors is also included. Air compressor #1 automatically stops operating after 24 hours, while air compressor #2 automatically starts. The two air compressors operate in a cycle to achieve balanced usage. Specifically, the automatic switching time between air compressor #1 and air compressor #2 is set to 0 when the PLC is powered on. By default, the Y0 terminal outputs an on signal first, and air compressor #1 starts running. After 24 hours, the Y1 terminal outputs a stop signal, and air compressor #1 stops. The Y2 terminal outputs an on signal, and air compressor #2 starts running. After 24 hours, the Y3 terminal outputs a stop signal, and air compressor #2 stops. This cycle continues, with air compressors #1 and #2 operating alternately.

[0034] In one specific embodiment, the pressure valves of multiple impregnation devices are connected to multiple input terminals of a PLC, with one pressure valve corresponding to one PLC input terminal; the start and stop terminals of multiple air compressors are connected to multiple PLC output terminals, such as... Figure 2As shown, the system is connected in a manner where one output terminal corresponds to the start of one air compressor and one output terminal corresponds to the stop of one air compressor. When any pressurizing valve terminal is turned on, a low-level input triggers the PLC output terminal to output a start signal, starting the air compressor. When the last pressurizing valve terminal is closed, a low-level input triggers the corresponding PLC output terminal to output a stop signal, shutting down the air compressor. The manual start and stop terminals of the impregnation control room are connected to the two input terminals of the PLC respectively. When the start terminal is manually turned on, a low-level input triggers the PLC output terminal to output a start signal, starting the air compressor. When the stop terminal is manually turned on, a low-level input triggers the PLC output terminal to output a stop signal, stopping the air compressor. The PLC is programmed to time and control the running time of multiple air compressors.

[0035] The invention features a simple circuit structure, a simple control process, and high reliability. It enables automatic control of the air compressor's start and stop according to the pressure and holding requirements of the impregnation process, improving the efficiency of automated impregnation production and avoiding waste of equipment, energy, and products caused by human error. It also allows for manual remote control of the air compressor's start and stop from the impregnation control room, facilitating operation. Furthermore, it enables automatic switching between two air compressors based on their operating time, allowing for cyclical use and avoiding equipment wear caused by uneven usage, thus reducing maintenance costs.

[0036] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should be considered within the scope of protection of the present invention.

Claims

1. A remote control system for an air compressor of a pressure impregnation device, characterized in that, It comprises a control unit, a plurality of air compressors, a plurality of pressurizing switches, a starting switch and a stopping switch, each of the pressurizing switches corresponds to each of the paint immersion tanks and is connected to the input end of the control unit one by one, and the starting switch and the stopping switch are connected to the input end of the control unit; the starting control end and the stopping end of each of the air compressors are connected to the output end of the control unit one by one; after any pressurizing switch is turned on, low voltage is input to the corresponding input end of the control unit, the output end of the control unit outputs a starting signal to control the corresponding air compressor to start; the air compressors automatically and cyclically alternate operation; The control unit is a PLC; The number of the air compressors is two, which are 1# air compressor and 2# air compressor; wherein the input X1, X2 and X3 of the PLC are connected to the pressurizing valves of the control rooms of 1#, 2# and 3# paint immersion tanks respectively; the output Y0 of the PLC is connected to the starting control end of the 1# air compressor, the output Y1 of the PLC is connected to the stopping control end of the 1# air compressor, the output Y2 of the PLC is connected to the starting control end of the 2# air compressor, and the output Y3 of the PLC is connected to the stopping control end of the 2# air compressor; the X4 and X5 of the PLC are connected to the starting switch and the stopping switch of the air compressor respectively.

2. A control method of a remote control system of an air compressor of a pressure impregnation device according to claim 1, characterized in that, It comprises an automatic remote control starting method, specifically: when any of the pressurizing valves of 1#, 2# and 3# tanks is turned on, low level is input to any of the X1, X2 and X3, the PLC is triggered, the Y0 end outputs a communication signal to the 1# air compressor, and the 1# air compressor starts; if the 2# air compressor has been switched to run, low level is input to any of the X1, X2 and X3, the PLC is triggered, the Y2 end outputs a communication signal to the 2# air compressor, and the 2# air compressor starts. It comprises an automatic remote control closing method, specifically: when all the paint immersion tanks are pressurized and enter the pressure maintaining, the pressurizing valves of the control rooms are closed, the output signal of the last closed pressurizing valve of 1#, 2# and 3# tanks becomes low level, low level is input to the X1, X2 and X3, the Y1 end of the PLC outputs a stopping signal to the running 1# air compressor, and the 1# air compressor is closed; if the 2# air compressor has been switched to run, low level is input to any of the X1, X2 and X3, the PLC is triggered, the Y3 outputs a stopping signal to the 2# air compressor for 1 second, and the 2# air compressor is closed.

3. The control method according to claim 2, characterized by, It comprises a manual remote starting and closing method of the air compressor, specifically: the starting switch of the air compressor is turned on, low level is input to the corresponding X4, the Y0 end of the PLC outputs a communication signal to the 1# air compressor, and the 1# air compressor starts; the stopping switch of the air compressor is turned on, low level is input to the corresponding X5, the Y1 end of the PLC outputs a stopping signal to the 1# air compressor, and the 1# air compressor is closed; if the 2# air compressor has been switched to run, the Y2 and Y3 ends output signals to the 2# air compressor, and the 2# air compressor is remotely started or closed.

4. The control method according to claim 3, characterized by Also include air compressor interaction method, specifically: 1# air compressor and 2# air compressor automatic switching time with PLC power on 0 point, the default situation is Y0 end first output communication signal, 1# air compressor first run, reach the predetermined time, Y1 end output stop signal, 1# air compressor stop; Y2 end output communication signal, 2# air compressor runs, reach the predetermined time, Y3 end output stop signal, 2# air compressor stop, in this way, 1#, 2# air compressor alternately run.

5. The control method according to claim 4, characterized by, The predetermined time is 20-30 hours.

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