A supercharged compressor closed experiment system and a full working condition control method thereof

Abstract

The application discloses a supercharged compressor closed experiment system and a full working condition control method thereof, which comprises a gas inlet separator, a measured supercharged compressor device, a gas outlet cooler, a gas outlet separator and a pipeline sequentially connected in sequence, wherein test sensors are installed in the measured supercharged compressor device, a gas inlet pressure gauge is installed on the gas inlet separator, a gas outlet pressure gauge is installed on the gas outlet separator, and a gas flow meter is installed between the outlet of the gas outlet cooler and the inlet of the gas outlet separator; the gas inlet separator is connected with a gas source in communication through a gas inlet pipeline, and a gas supplement regulating valve and a gas supplement stop valve are installed on the gas inlet pipeline; and the gas outlet separator is connected with a gas outlet muffler in communication through a gas outlet pipeline. The full working condition control method can realize accurate control of different gas inlet pressures, gas outlet pressures or flow rates, variable working condition regulation, regulation, stability and testing in a full working condition range, and improves the testing range of supercharged compressor performance experiment and reliability experiment and the reliability of testing conclusions.

Description

Technical Field

[0001] This invention relates to the field of compressor testing technology, and in particular to a closed-loop system and a full-condition control method for experimental testing of booster compressors. Background Technology

[0002] Compressors are core equipment in industries such as power, chemical, refrigeration, and energy storage, and their efficient and reliable operation is crucial for production. Compressor testing systems are devices used to experimentally test and study the performance, regulation, and reliability of various compressors. Various compressor testing systems have been developed in the industry for performance evaluation, control optimization, and new product development. However, most of these systems operate at atmospheric pressure or test under very narrow operating conditions, with the high-pressure air directly discharged into the atmosphere after the experiment, resulting in a waste of pressure energy. In particular, for the most widely used industrial compressors, their inlet pressure is generally higher than atmospheric pressure, and in most applications, their inlet and outlet pressures fluctuate significantly. For testing such compressors, existing testing systems require a large additional air source device to provide the necessary inlet pressure and gas flow, increasing the investment in the experimental system. Furthermore, the air source must remain continuously running during the test to maintain the required operating conditions and gas volume, inevitably leading to significant energy waste. Even so, existing testing systems struggle to fully cover the entire operating range of the compressor under test, relying only on extrapolation from partial experimental results and theoretical formulas. The conclusions obtained from these tests, especially reliability experiments, are highly unreliable. Summary of the Invention

[0003] To address the shortcomings of the existing technologies, the present invention aims to provide a closed-loop experimental system for booster compressors and its full-condition control method, in order to meet the testing requirements of booster compressors for non-pressure intake and large-scale variations in operating conditions, thereby improving the testing range and reliability of test conclusions for performance and reliability experiments of this type of compressor.

[0004] To address the aforementioned technical problems, this invention provides a closed-loop experimental system for a booster compressor, comprising an intake separator 1, a booster compressor device under test 2, an exhaust cooler 3, and an exhaust separator 4 connected sequentially via pipelines. A test sensor is installed inside the booster compressor device under test 2. An intake pressure gauge 5 is installed in the intake separator 1, and an exhaust pressure gauge 6 is installed in the exhaust separator 4. A gas flow meter 7 is installed between the outlet of the exhaust cooler 3 and the inlet of the exhaust separator 4. The intake separator 1 is connected to a gas source 9 via an intake pipe 8, and a supplementary gas regulating valve 1 is installed on it. 0 and the air supply shut-off valve 11; the exhaust separator 4 is connected to the exhaust muffler 13 through the exhaust pipe 12, and an exhaust regulating valve 14 and an exhaust shut-off valve 15 are installed on it; a first bypass branch pipe 16 is provided between the intake pipe 8 and the exhaust pipe 12, and a start-up unloading valve 17 is installed on it; a second bypass branch pipe 18 is also provided between the intake pipe 8 and the exhaust pipe 12, and a circulation regulating valve 19 is installed on it; all the above valves and sensors are connected to a measurement and control system 21 through the measurement and control cable 20. The measurement and control system 21 reads the data of each sensor and controls each valve.

[0005] As a preferred embodiment, the first bypass branch pipe 16 and the second bypass branch pipe 18 are arranged in order from near to far from the intake separator 1 and the exhaust separator 4.

[0006] As a preferred embodiment, the gas supply shut-off valve 11 is positioned close to the gas source 9.

[0007] As a preferred embodiment, the exhaust shut-off valve 15 is located near the exhaust muffler 13.

[0008] Another technical solution is a full-condition control method for a closed-loop experimental system of a booster compressor, comprising the following steps: 1) During the inflation stage, close the exhaust shut-off valve 15 and the exhaust regulating valve 14, open the start-up unloading valve 17, the circulation regulating valve 19 and the replenishment shut-off valve 11, open the replenishment regulating valve 10 to a suitable opening degree, and inflate the compressed gas in the gas source to the booster compressor closed experimental system through the intake pipe 8. When the reading of the intake pressure gauge 5 reaches the preset inflation pressure, close the replenishment regulating valve 10 and the replenishment shut-off valve 11. 2) Start the compressor. After the readings of the inlet pressure gauge 5 and the outlet pressure gauge 6 are balanced, start the tested booster compressor device 2 and keep the start unloading valve 17 and the circulation regulating valve 19 fully open. 3) During the stable operating phase, the intake pressure and exhaust pressure are stabilized at the predetermined experimental values ​​through the coordinated control of the circulation regulating valve 19, the replenishment regulating valve 10 and the exhaust regulating valve 14. 4) During the test data acquisition phase, after the pressure is stabilized, test data is acquired. At the same time, air replenishment is performed through the air replenishment regulating valve 10 to compensate for the pressure drop caused by leakage at various points of the tested booster compressor device 2. 5) Variable operating condition test phase: Repeat steps 3 and 4, setting different intake or exhaust pressures to achieve adjustment, stabilization and testing under different operating conditions; 6) Shutdown phase: Close all valves in the intake pipe 8, shut down the tested booster compressor device 2 according to the compressor shutdown procedure, and after shutdown, open the exhaust shut-off valve 15 and open the exhaust regulating valve 14 to a suitable opening degree to release the pressure of the closed test system of the booster compressor.

[0009] As a preferred embodiment, the method for achieving stable operating conditions in step 3 includes at least the following steps: (3a) Valve switching: Open the gas supply shut-off valve 11 and the exhaust shut-off valve 15, and close the start-up unloading valve 17; (3b) Coarse flow adjustment: Read the gas flow meter 7 and coarsely adjust the circulation regulating valve 19 to a suitable opening so that the flow rate of the booster compressor device 2 is close to the experimental set flow rate; (3c) Stable intake pressure: Read the intake pressure gauge 5 and compare the deviation of the reading with the intake pressure experimental set value. If the reading is too low, perform the intake pressure replenishment operation through the intake pressure regulating valve 10. If the reading is too high, perform the exhaust pressure relief operation through the exhaust regulating valve 14. (3d) Stable exhaust pressure: Read the reading of exhaust pressure gauge 6 and compare the deviation of the reading with the experimental set value of exhaust pressure. If the reading is too low, perform air replenishment operation through air replenishment regulating valve 10. If the reading is too high, perform air release operation through exhaust regulating valve 14. The control algorithm is used to achieve precise adjustment of exhaust pressure. (3e) Flow fine adjustment: After the intake pressure and exhaust pressure stabilize, fine adjust the opening of the circulation regulating valve 19 to accurately control the experimental flow rate and achieve flow regulation; (3f) Repeat (3c) to (3e) until the difference between the intake pressure and exhaust pressure and the set value meets the requirements of the experimental procedure, then the operating condition can be considered to be stable.

[0010] As a preferred option, step (3b) uses a pure proportional control algorithm to achieve coarse adjustment of the flow rate.

[0011] As a preferred embodiment, step (3c) employs a negative feedback PI control algorithm to achieve precise adjustment of the intake pressure.

[0012] As a preferred embodiment, step (3d) employs a negative feedback PID or PI control algorithm to achieve precise regulation of the exhaust pressure.

[0013] As a preferred option, step (3e) uses a negative feedback PID or PI control algorithm to regulate the flow rate.

[0014] The technical advantages of this invention are as follows: This invention discloses a closed-loop test system for a booster compressor and its full-condition control method. The booster compressor device under test is constructed as a closed system, with gas circulating within the system. The gas source only needs to meet the inlet pressure of the booster compressor under test, and only needs to supply the amount of gas leaking from the booster compressor device during operation, thereby effectively reducing test energy consumption and lowering equipment investment. On the other hand, the full-condition control method of this invention can achieve precise control of different inlet pressures, exhaust pressures, or flow rates, as well as variable operating condition adjustment, realizing adjustment, stabilization, and testing across the entire operating range. This improves the testing range and reliability of test conclusions for booster compressor performance and reliability experiments. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the closed-loop experimental system for the booster compressor described in the technical solution of this invention.

[0016] Figure 2 This is a flowchart illustrating the overall operating condition control method of the closed-loop experimental system for booster compressors described in the present invention.

[0017] Figure 3 This is a flowchart of step (3) in the above-mentioned full-condition control method of the present invention.

[0018] In the diagram: 1-Intake separator, 2-Tested booster compressor unit, 3-Exhaust cooler, 4-Exhaust separator, 5-Intake pressure gauge, 6-Exhaust pressure gauge, 7-Gas flow meter, 8-Intake pipe, 9-Gas source, 10-Make-up air regulating valve, 11-Make-up air shut-off valve, 12-Exhaust pipe, 13-Exhaust muffler, 14-Exhaust regulating valve, 15-Exhaust shut-off valve, 16-First bypass branch pipe, 17-Start-up unloading valve, 18-Second bypass branch pipe, 19-Circulation regulating valve, 20-Control cable, 21-Control system. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0020] like Figure 1As shown, this invention discloses a closed-loop experimental system for a booster compressor, comprising an intake separator 1, a booster compressor device under test 2, an exhaust cooler 3, and an exhaust separator 4 connected sequentially via pipelines. A test sensor is installed inside the booster compressor device under test 2. An intake pressure gauge 5 is installed in the intake separator 1, and an exhaust pressure gauge 6 is installed in the exhaust separator 4. A gas flow meter 7 is installed between the outlet of the exhaust cooler 3 and the inlet of the exhaust separator 4. The intake separator 1 is connected to a gas source 9 via an intake pipe 8, and a gas replenishment regulating valve 10 and a gas replenishment valve are installed on it. The exhaust separator 4 is connected to the exhaust muffler 13 via the exhaust pipe 12, and an exhaust regulating valve 14 and an exhaust shut-off valve 15 are installed on it; a first bypass branch pipe 16 is provided between the intake pipe 8 and the exhaust pipe 12, on which a start-up unloading valve 17 is installed; a second bypass branch pipe 18 is also provided between the intake pipe 8 and the exhaust pipe 12, on which a circulation regulating valve 19 is installed; all the above valves and sensors are connected to a measurement and control system 21 via a measurement and control cable 20. The measurement and control system 21 reads the data from each sensor and controls each valve.

[0021] As a preferred embodiment, the first bypass branch pipe 16 and the second bypass branch pipe 18 are arranged in order from near to far from the intake separator 1 and the exhaust separator 4.

[0022] As a preferred embodiment, the gas supply shut-off valve 11 is positioned close to the gas source 9.

[0023] As a preferred embodiment, the exhaust shut-off valve 15 is located near the exhaust muffler 13.

[0024] like Figures 2-3 As shown, this invention discloses a full-condition control method for a closed-loop experimental system of a booster compressor, comprising the following steps: 1) During the inflation stage, close the exhaust shut-off valve 15 and the exhaust regulating valve 14, open the start-up unloading valve 17, the circulation regulating valve 19 and the replenishment shut-off valve 11, open the replenishment regulating valve 10 to a suitable opening degree, and inflate the compressed gas in the gas source to the booster compressor closed experimental system through the intake pipe 8. When the reading of the intake pressure gauge 5 reaches the preset inflation pressure, close the replenishment regulating valve 10 and the replenishment shut-off valve 11. 2) Start the compressor. After the readings of the inlet pressure gauge 5 and the outlet pressure gauge 6 are balanced, start the tested booster compressor device 2 and keep the start unloading valve 17 and the circulation regulating valve 19 fully open. 3) During the stable operating phase, the intake pressure and exhaust pressure are stabilized at the predetermined experimental values ​​through the coordinated control of the circulation regulating valve 19, the replenishment regulating valve 10 and the exhaust regulating valve 14. 4) During the test data acquisition phase, after the pressure is stabilized, test data is acquired. At the same time, air replenishment is performed through the air replenishment regulating valve 10 to compensate for the pressure drop caused by leakage at various points of the tested booster compressor device 2. 5) Variable operating condition test phase: Repeat steps 3-4, set different intake or exhaust pressures to achieve adjustment, stabilization and testing under different operating conditions; 6) Shutdown phase: Close all valves in the intake pipe 8, shut down the tested booster compressor device 2 according to the compressor shutdown procedure, and after shutdown, open the exhaust shut-off valve 15 and open the exhaust regulating valve 14 to a suitable opening degree to release the pressure of the closed test system of the booster compressor.

[0025] As a preferred embodiment, the method for achieving stable operating conditions in step 3 includes at least the following steps: 3a) Valve switching: Open the air supply shut-off valve 11 and the exhaust shut-off valve 15, and close the start-up unloading valve 17; 3b) Coarse flow adjustment: Read the gas flow meter 7 and coarsely adjust the circulation regulating valve 19 to a suitable opening degree so that the flow rate of the booster compressor device 2 is close to the experimental set flow rate; 3c) Stable intake pressure: Read the intake pressure gauge 5 and compare the deviation of the reading with the intake pressure experimental set value. If the reading is too low, perform an air replenishment operation through the air replenishment regulating valve 10. If the reading is too high, perform an air release operation through the exhaust regulating valve 14. 3d) Stable exhaust pressure: Read the reading of exhaust pressure gauge 6 and compare the deviation of the reading with the experimental set value of exhaust pressure. If the reading is too low, perform air replenishment operation through air replenishment regulating valve 10. If the reading is too high, perform air release operation through exhaust regulating valve 14. The control algorithm is used to achieve precise adjustment of exhaust pressure. 3e) Fine-tuning of flow rate: After the intake and exhaust pressures have stabilized, fine-tune the opening of the circulation regulating valve 19 to precisely control the experimental flow rate and achieve flow rate regulation; 3f) Repeat steps 3c to 3e until the difference between the intake pressure and exhaust pressure and the set value meets the requirements of the test procedure. The operating condition can then be considered stable.

[0026] As a preferred option, step 3b) uses a pure proportional control algorithm to achieve coarse adjustment of the flow rate.

[0027] As a preferred embodiment, step 3c) employs a negative feedback PI control algorithm to achieve precise adjustment of the intake pressure.

[0028] As a preferred embodiment, step 3d) employs a negative feedback PID or PI control algorithm to achieve precise adjustment of the exhaust pressure.

[0029] As a preferred option, step 3e) uses a negative feedback PID or PI control algorithm to regulate the flow rate.

[0030] The above-described embodiments are merely preferred embodiments provided to fully illustrate the present invention, and the scope of protection of the present invention is not limited thereto. Equivalent substitutions or modifications made by those skilled in the art based on the present invention are all within the scope of protection of the present invention. The scope of protection of the present invention is defined by the claims.

Claims

1. A closed test system of a booster compressor, comprising a suction separator (1), a booster compressor device (2) to be tested, an exhaust cooler (3), an exhaust separator (4) connected in series through pipes, characterized in that, Test sensors are installed inside the tested booster compressor unit (2). An intake pressure gauge (5) is installed in the intake separator (1), and an exhaust pressure gauge (6) is installed in the exhaust separator (4). A gas flow meter (7) is installed between the outlet of the exhaust cooler (3) and the inlet of the exhaust separator (4). The intake separator (1) is connected to the gas source (9) through the intake pipe (8), and a supplementary gas regulating valve (10) and a supplementary gas shut-off valve (11) are installed on it. The exhaust separator (4) is connected to the exhaust muffler (13) through the exhaust pipe (12), and an exhaust regulating valve (14) and an exhaust shut-off valve (15) are installed on it. A first bypass branch pipe (16) is provided between the intake pipe (8) and the exhaust pipe (12), and a start-up unloading valve (17) is installed on it. A second bypass branch pipe (18) is also provided between the intake pipe (8) and the exhaust pipe (12), and a circulation regulating valve (19) is installed on it. All valves and sensors are present. The system is connected to a control system (21) via a control cable (20). The control system (21) reads data from each sensor and controls each valve. The first bypass branch (16) and the second bypass branch (18) are set from near to far from the intake separator (1) and the exhaust separator (4). The gas supply shut-off valve (11) is set near the gas source (9), and the exhaust shut-off valve (15) is set near the exhaust muffler (13). During the charging stage, the exhaust shut-off valve (15) and the exhaust regulating valve (14) are closed, and the start-up unloading valve (17), the circulation regulating valve (19) and the gas supply shut-off valve (11) are opened. The gas supply regulating valve (10) is opened to a suitable degree, and the compressed gas in the gas source is charged to the closed experimental system of the booster compressor through the intake pipe (8). When the reading of the intake pressure gauge (5) reaches the preset charging pressure of the experiment, the gas supply regulating valve (10) and the gas supply shut-off valve (11) are closed.

2. The full-condition control method for the closed-loop experimental system of the booster compressor according to claim 1, characterized in that, Includes the following steps: 1) During the inflation stage, close the exhaust shut-off valve (15) and exhaust regulating valve (14), open the start-up unloading valve (17), circulation regulating valve (19) and replenishment shut-off valve (11), open the replenishment regulating valve (10) to a suitable opening degree, and pressurize the compressed gas in the gas source to the booster compressor closed experimental system through the intake pipe (8). When the reading of the intake pressure gauge (5) reaches the experimental preset inflation pressure, close the replenishment regulating valve (10) and replenishment shut-off valve (11). 2) Start the compressor. After the readings of the inlet pressure gauge (5) and the outlet pressure gauge (6) are balanced, start the tested booster compressor device (2) and keep the start unloading valve (17) and the circulation regulating valve (19) fully open. 3) During the stable operating phase, the intake pressure and exhaust pressure are stabilized at the predetermined experimental values ​​through the coordinated control of the circulation regulating valve (19), the replenishment regulating valve (10) and the exhaust regulating valve (14). 4) During the test data acquisition phase, after achieving pressure stabilization, test data is acquired. At the same time, gas replenishment is performed through the gas replenishment regulating valve (10) to compensate for the pressure drop caused by leakage at various points of the tested booster compressor device (2). 5) Variable operating condition test stage: Repeat steps (3) and (4), set different intake pressure or exhaust pressure to achieve adjustment, stabilization and testing of different operating conditions; 6) Shutdown phase: Close all valves of the intake pipe (8), shut down the tested booster compressor device (2) according to the compressor shutdown procedure, open the exhaust shut-off valve (15) after shutdown, open the exhaust regulating valve (14) to the appropriate opening degree, and release the pressure of the closed test system of the booster compressor. The method for achieving stable operating conditions in step (3) includes at least the following steps: (3a) Valve switching: Open the gas supply shut-off valve (11) and the exhaust shut-off valve (15), and close the start-up unloading valve (17); (3b) Coarse flow adjustment: Read the gas flow meter (7) reading and coarsely adjust the circulation regulating valve (19) to a suitable opening so that the flow rate of the booster compressor device (2) is close to the experimental set flow rate; (3c) Stable intake pressure: Read the intake pressure gauge (5) reading and compare the deviation of the reading with the intake pressure experimental set value. If the reading is too low, perform the replenishment operation through the replenishment regulating valve (10). If the reading is too high, perform the exhaust operation through the exhaust regulating valve (14). (3d) Stable exhaust pressure: Read the reading of the exhaust pressure gauge (6) and compare the deviation of the reading with the experimental set value of exhaust pressure. If the reading is too low, perform the gas replenishment operation through the gas replenishment regulating valve (10). If the reading is too high, perform the gas release operation through the exhaust regulating valve (14). The control algorithm is used to achieve precise adjustment of exhaust pressure. (3e) Flow fine adjustment: wait for the intake pressure and exhaust pressure to stabilize, fine adjust the opening of the circulation regulating valve (19) to accurately control the experimental flow rate and realize the flow rate regulation; (3f) Repeat (3c) to (3e) above until the difference between the intake pressure and exhaust pressure and the set value meets the requirements of the test procedure, then the operating condition can be considered to be stable.

3. The full-condition control method according to claim 2, characterized in that, Step (3b) uses a pure proportional control algorithm to achieve coarse adjustment of the flow rate.

4. The full-condition control method according to claim 3, characterized in that, Step (3c) employs a negative feedback PI control algorithm to achieve precise adjustment of the intake pressure.

5. The full-condition control method according to claim 4, characterized in that, The (3d) step employs a negative feedback PID or PI control algorithm to achieve precise regulation of the exhaust pressure.

6. The full-condition control method according to claim 5, characterized in that, The (3e) step uses a negative feedback PID or PI control algorithm to regulate the flow rate.

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