Energy-saving and efficiency-improving system for air compression station

Abstract

The present application relates to air compression station technical field, provide a kind of air compression station energy-saving and efficiency increasing system, comprising: air compressor, air filter, air tank, gas supply main pipeline, air pressure sensor, air pressure alarm, operating platform, computer, air compressor remote operating device;Gas supply main pipeline is equipped with air pressure sensor;Air compressor remote operating device includes fixedly arranged in operating platform air compressor number label, air compressor exhaust capacity label, air compressor start indicator light, air compressor stop indicator light, air compressor start button and air compressor stop button;Computer is installed in operating platform, air pressure sensor is electrically connected with computer, computer is electrically connected with air pressure alarm.The present application has the advantages that: the start and stop of air compressor are remotely operated in operating platform, the air pressure value of main gas supply main pipeline can be conveniently seen from the display screen of computer, when air pressure value is found to be abnormal, the air pressure of gas supply main pipeline can be quickly operated to ensure, increase work efficiency, save electric energy.

Description

Technical Field

[0001] This invention relates to the field of air compressor station technology, and more specifically to an energy-saving and efficiency-enhancing system for air compressor stations. Background Technology

[0002] An air compressor is short for an air compressor. An air compressor is the main component of an air source device. It is a device that converts the mechanical energy of a prime mover (usually an electric motor) into the pressure energy of gas, and is a device that generates compressed air pressure.

[0003] The glass bottle manufacturing plant requires compressed air. The air compressor station is the working area of ​​the air compressors, responsible for delivering compressed air to the workshops. The compressed air generated by the air compressors first enters the air storage tank, then flows to the main air supply pipeline. The outlet of the main air supply pipeline connects to the air supply pipelines of each workshop. A valve is installed at the outlet of the main air supply pipeline; opening the valve supplies air to the workshops. When the demand for compressed air in the workshops exceeds the supply capacity of the air compressor station, the air pressure in the main air supply pipeline decreases, and the amount of compressed air in the air storage tank decreases. When the demand for compressed air in the workshops is less than the supply capacity of the air compressor station, the air pressure in the main air supply pipeline increases, and the amount of compressed air in the air storage tank increases. A pressure sensor is installed on the main air supply pipeline, and a pressure display is installed in the working chamber of the air compressor station. The pressure sensor sends the detected pressure value to the pressure display.

[0004] Currently, when the pressure display shows a reading below the required lower threshold, staff move to the air compressor site, operate the control cabinet, and start the corresponding air compressor to increase the pressure in the main air supply pipeline. Conversely, when the pressure display shows a reading above the required upper threshold, the same procedure is performed to stop the corresponding air compressor and reduce the pressure in the main air supply pipeline. However, the air compressor control cabinets are geographically dispersed, making on-site operation inefficient. After starting and stopping the compressors, staff must observe the pressure display readings to confirm whether the required pressure has been achieved. Starting a smaller compressor for a larger demand cannot guarantee the required pressure in the main air supply pipeline; conversely, starting a larger compressor for a smaller demand increases energy consumption. Generally, larger compressors have higher power outputs. Furthermore, the high noise levels at the air compressor sites hinder communication and confirmation between staff, resulting in low work efficiency. Therefore, it is necessary to increase the work efficiency of the air compressor station staff. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide an energy-saving and efficiency-enhancing system for air compressor stations.

[0006] This invention is implemented as follows: an energy-saving and efficiency-enhancing system for air compressor stations, comprising:

[0007] Air compressor, air filter, air tank, main air supply pipeline, air pressure sensor, air pressure alarm, control panel, computer, remote control device for air compressor;

[0008] The air filter is installed at the air inlet of the air compressor, the air outlet of the air compressor is connected to the air inlet of the air storage tank, the air outlet of the air storage tank is connected to the air inlet of the main air supply pipeline, and the air pressure sensor is installed on the main air supply pipeline.

[0009] The air compressor remote operation device includes an air compressor number label, an air compressor discharge capacity label, an air compressor start indicator light, an air compressor stop indicator light, an air compressor start button, and an air compressor stop button, all fixedly installed on the control panel. The air compressor start indicator light, air compressor stop indicator light, air compressor start button, and air compressor stop button are all electrically connected to the control cabinet of the air compressor. There are multiple air compressors, and the number of air compressor remote operation devices is the same as the number of air compressors.

[0010] The computer is installed on the control panel. The air pressure sensor is electrically connected to the computer. The computer is electrically connected to the air pressure alarm. The computer's display screen shows the air pressure value of the main air supply pipeline and the air pressure change curve over time. The computer stores an upper air pressure threshold and a lower air pressure threshold. When the air pressure value is outside the range of the upper air pressure threshold and the lower air pressure threshold, the computer causes the air pressure alarm to sound an alarm.

[0011] Furthermore, the computer acquires the air compressor number, air compressor discharge volume, and air compressor power. The computer then performs a full combination processing on the air compressor number to obtain and save a number combination data table, a discharge volume sum data table, and a power sum data table. The number combination items in the number combination data table, the discharge volume sum values ​​in the discharge volume sum data table, and the power sum values ​​in the power sum data table correspond one-to-one. The computer's display screen also displays the number combination data table, the discharge volume sum data table, and the power sum data table.

[0012] Furthermore, the computer is electrically connected to the control cabinets of multiple air compressors. The computer controls the start and stop status of the air compressors according to the number combination item. The computer's display screen also displays the current number combination item, the sum of the current exhaust volume, and the sum of the current power for the air compressor that is in the start state.

[0013] When the air pressure value is lower than the lower limit threshold, the computer first searches the exhaust volume summation data table, selects the exhaust volume summation value that is higher than the current exhaust volume summation value and is the smallest, records it as the exhaust volume increase parameter, and then searches the number combination data table, selects the number combination item corresponding to the exhaust volume increase parameter, and controls the start and stop status of the air compressor.

[0014] When the air pressure value is higher than the upper limit threshold, the computer first searches the exhaust volume summation data table, selects the largest exhaust volume summation value that is lower than the current exhaust volume summation value, records it as the exhaust volume reduction parameter, and then searches the number combination data table, selects the number combination item corresponding to the exhaust volume reduction parameter, and controls the start and stop status of the air compressor.

[0015] Furthermore, when the air pressure value does not change, the computer records the current number combination item as the balance number combination parameter;

[0016] When the air pressure value is within the range of the upper air pressure threshold and the lower air pressure threshold, the computer controls the start-stop state of the air compressor according to the balance number combination parameter.

[0017] Furthermore, when the air pressure value does not change, the computer will also record the current exhaust volume sum value as the balanced exhaust volume parameter. Then, the computer will sequentially search the exhaust volume sum data table, the power sum data table, and the number combination data table, and select the number combination item corresponding to the same balanced exhaust volume parameter and the smallest power sum value as the balanced number combination parameter.

[0018] Furthermore, the computer also stores a table corresponding to the rate of change of air pressure and the increase or decrease of exhaust volume. When the air pressure value is outside the range of the upper and lower air pressure thresholds, the computer calculates the required exhaust volume value based on the table of the rate of change of air pressure and the increase or decrease of exhaust volume, combined with the current exhaust volume sum value. Then, it searches the exhaust volume sum data table, selects the exhaust volume sum value closest to the required exhaust volume value, records it as the adjusted exhaust volume parameter, and searches the numbered combination data table, selects the numbered combination item corresponding to the adjusted exhaust volume parameter, and controls the start and stop status of the air compressor.

[0019] Furthermore, the remote operation device for the air compressor also includes a venting button and a power-off delay relay. The air compressor has a venting solenoid valve. The venting button is electrically connected to the input terminal of the power-off delay relay. The output terminal of the power-off delay relay is electrically connected to the venting solenoid valve. The venting button is fixedly mounted on the control panel. The computer is also electrically connected to the input terminal of the power-off delay relay.

[0020] Furthermore, it also includes water pumps, cooling towers, water storage tanks, hot water main pipes, cold water main pipes, water temperature sensors, water temperature alarms, and remote operation devices for water pumps;

[0021] The hot water outlet of the air compressor is connected to the inlet of the hot water main pipeline, the outlet of the hot water main pipeline is connected to the inlet of the cooling tower, the outlet of the cooling tower is connected to the inlet of the water storage tank, the outlet of the water storage tank is connected to the inlet of the water pump, the outlet of the water pump is connected to the inlet of the cold water main pipeline, the outlet of the cold water main pipeline is connected to the cold water inlet of the air compressor, and the water temperature sensor is installed on the hot water main pipeline.

[0022] The water pump remote operation device includes a water pump number label, a water pump start indicator light, a water pump stop indicator light, a water pump start button, and a water pump stop button, all fixedly installed on the control panel. The water pump start indicator light, water pump stop indicator light, water pump start button, and water pump stop button are all electrically connected to the water pump controller. There are multiple water pumps, and the number of water pump remote operation devices is the same as the number of water pumps.

[0023] The water temperature sensor is electrically connected to the computer, which is also electrically connected to the water temperature alarm. The computer's display screen shows the water temperature value of the main hot water pipe. The computer stores a water temperature threshold. When the water temperature value exceeds the water temperature threshold, the computer causes the water temperature alarm to sound an alarm.

[0024] Furthermore, the computer is electrically connected to the controllers of multiple water pumps, and the computer also stores a table corresponding to the number of water pumps started and the number of air compressors started. The computer determines the number of water pumps to be started based on the current number of air compressors started.

[0025] Furthermore, the computer obtains the air compressor's operating status parameters from the air compressor's control cabinet, and the computer's display screen also displays the air compressor's operating status parameters, which include primary exhaust pressure, secondary exhaust pressure, lubricating oil pressure, inlet water pressure, primary exhaust temperature, secondary intake temperature, secondary exhaust temperature, lubricating oil temperature, aftercooler temperature, front bearing temperature, middle bearing temperature, rear bearing temperature, motor current, excitation current, excitation voltage, and power factor.

[0026] The advantages of this invention are as follows: 1. Operators can remotely start and stop the air compressor from the control panel. The air compressor's serial number label corresponds to the control cabinet of the air compressor on site. The operating status of the air compressor can be confirmed by the air compressor start indicator and the air compressor stop indicator. The air pressure value of the main air supply pipeline and the air pressure change curve over time can be easily viewed on the computer display screen of the control panel. When an abnormal air pressure value is found, the air pressure of the main air supply pipeline can be quickly ensured, increasing work efficiency. The total discharge volume of the air compressor in the starting state can be quickly obtained from the corresponding air compressor discharge volume label, effectively avoiding the situation where a small amount of compressed air is required but a large discharge volume air compressor is started, saving energy.

[0027] 2. The computer on the control panel generates a data table of numbered combinations, a data table of total exhaust volume, and a data table of total power. This helps staff to make judgments and comparisons based on actual conditions, select the air compressor starting combination that meets the requirements of air pressure supply while having the lowest power consumption, save energy, and increase efficiency.

[0028] 3. Based on the actual air pressure value from the air pressure sensor, and combined with the number combination data table, the exhaust volume summation data table, and the power summation data table, the computer automatically finds the optimal air compressor number combination and controls the start and stop status of the air compressor. It has a high degree of automation and high execution efficiency.

[0029] 4. After the air compressor stops and before it starts, remotely operate the venting solenoid valve to release pressure from the air compressor, effectively preventing damage during startup.

[0030] 5. Operators can remotely start and stop the water pump from the control panel, making it convenient to adjust the cooling water temperature of the air compressor in a timely manner.

[0031] 6. The computer determines the number of water pumps to be started based on the current number of air compressors started, so as to optimize the total power of the water pumps while meeting the cooling requirements of the air compressors.

[0032] 7. The computer periodically saves the air compressor's operating status parameters, allowing staff to check these parameters and determine if the air compressor is operating normally. If the air compressor's operating status parameters exceed the normal range, maintenance should be prepared. Attached Figure Description

[0033] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0034] Figure 1 This is a schematic diagram of the structure of the air compressor station energy-saving and efficiency-enhancing system of the present invention.

[0035] Figure 2This is a schematic diagram showing the connection of the control panel, computer, air compressor remote control device, and water pump remote control device in this invention.

[0036] Reference numerals: 10 air compressor; 11 air filter; 12 air tank;

[0037] 20. Main gas supply pipeline; 21. Gas pressure sensor; 22. Gas pressure alarm;

[0038] Control panel 30;

[0039] Computer 40; Display screen 41;

[0040] 50. Air compressor remote control device; 51. Air compressor serial number label; 52. Air compressor discharge capacity label; 53. Air compressor start indicator light; 54. Air compressor stop indicator light; 55. Air compressor start button; 56. Air compressor stop button; 57. Vent button;

[0041] 60. Water pump; 61. Cooling tower; 62. Water storage tank; 63. Hot water main pipeline; 64. Cold water main pipeline; 65. Water temperature sensor; 66. Water temperature alarm.

[0042] 70. Water pump remote operation device; 71. Water pump number label; 72. Water pump start indicator light; 73. Water pump stop indicator light; 74. Water pump start button; 75. Water pump stop button. Detailed Implementation

[0043] This invention provides an energy-saving and efficiency-enhancing system for air compressor stations, overcoming the shortcomings of the prior art where staff have to operate the control cabinet on-site when the air pressure in the main air supply pipeline is abnormal. It enables remote operation of the air compressor's start and stop from the control panel, saving energy and increasing efficiency.

[0044] The overall concept of the technical solution of this invention is as follows:

[0045] Operators can remotely start and stop the air compressor from the control panel. The control panel has an air compressor number label, an air compressor discharge capacity label, an air compressor start indicator light, an air compressor stop indicator light, an air compressor start button, and an air compressor stop button, all corresponding to the air compressor. Operators can also remotely start and stop the water pump from the control panel and adjust the air compressor's cooling water temperature in a timely manner.

[0046] The computer on the control panel provides optimization functions: view the air pressure value of the main air supply pipeline, the air pressure change curve over time, automatically generate number combination data tables, exhaust volume summation data tables and power summation data tables, automatically find the optimal air compressor number combination, control the start and stop status of the air compressor, automatically adjust the number of water pumps started, and automatically save the air compressor operating status parameters.

[0047] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0048] See Figure 1 and Figure 2 The preferred embodiment of the present invention.

[0049] An energy-saving and efficiency-enhancing system for an air compressor station includes:

[0050] Air compressor 10, air filter 11, air tank 12, main air supply pipeline 20, air pressure sensor 21, air pressure alarm 22, control panel 30, computer 40, air compressor remote operation device 50;

[0051] The air filter 11 is installed at the air inlet of the air compressor 10, the exhaust port of the air compressor 10 is connected to the air inlet of the air storage tank 12, the air outlet of the air storage tank 12 is connected to the air inlet of the main air supply pipeline 20, and the main air supply pipeline 20 is equipped with the air pressure sensor 21.

[0052] The air compressor remote operation device 50 includes an air compressor number label 51, an air compressor discharge capacity label 52, an air compressor start indicator light 53, an air compressor stop indicator light 54, an air compressor start button 55, and an air compressor stop button 56, all fixedly installed on the control panel 30. The air compressor start indicator light 53, air compressor stop indicator light 54, air compressor start button 55, and air compressor stop button 56 are all electrically connected to the control cabinet of the air compressor. There are multiple air compressors 10, and the number of air compressor remote operation devices 50 is the same as the number of air compressors 10.

[0053] The computer 40 is installed on the operating console 30. The air pressure sensor 21 is electrically connected to the computer 40. The computer 40 is electrically connected to the air pressure alarm 22. The display screen 41 of the computer 40 displays the air pressure value and the air pressure change curve over time of the main air supply pipeline 20. The computer 40 stores an upper air pressure threshold and a lower air pressure threshold. When the air pressure value is outside the range of the upper air pressure threshold and the lower air pressure threshold, the computer 40 causes the air pressure alarm 22 to sound an alarm.

[0054] Operators can remotely start and stop the air compressor 10 from the control panel 30. The air compressor's serial number label corresponds to the control cabinet of the air compressor on site. The operating status of the air compressor can be confirmed by the air compressor start indicator light 53 and the air compressor stop indicator light 54. The air pressure value and air pressure change curve of the main air supply pipeline 20 can be easily viewed on the display screen 41 of the computer 40 on the control panel 30. When an abnormal air pressure value is detected, the operator can quickly take action to ensure the air pressure of the main air supply pipeline 20, increasing work efficiency. The total discharge volume of the air compressor in the starting state can be quickly obtained from the corresponding air compressor discharge volume label 52, effectively avoiding the situation where a small amount of compressed air is required but a large discharge volume air compressor is started, saving energy.

[0055] The air pressure alarm 22 serves to alert staff to abnormal air pressure in the main air supply pipeline 20, allowing staff to quickly operate the air compressor 10 remotely from the control panel 30. The remote operation device 50 easily displays which air compressor is running and which is stopped. After adjusting the air compressor on the control panel 30, the air pressure changes in the main air supply pipeline 20 can be viewed on the display screen 41 of the computer 40. The computer 40 is an industrial-grade computer. Compared to the prior art, staff do not need to move to the air compressor site to operate the control cabinet, and are not disturbed by machine noise when communicating with others.

[0056] The computer 40 acquires the air compressor number, air compressor discharge volume, and air compressor power. The computer 40 then performs a full combination processing on the air compressor number to obtain and save a number combination data table, a discharge volume sum data table, and a power sum data table. The number combination items in the number combination data table, the discharge volume sum values ​​in the discharge volume sum data table, and the power sum values ​​in the power sum data table correspond one-to-one. The display screen 41 of the computer 40 also displays the number combination data table, discharge volume sum data table, and power sum data table. The beneficial effect here is that the number combination data table, discharge volume sum data table, and power sum data table generated by the computer 40 on the control panel 30 help operators make judgments and comparisons based on actual conditions, selecting the air compressor start-up combination that meets the requirements of air pressure supply while having the lowest power consumption, thus saving energy and increasing efficiency.

[0057] In this embodiment, it is assumed that there are five air compressors, numbered A1, A2, A3, A4, and A5 respectively; their discharge capacities are E1, E2, E3, E4, and E5 respectively; and their power is P1, P2, P3, P4, and P5 respectively. The air compressor number, discharge capacity, and power are input into the computer 40 by the operator via keyboard, or obtained by the computer 40 from the air compressor control cabinet after the computer 40 is connected to the air compressor control cabinet.

[0058] For example, E1 = 10m 3 / min, E2=20m 3 / min, E3=20m 3 / min, E4=40m 3 / min, E5=100m 3 / min; P1=63kw, P2=132kw, P3=132kw, P4=250kw, P5=500kw.

[0059] The computer performs a full combination processing on the air compressor numbers to obtain a number combination data table, namely {Air, A1, A2, A3, A4, A5, A1A2, A1A3, A1A4, A1A5, A2A3, A2A4, A2A5, A3A4, A3A5, A4A5, A1A2A3, A1A2A4, A1A2A5, A1A3A4, A1A3A5, A1A4A5, A2A3A4, A2A3A5, A2A4A5, A3A4A5, A1A2A3A4, A1A2A3A5, A1A3A4A5, A1A2A4A5, A2A3A4A5, A1A2A3A4A5}.

[0060] The table showing the added displacement data is as follows: {0, E1, E2, E3, E4, E5, E1+E2, E1+E3, E1+E4, E1+E5, E2+E3, E2+E4, E2+E5, E3+E4, E3+E5, E4+E5, E1+E2+E3, E1+E2+E4, E1+E2+E5, E1+E3+E4, E1+...} E3+E5, E1+E4+E5, E2+E3+E4, E2+E3+E5, E2+E4+E5, E3+E4+E5, E1+E2+E3+E4, E1+E2+E3+E5, E1+E3+E4+E5, E1+E2+E4+E5, E2+E3+E4+E5, E1+E2+E3+E4+E5}.

[0061] The power summation data table is as follows: {0, P1, P2, P3, P4, P5, P1+P2, P1+P3, P1+P4, P1+P5, P2+P3, P2+P4, P2+P5, P3+P4, P3+P5, P4+P5, P1+P2+P3, P1+P2+P4, P1+P2+P5, P1+P3+P4, P1+P...} 3+P5, P1+P4+P5, P2+P3+P4, P2+P3+P5, P2+P4+P5, P3+P4+P5, P1+P2+P3+P4, P 1+P2+P3+P5, P1+P3+P4+P5, P1+P2+P4+P5, P2+P3+P4+P5, P1+P2+P3+P4+P5}.

[0062] The computer 40 is electrically connected to the control cabinets of the multiple air compressors. The computer 40 controls the start / stop status of the air compressors according to the numbered combination items. The display screen 41 of the computer 40 also displays the current numbered combination item, the sum of the current exhaust volume, and the sum of the current power for the air compressors that are in the start-up state. For example, if the numbered combination item A1A2A5 is selected, the computer will start the air compressors numbered A1, A2, and A5, and stop the air compressors numbered A3 and A4. The current numbered combination item is A1A2A5, and the sum of the current exhaust volume is E1+E2+E5, where E1+E2+E5 = 130m³. 3 / min, the current power sum value P1+P2+P5, P1+P2+P5=695kW. If the current number combination item is empty, it means all air compressors are stopped, and the sum value of the current discharge volume and the sum value of the current power are both 0. If the current number combination item is A1A2A3A4A5, it means all air compressors are started, and the sum value of the current discharge volume and the sum value of the current power are both at their maximum.

[0063] When the air pressure value is lower than the lower air pressure threshold, the computer first searches the exhaust volume summation data table, selects the smallest exhaust volume summation value that is higher than the current exhaust volume summation value, records it as the exhaust volume increase parameter, and then searches the number combination data table, selects the number combination item corresponding to the exhaust volume increase parameter, and controls the start / stop state of the air compressor; for example, the current exhaust volume summation value is E1+E2+E5; and in the exhaust volume summation data table, E1+E4+E5, E2+E3+E5, E2+E4+E5, E3+E4+E5, E The sequences 1+E2+E3+E5, E1+E3+E4+E5, E1+E2+E4+E5, E2+E3+E4+E5, and E1+E2+E3+E4+E5 are all higher than E1+E2+E5. Among E1+E4+E5, E2+E3+E5, E2+E4+E5, E3+E4+E5, E1+E2+E3+E5, E1+E3+E4+E5, E1+E2+E4+E5, E2+E3+E4+E5, and E1+E2+E3+E4+E5, E2+E3+E5 and E4+E5 are the smallest, both at 140m. 3 If the displacement adjustment parameter is set to E2+E3+E5 or E4+E5, then the corresponding number combination item is A2A3A5. The computer will then start air compressors numbered A2, A3, and A5, and stop air compressors numbered A1 and A4. Alternatively, if the corresponding number combination item is A4A5, the computer will start air compressors numbered A4 and A5, and stop air compressors numbered A1, A2, and A3.

[0064] However, since the power of P2+P3+P5 is 764kw and the power of P4+P5 is 750kw in the power summation table, and the power of the numbered combination item A4A5 corresponding to the displacement adjustment parameter E4+E5 is smaller, the numbered combination item A4A5 is selected first.

[0065] When the air pressure value is higher than the upper limit threshold, the computer first searches the exhaust volume summation data table, selects the largest exhaust volume summation value that is lower than the current exhaust volume summation value, records it as the exhaust volume reduction parameter, and then searches the number combination data table, selects the number combination item corresponding to the exhaust volume reduction parameter, and controls the start / stop state of the air compressor. For example, the current exhaust volume summation value is E1+E2+E5; and in the exhaust volume summation data table, 0, E1, E2, E3, E4, E5, E1+E2, E1+E3, E1+E4, E1+E5, E2+E3, E2+E4, E2+E5, E3+E4, E3+E5, E1+E2+E3, E1+E2+E4, E1+E3+E4, E2+E3+E4, E1+E2+E3+E4 All are lower than E1+E2+E5. Among 0, E1, E2, E3, E4, E5, E1+E2, E1+E3, E1+E4, E1+E5, E2+E3, E2+E4, E2+E5, E3+E4, E3+E5, E1+E2+E3, E1+E2+E4, E1+E3+E4, E2+E3+E4, and E1+E2+E3+E4, E2+E5 and E3+E5 are the largest, both at 120m. 3 If the displacement is adjusted to / min, then the air compressor with displacement is reduced to E2+E5 or E3+E5. In this case, the number combination item corresponding to the displacement parameter adjustment is A2A5, and the computer will start the air compressors numbered A2 and A5, and stop the air compressors numbered A1, A3, and A4. Alternatively, if the number combination item corresponding to the displacement parameter adjustment is A3A5, the computer will start the air compressors numbered A3 and A5, and stop the air compressors numbered A1, A2, and A4.

[0066] The current total displacement value E1+E2+E5 corresponds to the numbered combination item A1A2A5. In comparison, the numbered combination item A2A5 corresponding to E2+E5 can be changed from A1A2A5 to A2A5 simply by shutting down the air compressor A1. Therefore, the numbered combination item A2A5 is preferred.

[0067] When the air pressure value does not change, the computer records the current number combination item as the balance number combination parameter. If the air pressure value does not change, it means that the demand for compressed air in the workshop is equal to the supply of compressed air from the air compressor station. For example, if the air compressors numbered A2 and A3 are started and the air compressors A1, A4, and A5 are stopped, and the air pressure value does not change, then the balance number combination parameter is A2A3.

[0068] When the air pressure value is within the range of the upper and lower air pressure thresholds, the computer controls the start and stop status of the air compressor according to the balance number combination parameters. This keeps the air pressure in the main air supply pipeline 20 stable. When the air pressure value is lower than the lower air pressure threshold, if the computer continuously increases the air pressure in the main air supply pipeline 20 during the start and stop adjustment of the air compressor, the air pressure value will become higher than the upper air pressure threshold, and an alarm will sound. When the air pressure value exceeds the upper air pressure threshold, if the computer continuously decreases the air pressure in the main air supply pipeline 20 during the start and stop adjustment of the air compressor, the air pressure value will become lower than the lower air pressure threshold, and an alarm will sound.

[0069] When the air pressure value remains unchanged, the computer records the sum of the current exhaust volume as the balanced exhaust volume parameter. Then, the computer sequentially searches the exhaust volume sum data table, the power sum data table, and the numbered combination data table, selecting the numbered combination item that corresponds to the balanced exhaust volume parameter and has the smallest power sum value, and records it as the balanced numbered combination parameter. For example, if the current numbered combination parameter is A2A3 when the air pressure value remains unchanged, then the current exhaust volume sum value E2+E3 is the balanced exhaust volume parameter, and E2+E3 = 40m³. 3 / min, in the displacement addition data table, E4 is the same as E2+E3, while the power addition value P4 is smaller than P2+P3, P4=250kw, P2+P3=264kw, then the number combination item A4 corresponding to P4 is the balance number combination parameter.

[0070] The computer also stores a table corresponding to the rate of change of air pressure and the increase or decrease of exhaust volume. When the air pressure value is outside the range of the upper and lower air pressure thresholds, the computer calculates the required exhaust volume value based on the table and the sum of the current exhaust volume values. Then, it searches the exhaust volume sum data table, selects the exhaust volume sum value closest to the required exhaust volume value, records it as the adjusted exhaust volume parameter, and searches the numbered combination data table to select the numbered combination item corresponding to the adjusted exhaust volume parameter to control the start and stop status of the air compressor. For example, if the air pressure changes from Q1 to Q2 within one minute, the rate of change is Δq1. In the corresponding table, the displacement increase / decrease corresponding to Δq1 is Δe1. The current displacement sum is E2+E3, and the required displacement is E2+E3+Δe1. In the displacement sum data table, E1+E2+E3+E4 is closest to or equal to E2+E3+Δe1. Therefore, the displacement adjustment parameter is E1+E2+E3+E4. In the numbered combination data table, the numbered combination corresponding to the adjusted displacement parameter E1+E2+E3+E4 is A1A2A3A4. At this time, the computer controls the air compressors numbered A1, A2, A3, and A4 to start, and the air compressor numbered A5 to stop. This allows for rapid adjustment of the air compressor's start / stop status.

[0071] Based on the actual air pressure value of the air pressure sensor 21, the computer automatically finds the optimal air compressor number combination by combining the number combination data table, the exhaust volume sum data table, and the power sum data table, and controls the start and stop status of the air compressor. It has a high degree of automation and high execution efficiency.

[0072] The remote operation device 50 for the air compressor also includes a vent button 57 and a power-off delay relay (not shown). The air compressor 10 has a vent solenoid valve (not shown). The vent button 57 is electrically connected to the input terminal of the power-off delay relay, and the output terminal of the power-off delay relay is electrically connected to the vent solenoid valve. The vent button 57 is fixedly mounted on the control panel 30, and the computer is also electrically connected to the input terminal of the power-off delay relay. The beneficial effect here is that after the air compressor stops and before it starts, the operator can remotely operate the vent solenoid valve to depressurize the air compressor, effectively preventing damage during startup. The power-off delay relay outputs a signal immediately upon receiving an input signal; however, after the input signal disappears, the relay requires a certain delay to return to its state before the action. Before starting the air compressor, pressing the vent button 57 sends a signal to the power-off delay relay. The power-off delay relay outputs a signal to activate the vent solenoid valve, depressurizing the air compressor. The delay time of the relay is the depressurization time of the air compressor. After the delay time, the power-off delay relay stops outputting the signal, and the vent solenoid valve stops depressurizing. Each time the air compressor is started, the computer sends a signal to the power-off delay relay to activate the vent solenoid valve and depressurize the corresponding air compressor.

[0073] It also includes a water pump 60, a cooling tower 61, a water storage tank 62, a hot water main pipe 63, a cold water main pipe 64, a water temperature sensor 65, a water temperature alarm 66, and a water pump remote operation device 70;

[0074] The hot water outlet of the air compressor is connected to the inlet of the hot water main pipe 63, the outlet of the hot water main pipe 63 is connected to the inlet of the cooling tower 61, the outlet of the cooling tower 61 is connected to the inlet of the water storage tank 62, the outlet of the water storage tank 62 is connected to the inlet of the water pump 60, the outlet of the water pump 60 is connected to the inlet of the cold water main pipe 64, the outlet of the cold water main pipe 64 is connected to the cold water inlet of the air compressor, and the water temperature sensor 65 is installed on the hot water main pipe 63.

[0075] The water pump remote operation device 70 includes a water pump number label 71, a water pump start indicator light 72, a water pump stop indicator light 73, a water pump start button 74, and a water pump stop button 75, all fixedly installed on the control panel 30. The water pump start indicator light 72, the water pump stop indicator light 73, the water pump start button 74, and the water pump stop button 75 are all electrically connected to the water pump controller. There are multiple water pumps 60, and the number of water pump remote operation devices 70 is the same as the number of water pumps 60.

[0076] The water temperature sensor 65 is electrically connected to the computer 40, which is also electrically connected to the water temperature alarm 66. The display screen 41 of the computer 40 displays the water temperature value of the main hot water pipe 63. The computer stores a water temperature threshold; when the water temperature value exceeds the threshold, the computer causes the water temperature alarm 66 to sound an alarm. The advantage here is that after hearing the alarm, the operator can remotely start and stop the water pump 60 from the control panel 30, facilitating timely adjustment of the air compressor's cooling water temperature. The water pump 60 delivers cold water from the storage tank 62 to the air compressor for heat exchange. The resulting hot water is cooled by the cooling tower 61 and then flows back to the storage tank 62. When more air compressors are running, more hot water is produced, causing the water level in the main hot water pipe 63 to rise. The operator can also see the real-time water temperature changes in the main hot water pipe on the display screen 41 of the computer 40.

[0077] The computer is also electrically connected to the controllers of multiple water pumps 60. The computer also stores a table mapping the number of water pumps started to the number of air compressors started. The computer determines the number of water pumps to start based on the current number of air compressors started. The beneficial effect here is that by determining the number of water pumps to start based on the current number of air compressors started, the computer optimizes the total power of the water pumps while meeting the cooling requirements of the air compressors. For example, the ratio of air compressor start count to water pump start count is 2:1, rounded down; there are three water pumps and five air compressors. When two air compressors are started, the computer starts one water pump; when four air compressors are started, the computer starts two water pumps; when the water temperature in the main hot water pipe 63 exceeds the water temperature threshold during air compressor operation, the water temperature alarm 66 sounds, and the computer starts another water pump. For example, if the current combination of numbers is A1A2A5, it means that three air compressors are started, and the computer will start one water pump. If the water temperature exceeds the water temperature threshold, the computer will start two water pumps.

[0078] The computer obtains the air compressor's operating status parameters from the air compressor's control cabinet. The computer's display screen 41 also displays these parameters. The computer saves the air compressor's operating status parameters at preset intervals. These parameters include primary exhaust pressure, secondary exhaust pressure, lubricating oil pressure, inlet water pressure, primary exhaust temperature, secondary intake temperature, secondary exhaust temperature, lubricating oil temperature, aftercooler temperature, front bearing temperature, middle bearing temperature, rear bearing temperature, motor current, excitation current, excitation voltage, and power factor. The beneficial effect here is that the computer periodically saves the air compressor's operating status parameters, making it convenient for operators to check these parameters, determine whether the air compressor is operating normally, and prepare for maintenance when the air compressor's operating status parameters exceed the normal range. As air compressors are used, their components inevitably wear out, causing changes in their operating parameters. To accurately monitor the compressor's performance, operators need to regularly check these parameters and, based on their changes over time, identify worn parts to prepare for replacement during maintenance. The computer saves these operating parameters to an Excel spreadsheet, or alternatively, it can periodically take screenshots and save them as image files.

[0079] While specific embodiments of the present invention have been described above, those skilled in the art should understand that the specific embodiments described are merely illustrative and not intended to limit the scope of the present invention. Equivalent modifications and variations made by those skilled in the art in accordance with the spirit of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. An energy-saving and efficiency-enhancing system for an air compressor station, characterized in that, include: Air compressor, air filter, air tank, main air supply pipeline, air pressure sensor, air pressure alarm, control panel, computer, remote control device for air compressor; The air filter is installed at the air inlet of the air compressor, the air outlet of the air compressor is connected to the air inlet of the air storage tank, the air outlet of the air storage tank is connected to the air inlet of the main air supply pipeline, and the air pressure sensor is installed on the main air supply pipeline. The air compressor remote operation device includes an air compressor number label, an air compressor discharge capacity label, an air compressor start indicator light, an air compressor stop indicator light, an air compressor start button, and an air compressor stop button, all fixedly installed on the control panel. The air compressor start indicator light, air compressor stop indicator light, air compressor start button, and air compressor stop button are all electrically connected to the control cabinet of the air compressor. There are multiple air compressors, and the number of air compressor remote operation devices is the same as the number of air compressors. The computer is installed on the control panel. The air pressure sensor is electrically connected to the computer. The computer is electrically connected to the air pressure alarm. The computer's display screen shows the air pressure value of the main air supply pipeline and the air pressure change curve over time. The computer stores an upper air pressure threshold and a lower air pressure threshold. When the air pressure value is outside the range of the upper air pressure threshold and the lower air pressure threshold, the computer causes the air pressure alarm to sound an alarm. The computer acquires the air compressor number, air compressor discharge volume, and air compressor power. The computer then performs a full combination processing on the air compressor number to obtain and save a number combination data table, a discharge volume sum data table, and a power sum data table. The number combination items in the number combination data table, the discharge volume sum values ​​in the discharge volume sum data table, and the power sum values ​​in the power sum data table correspond one-to-one. The computer's display screen also displays the number combination data table, the discharge volume sum data table, and the power sum data table. The computer is electrically connected to the control cabinets of the multiple air compressors. The computer controls the start and stop status of the air compressors according to the number combination item. The computer's display screen also displays the current number combination item, the sum of the current exhaust volume, and the sum of the current power for the air compressors that are in the start state. When the air pressure value is lower than the lower limit threshold, the computer first searches the exhaust volume summation data table, selects the exhaust volume summation value that is higher than the current exhaust volume summation value and is the smallest, records it as the exhaust volume increase parameter, and then searches the number combination data table, selects the number combination item corresponding to the exhaust volume increase parameter, and controls the start and stop status of the air compressor. When the air pressure value is higher than the upper limit threshold, the computer first searches the exhaust volume summation data table, selects the largest exhaust volume summation value that is lower than the current exhaust volume summation value, records it as the exhaust volume reduction parameter, and then searches the number combination data table, selects the number combination item corresponding to the exhaust volume reduction parameter, and controls the start and stop status of the air compressor. When the air pressure value does not change, the computer records the current number combination item as the balance number combination parameter; When the air pressure value is within the range of the upper air pressure threshold and the lower air pressure threshold, the computer controls the start and stop status of the air compressor according to the balance number combination parameter; When the air pressure value does not change, the computer will also record the current exhaust volume sum value as the balanced exhaust volume parameter. Then, the computer will sequentially search the exhaust volume sum data table, the power sum data table, and the number combination data table, and select the number combination item corresponding to the same balanced exhaust volume parameter and the smallest power sum value as the balanced number combination parameter.

2. The energy-saving and efficiency-enhancing system for an air compressor station according to claim 1, characterized in that, The computer also stores a table corresponding to the rate of change of air pressure and the increase or decrease of exhaust volume. When the air pressure value is outside the range of the upper and lower air pressure thresholds, the computer calculates the required exhaust volume value based on the table and the sum of the current exhaust volume values. Then, it searches the exhaust volume sum data table, selects the exhaust volume sum value closest to the required exhaust volume value, records it as the adjusted exhaust volume parameter, and searches the numbered combination data table to select the numbered combination item corresponding to the adjusted exhaust volume parameter to control the start and stop status of the air compressor.

3. The energy-saving and efficiency-enhancing system for an air compressor station according to claim 1, characterized in that, The remote operation device for the air compressor also includes a venting button and a power-off delay relay. The air compressor has a venting solenoid valve. The venting button is electrically connected to the input terminal of the power-off delay relay. The output terminal of the power-off delay relay is electrically connected to the venting solenoid valve. The venting button is fixedly mounted on the control panel. The computer is also electrically connected to the input terminal of the power-off delay relay.

4. The energy-saving and efficiency-enhancing system for an air compressor station according to claim 1, characterized in that, It also includes water pumps, cooling towers, water storage tanks, hot water main pipes, cold water main pipes, water temperature sensors, water temperature alarms, and remote operation devices for water pumps; The hot water outlet of the air compressor is connected to the inlet of the hot water main pipeline, the outlet of the hot water main pipeline is connected to the inlet of the cooling tower, the outlet of the cooling tower is connected to the inlet of the water storage tank, the outlet of the water storage tank is connected to the inlet of the water pump, the outlet of the water pump is connected to the inlet of the cold water main pipeline, the outlet of the cold water main pipeline is connected to the cold water inlet of the air compressor, and the water temperature sensor is installed on the hot water main pipeline. The water pump remote operation device includes a water pump number label, a water pump start indicator light, a water pump stop indicator light, a water pump start button, and a water pump stop button, all fixedly installed on the control panel. The water pump start indicator light, water pump stop indicator light, water pump start button, and water pump stop button are all electrically connected to the water pump controller. There are multiple water pumps, and the number of water pump remote operation devices is the same as the number of water pumps. The water temperature sensor is electrically connected to the computer, which is also electrically connected to the water temperature alarm. The computer's display screen shows the water temperature value of the main hot water pipe. The computer stores a water temperature threshold. When the water temperature value exceeds the water temperature threshold, the computer causes the water temperature alarm to sound an alarm.

5. The energy-saving and efficiency-enhancing system for an air compressor station according to claim 4, characterized in that, The computer is also electrically connected to the controllers of multiple water pumps, and the computer also stores a table corresponding to the number of water pumps started and the number of air compressors started. The computer determines the number of water pumps to start based on the current number of air compressors started.

6. The energy-saving and efficiency-enhancing system for an air compressor station according to claim 1, characterized in that, The computer obtains the air compressor's operating status parameters from the air compressor's control cabinet. The computer's display screen also displays the air compressor's operating status parameters, which include primary exhaust pressure, secondary exhaust pressure, lubricating oil pressure, inlet water pressure, primary exhaust temperature, secondary intake temperature, secondary exhaust temperature, lubricating oil temperature, aftercooler temperature, front bearing temperature, middle bearing temperature, rear bearing temperature, motor current, excitation current, excitation voltage, and power factor.

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