An intelligent control system for air compression station based on dew point sensor

Abstract

The present invention relates to an intelligent control system for an air compressor station based on a dew point sensor, which is used to effectively manage the dew point temperature of compressed air to ensure the efficient operation of the system and the air quality. The system includes a dew point sensor, which is specifically used to measure the dew point temperature of compressed air and send the measurement results to a controller in real time. The controller integrates data on ambient temperature, ambient humidity and air compressor output pressure, and uses this information and the dew point temperature received from the dew point sensor to generate accurate control signals. These control signals are then sent to the cold dryer to guide the adjustment of the opening degree of the cold dryer inlet ball valve. By adjusting the cold dryer inlet flow, the system ensures that the dew point temperature of the compressed air is maintained within the set safety and efficiency range, thereby optimizing the performance of the air compressor station and extending the equipment life. This intelligent control system provides an efficient and automated humidity management solution for the air compressor station, significantly improving energy efficiency and operational convenience.

Description

Technical Field

[0001] The invention relates to the technical field of control systems, and in particular to an intelligent control system for an air compressor station based on a dew point sensor. Background Art

[0002] In existing air compressor station control systems, it is crucial to maintain the dew point temperature of compressed air within an ideal range. The dew point temperature refers to the temperature at which water vapor in the air begins to condense into dewdrops, which is a key parameter for evaluating the drying effect of compressed air systems. Traditional control systems often use basic temperature and humidity sensors to monitor the environment and adjust the operation of the dryer accordingly, but these systems often cannot accurately reflect the actual humidity state of the compressed air in real time.

[0003] The main problem with existing technologies is that they lack real-time and accuracy in responding to environmental changes. Due to their reliance on general environmental monitoring data, traditional systems often cannot accurately control the dryer, resulting in large fluctuations in the dew point temperature of the compressed air, which not only affects air quality, but may also lead to low equipment efficiency and increased energy consumption. In addition, these systems are unable to automatically adapt to changing environmental conditions, such as day and night changes in temperature and humidity, making the air compressor station operation lack flexibility and economic efficiency.

[0004] Therefore, it is urgent to develop a new type of air compressor station intelligent control system based on dew point sensor. Summary of the invention

[0005] The present application provides an intelligent control system for an air compression station based on a dew point sensor to improve the energy efficiency of the air compression station.

[0006] The present application provides an intelligent control system for an air compressor station based on a dew point sensor, comprising:

[0007] Dew point sensor, used to detect the dew point temperature of compressed air and send the detection result to the controller;

[0008] A controller, used for generating a control signal according to the ambient temperature, ambient humidity, output pressure of the air compressor and the dew point temperature sent by the dew point sensor; and sending the generated control signal to the cold dryer;

[0009] The cold dryer is used to adjust the opening degree of the cold dryer inlet ball valve according to the received control signal to adjust the cold dryer inlet flow so as to keep the dew point temperature of the compressed air within the specified range.

[0010] Furthermore, the air compression station intelligent control system also includes a waste heat recovery unit, which recovers and converts the heat discharged by the air compressor and the cold dryer through a heat exchanger controlled by the controller.

[0011] The air compressor station intelligent control system also includes a digital monitoring subsystem, which is used to collect, store and display air compressor station operation data, wherein the air compressor station operation data includes pressure, flow, temperature and energy consumption.

[0012] Furthermore, the controller calculates the optimal opening degree of the cold dryer inlet ball valve through a mathematical model; wherein the mathematical model is expressed by the following formula 1:

[0013]

[0014] in, It is the adjustment amount of the opening of the inlet ball valve of the cold dryer; is the dew point temperature detected by the dew point sensor; is the set target dew point temperature; is the ambient temperature; is the ambient humidity; It is the compressor output pressure data; , , , and is the adjustment coefficient; is the environmental adaptability dew point adjustment function, which is implemented using the following formula 2:

[0015]

[0016] in, , , and is the adjustment parameter;

[0017] is the pressure response function, which is implemented using the following formula 3:

[0018]

[0019] in, , , and is a tuning parameter.

[0020] Furthermore, the controller also includes a user interface, which has a graphical dashboard that displays the dew point temperature, ambient temperature, ambient humidity and compressor output pressure of the compressed air in real time, wherein each dashboard is configured with dynamic color coding, and the color change is automatically adjusted according to the degree of deviation of the real-time data relative to the preset threshold value to provide an intuitive system status warning.

[0021] Furthermore, the user interface of the controller includes an interactive control module that allows the user to adjust the mathematical model through intuitive drag and drop operations. , , , and Parameters; after the user adjusts the parameters, the interface immediately displays a predicted effect diagram after the parameter adjustment, so that the user can optimize the system settings according to the expected operation results.

[0022] Furthermore, the air compressor station intelligent control system also includes a remote control module, which is used to receive control instructions from a remote terminal to achieve remote monitoring and operation of the air compressor station.

[0023] Furthermore, the controller optimizes and adjusts the inlet flow of the cold dryer according to historical operation data and a load prediction model to improve the operation efficiency and energy saving effect of the air compression station.

[0024] Furthermore, the controller is specifically used for:

[0025] Based on the following formula 4, the predicted load is calculated :

[0026]

[0027] in, It is the current moment Before Load data at each moment; are model coefficients, learned from historical data; is the error term;

[0028] According to the following formula 5, calculate the optimal inlet flow rate of the cold dryer :

[0029]

[0030] in, and is the regulation function; This is achieved using the following formula 6:

[0031]

[0032] in, and is a preset constant; It is the historical load data for a period of time in the past The variance of

[0033] This is achieved using the following formula 7:

[0034]

[0035] in, and is a preset constant; It is the historical load data for a period of time in the past The standard deviation of

[0036] According to the following formula 8, calculate the inlet flow rate of the cold dryer :

[0037]

[0038] in, is the load change ; Represents the difference feedback between the predicted load and the actual load; , and is the adjustment coefficient.

[0039] Furthermore, the dew point sensor is a high-precision dew point sensor.

[0040] The beneficial effects of the present application mainly include: (1) By using a dew point sensor to monitor the dew point temperature of compressed air in real time, the system can accurately control the moisture content in the air and prevent water vapor from condensing into water droplets, thereby avoiding pipeline corrosion, equipment damage and product quality problems caused by excessive moisture. This precise control ensures the dryness of the compressed air and meets the high standards of different industrial applications. (2) The controller in the system can adjust the operation of the cold dryer according to real-time data, such as adjusting the opening degree of the cold dryer inlet ball valve to control the inlet flow. This precise control can reduce unnecessary energy consumption. By maintaining the dew point temperature within the optimal range, the cold dryer will not over-operate, thereby reducing energy consumption and operating costs. (3) The controller in the system can adjust the operation of the cold dryer according to real-time data, such as adjusting the opening degree of the cold dryer inlet ball valve to control the inlet flow. This precise control can reduce unnecessary energy consumption. By maintaining the dew point temperature within the optimal range, the cold dryer will not over-operate, thereby reducing energy consumption and operating costs. (4) By continuously monitoring and adjusting the dew point temperature of compressed air, the system can prevent many common problems caused by improper dew point temperature, such as icing of the dryer, filter clogging and pipeline corrosion, thereby reducing maintenance frequency and costs. This not only extends the service life of the equipment, but also reduces downtime and improves production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1It is a schematic diagram of an intelligent control system for an air compressor station based on a dew point sensor provided in the first embodiment of the present application. DETAILED DESCRIPTION

[0042] Many specific details are described in the following description to facilitate a full understanding of the present application. However, the present application can be implemented in many other ways than those described herein, and those skilled in the art can make similar generalizations without violating the connotation of the present application, so the present application is not limited by the specific implementation disclosed below.

[0043] The first embodiment of the present application provides an intelligent control system for an air compressor station based on a dew point sensor. Figure 1 , which is a schematic diagram of the first embodiment of the present application. Figure 1 The first embodiment of the present application provides an intelligent control system for an air compressor station based on a dew point sensor and is described in detail.

[0044] The air compression station intelligent control system includes a dew point sensor 101 , a controller 102 and a cold dryer 103 .

[0045] The dew point sensor 101 is used to detect the dew point temperature of the compressed air and send the detection result to the controller.

[0046] In the dew point sensor-based air compression station intelligent control system, the dew point sensor 101 plays a vital role. This sensor is specifically used to monitor the dew point temperature of compressed air, which is the temperature at which water vapor in the air begins to condense into liquid water. Accurate monitoring of the dew point temperature is essential to ensure the efficiency of the air compression system and prevent corrosion or other problems caused by water vapor.

[0047] The dew point sensor 101 uses advanced sensing technology to measure the dew point temperature in the air. This sensor usually includes a humidity sensing element and a temperature sensing element, which work together to accurately determine the dew point temperature. The microprocessor inside the sensor calculates the current dew point temperature and transmits this information to the control system in real time.

[0048] To ensure data accuracy, the dew point sensor 101 uses highly sensitive hygroscopic materials that react quickly and accurately to humidity changes. The circuit design inside the sensor optimizes signal processing and transmission, ensuring high reliability and stability of the measurement results. In addition, the sensor design also takes into account the influence of environmental factors, such as temperature fluctuations, chemical vapors or dust, which are appropriately adjusted through the built-in compensation mechanism to ensure accurate readings in different environments.

[0049] The installation position of the dew point sensor 101 is usually located on the compressed air delivery pipeline between the air compressor and the cold dryer, so as to directly monitor the dew point temperature of the compressed air flowing through the pipeline. During the installation process, it is necessary to ensure that the contact area between the sensor and the air flow is large enough to obtain more accurate data. In addition, the housing of the sensor is designed to be dustproof and waterproof, and can withstand various challenges in the industrial environment.

[0050] For maintenance, the dew point sensor 101 is designed to be easy to clean and calibrate. Regular cleaning can remove dust and contaminants accumulated on the sensor surface and maintain sensing performance. In addition, the sensor also supports on-site or remote calibration to ensure that it can maintain high accuracy after long-term use.

[0051] The dew point sensor 101 transmits the measured dew point temperature to the controller 102 via electronic signals. These signals can be analog or digital, depending on the design of the control system. In order to ensure the integrity of the signal and prevent data loss, the sensor usually adopts anti-interference signal transmission technology. At the controller end, the received data will be further processed to generate instructions for controlling the cold dryer 103, such as adjusting the opening degree of the inlet ball valve, so as to ensure that the dew point temperature of the compressed air is always kept within the set safety range.

[0052] Through the above description, technicians can fully understand the role, technical implementation, installation and maintenance requirements of the dew point sensor 101, as well as its key position in the entire air compression station intelligent control system. This information ensures that technicians can effectively implement and maintain the system and optimize the operating efficiency and safety of the air compression station.

[0053] Furthermore, the dew point sensor is a high-precision dew point sensor.

[0054] In the intelligent control system of air compressor station based on dew point sensor, the dew point sensor used is a high-precision type, which is one of the key components in the system. The application of high-precision dew point sensor ensures that the system can accurately monitor the moisture content in compressed air in real time, thereby allowing the control system to accurately adjust the cold dryer to ensure that the air quality meets the strict standards of industrial applications.

[0055] The main function of the dew point sensor is to measure and monitor the dew point temperature in the compressed air system, that is, the temperature at which the air reaches saturation and begins to condense water droplets. In the compressed air system, maintaining the correct dew point temperature is essential to prevent water vapor condensation in pipes, equipment and processes, especially in applications involving precision control and processing.

[0056] The high-precision dew point sensors used usually have the following characteristics:

[0057] Very high measurement accuracy: These sensors provide very low measurement errors, often as low as ±2°C dew point temperature, which is critical to ensure that the system operates under optimal humidity conditions.

[0058] Fast response time: High-precision sensors can quickly respond to changes in dew point temperature in the environment, which is necessary to dynamically adjust the operating parameters of the air compression system to cope with rapidly changing production conditions.

[0059] High stability and reliability: These sensors are designed to operate over long periods of time and maintain stable performance even in extreme industrial environments, reducing maintenance needs and downtime.

[0060] Compatibility and network connectivity: Modern high-precision dew point sensors are often equipped with interfaces that enable direct communication with the control system, such as 4-20 mA, RS485 or Ethernet, which makes them easy to integrate into intelligent control systems.

[0061] In the intelligent control system of air compressor station, high-precision dew point sensors are installed at key monitoring points, such as compressor outlet, cold dryer inlet and outlet. The controller in the system receives the data measured by the dew point sensor in real time and adjusts the operating parameters according to the data, such as adjusting the inlet flow of the cold dryer or changing the operating mode of the compressor.

[0062] To ensure the continued accuracy and reliability of the dew point sensor, regular maintenance and calibration are necessary. This typically includes cleaning the sensor head to prevent dust and contaminant accumulation, and calibration with a standard humidity source to correct for any deviations. Proper maintenance and calibration ensures the accuracy of the sensor output, allowing the control system to rely on this data for efficient operation and regulation.

[0063] By adopting high-precision dew point sensors, the intelligent control system of the air compression station can achieve precise control of the compressed air treatment process, optimize operating efficiency and energy saving effects, while ensuring that the quality of compressed air meets the high standards of industrial applications.

[0064] The controller 102 is used to generate a control signal according to the ambient temperature, ambient humidity, the output pressure of the air compressor and the dew point temperature sent by the dew point sensor; and send the generated control signal to the cold dryer.

[0065] The controller 102 plays a core role in the intelligent control system of the air compressor station based on the dew point sensor. It is responsible for receiving the compressed air dew point temperature data provided by the dew point sensor 101, and combining other environmental parameters such as ambient temperature, humidity and the output pressure of the air compressor to generate accurate control signals. These signals are then used to adjust the operation of the cold dryer 103 to ensure that the dew point temperature of the compressed air is maintained within a preset safe and effective range.

[0066] In the intelligent control system of air compression station based on dew point sensor, ambient temperature and ambient humidity are two key monitoring parameters, which directly affect the decision-making of the control system and the processing process of compressed air.

[0067] Ambient temperature refers to the temperature of the air surrounding the compressor station. This parameter is critical to the operation of the system because it affects the capacity of water vapor in the air and thus indirectly affects the dew point temperature of the compressed air. Changes in ambient temperature can lead to changes in relative humidity, which has a direct impact on the behavior of water vapor during the handling of compressed air. For example, an increase in temperature will generally increase the amount of water vapor that the air can contain, which may result in a higher dew point temperature, which requires the dryer to take more measures to remove the excess moisture.

[0068] Ambient humidity refers to the amount of water vapor in the air around the air compressor station, usually expressed as relative humidity. Relative humidity is the percentage of the current water vapor content in the air to the maximum amount of water vapor that the air can hold at the same temperature. The level of ambient humidity directly affects the amount of water vapor in the air entering the compressor, so it is crucial to control the dew point of the compressed air in the air compressor station. In a high humidity environment, the condensation of water vapor during the compression process is more significant, and the dryer is required to perform more active drying treatment to ensure the quality of the compressed air.

[0069] Ambient temperature monitoring in controllers is accomplished through built-in or externally connected temperature sensors that provide accurate and continuous temperature data. These temperature sensors, usually in the form of thermocouples or thermistors, sense temperature changes in the surrounding environment and convert them into electrical signals. The controller receives these signals and converts them into digital readings for further processing. The selection and placement of temperature sensors take into account the accuracy of measurement and rapid response to environmental changes, ensuring that the control system can adjust operations to temperature changes in a timely and accurate manner.

[0070] Monitoring the humidity of the environment is also critical, using humidity sensors that measure the water vapor content in the air. These sensors generally use capacitive or resistive humidity sensing technology, which can convert changes in air humidity into changes in resistance or capacitance, and then into electrical signals. The controller calculates the relative humidity value of the environment based on these signals. Correct humidity data is essential to determine the working intensity of the dryer and regulate the removal of moisture from the compressed air.

[0071] In the intelligent control system, the controller measures these two parameters and combines the data from the dew point sensor to adjust the operating status of the dryer in real time. This adjustment ensures that the dew point temperature of the compressed air can be maintained within the ideal setting range regardless of changes in the external environment, thereby ensuring the quality of the compressed air and the efficient operation of the system. In this way, the system not only responds to instant changes in environmental conditions, but also optimizes energy consumption and operating costs, ensuring the overall economic benefits and reliability of the system.

[0072] The controller 102 is designed as a highly integrated electronic device, which integrates a variety of processing units and interfaces to support complex data processing and device control tasks. First, the controller includes one or more microprocessors or microcontrollers, which are the "brains" of the controller and are responsible for executing software programs that process input data through algorithms and generate output signals based on these data.

[0073] One of the main functions of the controller is to receive data from the dew point sensor. This data is transmitted via a wired or wireless connection, depending on the actual engineering requirements and system design. The software system within the controller monitors these data streams in real time to ensure the accuracy and real-time nature of the data. Once the dew point temperature data is received, the controller immediately begins to conduct a comprehensive analysis with other environmental data that may be obtained through other sensors connected to the controller, such as temperature and humidity sensors.

[0074] The control logic of the controller 102 is implemented by preset algorithms, which are designed based on physical and engineering principles to ensure optimal control under various operating conditions. The algorithm will consider how to adjust the operation of the dryer based on the dew point temperature and other environmental and operating parameters, such as adjusting the opening degree of the dryer inlet ball valve to control the inlet flow. These control signals are sent through the output interface of the controller and can be electrical signals or other forms of control commands, depending on the interface design of the dryer.

[0075] In order to enable operators to easily manage and monitor the system status, the controller 102 is usually equipped with a user interface. This interface may include a display screen, buttons, a touch screen or other input devices, allowing users to intuitively view system information, such as the current dew point temperature, environmental conditions and dryer status. The interface also allows users to manually input or adjust control parameters, providing flexibility in system operation and the possibility of manual intervention.

[0076] The controller is also designed with ease of maintenance and system safety in mind. It is equipped with self-diagnostic features that monitor and report system failures or performance degradation. In addition, to ensure safe operation, the controller implements a variety of safety measures, including electrical isolation, data encryption, and physical security mechanisms.

[0077] Furthermore, the controller calculates the optimal opening degree of the cold dryer inlet ball valve through a mathematical model; wherein the mathematical model is expressed by the following formula 1:

[0078]

[0079] in, It is the adjustment amount of the opening of the inlet ball valve of the cold dryer; is the dew point temperature detected by the dew point sensor; is the set target dew point temperature; is the ambient temperature; is the ambient humidity; It is the compressor output pressure data; , , , and is the adjustment coefficient; is the environmental adaptability dew point adjustment function, which is implemented using the following formula 2:

[0080]

[0081] in, , , and is the adjustment parameter;

[0082] is the pressure response function, which is implemented using the following formula 3:

[0083]

[0084] in, , , and is a tuning parameter.

[0085] In the intelligent control system of the air compressor station based on the dew point sensor, the controller uses a mathematical model to calculate and optimize the opening degree of the inlet ball valve of the cold dryer. The mathematical model combines multiple variables and parameters to ensure that the dew point temperature of the compressed air is accurately controlled to meet the optimization of system efficiency and energy utilization. The mathematical model is explained below.

[0086] Formula 1:

[0087]

[0088] This formula provides the controller with the calculation of the opening adjustment of the cold dryer inlet ball valve. method to ensure the accuracy and responsiveness of dew point temperature control.

[0089] : Indicates the adjustment amount of the opening degree of the cold dryer inlet ball valve.

[0090] : Dew point temperature detected in real time by the dew point sensor.

[0091] : The set target dew point temperature, which is the dew point temperature standard that the system needs to achieve.

[0092] : Ambient temperature, which affects the dew point temperature and the processing efficiency of compressed air.

[0093] : Ambient humidity directly affects the moisture content in compressed air.

[0094] : The pressure data output by the compressor affects the air flow and pressure balance of the system.

[0095] , , , and : Adjustment coefficients, which are set according to system design and operating experience and are used to adjust the weights of each item in the model to adapt to different operating conditions and environmental changes.

[0096] Formula 2:

[0097]

[0098] This is the environmental adaptability dew point adjustment function, which is used to adjust the operation of the dryer according to the current environmental conditions.

[0099] , , and : Adjustment parameters, which are set according to system design and operating experience, and are used to adjust the impact of temperature difference, ambient temperature and ambient humidity on dew point control.

[0100] Formula 3:

[0101]

[0102] This is the pressure response function that takes into account the combined effects of pressure, temperature, and humidity on the overall performance of the system.

[0103] , , and : Adjustment parameters, which are set based on system design and operating experience and are used to adjust the response of the ball valve based on pressure and environmental factors.

[0104] In order to implement this mathematical model, the software in the controller needs to collect and process the data from the dew point sensor, temperature and humidity sensor, and pressure sensor in real time. The imported ball valve used in the cold dryer can accurately control the amount of compressed air passing through the cold dryer by adjusting the opening degree of the ball valve, thereby ensuring that the dew point temperature of the compressed air is maintained within the set range.

[0105] In addition, the control system requires precise parameter adjustment and regular system calibration to maintain control accuracy and long-term stability of the system. , , , and The optimization and updating of equal adjustment coefficients ensure the adaptability and efficiency of the system in the face of environmental changes and different operating conditions.

[0106] Furthermore, the controller also includes a user interface, which has a graphical dashboard that displays the dew point temperature, ambient temperature, ambient humidity and compressor output pressure of the compressed air in real time, wherein each dashboard is configured with dynamic color coding, and the color change is automatically adjusted according to the degree of deviation of the real-time data relative to the preset threshold value to provide an intuitive system status warning.

[0107] In the dew point sensor-based air compressor station intelligent control system, the controller is equipped with a user interface designed to provide direct visual feedback on system operation and allow operators to monitor key system parameters. The core function of the user interface is to display the dew point temperature, ambient temperature, ambient humidity and compressor output pressure of the compressed air in real time, and display the data through a carefully designed graphical dashboard, so that operators can quickly and intuitively understand the current status of the system.

[0108] The user interface displays core monitoring data through graphical dashboards, each of which uses a dynamic color coding system. This design allows the color to automatically adjust according to the deviation of the monitoring data from the preset threshold, allowing operators to identify any abnormalities or deviations from the normal operating range at a glance. For example, if the dew point temperature exceeds the set safety range, the corresponding dashboard will change from green to red, immediately alerting the operator.

[0109] The user interface is designed with ease of use and intuitiveness in mind so that operators can effectively manage the compressor station without an in-depth technical background. The interface is usually operated via a touch screen or physical control buttons, ensuring easy use even under industrial operating conditions such as wearing gloves. Information displayed on the interface includes digital readouts and graphical displays such as curve graphs, bar graphs, and digital tables, all of which are designed to make data reading more intuitive.

[0110] The software inside the controller processes the data input from various sensors in real time and reflects the processing results instantly on the dashboard of the user interface. This real-time data processing ensures that the system responds quickly and can adjust operations in time to cope with any immediate changes. For example, if the ambient temperature suddenly rises and the system efficiency decreases, the user interface will display the temperature increase trend and warn the operator through color changes.

[0111] Color coding not only makes the interface beautiful, but also has practical monitoring and warning functions. The system presets multiple warning levels, which are graded according to the importance of the data and the degree of impact on the system. Color changes are not limited to red and green, but may also include yellow or other colors to indicate different levels of warnings.

[0112] The user interface design takes into account long-term maintenance and upgrade needs. The system design allows software updates via the network to introduce new features or improve existing features. In addition, maintenance of the interface usually includes regular checks on the functionality of the display and calibration of the touch screen sensitivity to ensure accuracy and responsiveness of operation.

[0113] By providing this user interface design, the air compressor station intelligent control system provides an efficient, intuitive and user-friendly operating platform, making the daily operation and monitoring of the system simple and efficient. Such a design not only optimizes the operator's workflow, but also greatly enhances the safety and reliability of the system, providing strong technical support for the management and maintenance of the air compressor station.

[0114] Furthermore, the user interface of the controller includes an interactive control module that allows the user to adjust the mathematical model through intuitive drag and drop operations. , , , and Parameters; after the user adjusts the parameters, the interface immediately displays a predicted effect diagram after the parameter adjustment, so that the user can optimize the system settings according to the expected operation results.

[0115] In the dew point sensor-based air compressor station intelligent control system, the controller is equipped with a user interface, especially including an interactive control module. This module is the core part of the well-designed user interface, which allows operators to adjust the key adjustment coefficients in the control system in real time through intuitive operations such as drag and drop. , , , and This design not only improves the flexibility of user operations, but also enhances the adaptability and response efficiency of the system.

[0116] The main function of the interactive control module is to allow users to directly participate in the control logic of the system and adjust the parameters in the mathematical model through an intuitive user interface. , , , and , are the key coefficients used in the control model to refine the system response, which affect the model's adaptability to environmental changes, the response speed to pressure changes, the time integral factor, the combined influence of pressure and environmental factors, and the response to the humidity change rate.

[0117] The user can simply select and move the control sliders or graphical elements representing these coefficients on the interface by dragging and dropping. Each control element is tied to a specific coefficient, and each movement is instantly reflected in the preset adjustment of the system. This method of operation does not require complex programming or in-depth technical knowledge from the user, making system management more user-friendly, while also allowing faster real-time reactions and more precise control.

[0118] Once parameter adjustments are complete, the controller’s user interface immediately displays a prediction graph. This graph shows the expected operational results, such as predicted dew point temperature changes, system energy efficiency improvements, or potential operational issues, based on the current system status and the newly adjusted parameters. This enables operators to evaluate the potential impact of these adjustments before actually applying the changes.

[0119] Through real-time effect prediction graphs, users can more accurately understand the specific impact of each parameter adjustment on system performance. This not only helps operators optimize system settings to achieve optimal operating efficiency, but also helps identify and avoid possible operating errors or undesirable system responses. For example, if the prediction graph shows that extreme adjustments to a parameter may lead to reduced system efficiency or excessive energy consumption, operators can make immediate adjustments to find the best balance point.

[0120] Through this interactive control module, the operation of the air compressor station intelligent control system becomes more intuitive and efficient, greatly improving the user's operating experience and the overall performance of the system. In addition, the design of this module also takes into account ease of use and accessibility, ensuring that a variety of technicians can effectively manage and optimize the operation of the air compressor station.

[0121] Furthermore, the air compressor station intelligent control system also includes a remote control module, which is used to receive control instructions from a remote terminal to achieve remote monitoring and operation of the air compressor station.

[0122] In the dew point sensor-based air compressor station intelligent control system, a key feature is the integration of the remote control module. This module expands the system's functionality, allowing operators and managers to monitor and control the air compressor station through remote terminal devices without being restricted by geographical location. This capability not only improves operational flexibility, but also increases the efficiency and response speed of system management.

[0123] The core function of the remote control module is to enable remote access and control of the compressor station operation. This includes sending control commands from the remote terminal to the compressor station's control system and receiving real-time feedback from the control system. In this way, the remote user can perform a variety of operations, such as starting or stopping the compressor, adjusting the settings of the dryer, monitoring the operating status of the system, and modifying the parameters of the dew point control.

[0124] The remote control module communicates with the remote terminal through a secure network connection. This usually involves the use of a VPN (virtual private network) or other encrypted communication protocols to ensure the security and reliability of data transmission. The operator issues instructions through a dedicated application or web interface on the remote terminal - such as a smartphone, tablet or laptop, and these instructions are securely transmitted to the control system of the air compressor station.

[0125] The user interface design of remote control focuses on user experience, ensuring that even non-professionals can easily understand and operate it. The interface usually includes an intuitive graphical user interface that displays key operating data and control buttons. In addition, the interface provides real-time data updates, system warnings, and operation history, which are presented through data visualization technology to enhance the readability of information and the intuitiveness of operation.

[0126] When remote control commands are sent to the compressor station's control system, the built-in processing software verifies the validity and safety of the commands and then executes them. This process includes command decoding, parameter verification, safety checks before execution, and final control execution. The system is designed to ensure that all operations are correctly processed and confirmed even when the network connection is unstable.

[0127] The remote control module is designed with security in mind. In addition to using encrypted communication protocols, multiple authentication and access control mechanisms are implemented to prevent unauthorized access and manipulation. In addition, all remote operations are recorded in the system's security log for easy review and tracking.

[0128] By implementing such a remote control module, the intelligent control system of the air compressor station can not only provide efficient and flexible operation methods, but also significantly improve the system's operating efficiency and safety management level through real-time data access and remote monitoring functions. This modern remote operation function ensures that even in a complex and demand-changing industrial environment, the system's maintenance and management can maintain the highest standards.

[0129] Furthermore, the controller optimizes and adjusts the inlet flow of the cold dryer according to historical operation data and a load prediction model to improve the operation efficiency and energy saving effect of the air compression station.

[0130] In the intelligent control system of the air compressor station based on the dew point sensor, the controller has advanced functions that can use historical operating data and load forecasting models to optimize the regulation of the inlet flow of the cold dryer. The integration of this function enables the system to not only respond to the current operating conditions in real time, but also adjust the settings in advance by analyzing historical data and predicting future operating loads, thereby significantly improving the energy efficiency and operating efficiency of the air compressor station.

[0131] The controller collects and analyzes historical operating data of the air compressor station to understand the performance and operating mode of the equipment. This includes data such as the energy consumption of the refrigerated dryer, inlet flow, outlet temperature and pressure, and environmental conditions such as temperature and humidity. This historical data provides the controller with rich information to help identify efficiency bottlenecks and potential energy-saving points in operation.

[0132] The load forecasting model is implemented through an advanced algorithm that is able to predict the operating load of the air compressor station based on historical data and factors that may affect future operations, such as seasonal changes, industrial activity cycles, and predicted environmental changes. This prediction enables the controller to pre-adjust the inlet flow of the dryer to adapt to the predicted load changes, thereby avoiding excessive energy consumption or failure to meet the compressed air demand during peak demand.

[0133] The controller adjusts the dryer inlet flow settings based on information obtained from the load forecast model. For example, if the model predicts that demand will increase in the next few hours, the controller will increase the dryer flow in advance to ensure sufficient compressed air processing capacity; conversely, if the forecast demand decreases, the controller will reduce the flow to reduce energy consumption. This optimization adjustment is not only based on instant readings, but also combines long-term data and trend analysis to make control decisions more accurate and forward-looking.

[0134] Through this intelligent flow control, the air compressor station can significantly improve energy efficiency without sacrificing performance. The energy saving effect is not only reflected in the power consumption, but also in the reduction of maintenance costs, because the optimized operation of the system reduces the wear and failure rate of equipment. In addition, by reducing unnecessary energy consumption, the overall operating efficiency of the air compressor station is improved, further reducing operating costs and environmental impact.

[0135] By combining historical operating data with a load forecasting model to control the flow of the cold dryer, this intelligent control system not only improves operational efficiency but also demonstrates the potential for sustainable development through technological innovation in modern industrial applications.

[0136] Furthermore, the controller is specifically used for:

[0137] Based on the following formula 4, the predicted load is calculated :

[0138]

[0139] in, It was before Load data at each moment; are model coefficients, learned from historical data; is the error term;

[0140] According to the following formula 5, calculate the optimal inlet flow rate of the cold dryer :

[0141]

[0142] in, and is the regulation function; This is achieved using the following formula 6:

[0143]

[0144] in, and is a preset constant; It is the historical load data for a period of time in the past The variance of

[0145] This is achieved using the following formula 7:

[0146]

[0147] in, and is a preset constant; It is the historical load data for a period of time in the past The standard deviation of

[0148] According to the following formula 8, calculate the inlet flow rate of the cold dryer :

[0149]

[0150] in, is the load change ; Represents the difference feedback between the predicted load and the actual load; , and is the adjustment coefficient.

[0151] In the intelligent control system of the air compressor station based on the dew point sensor, the controller uses a mathematical model to optimize the inlet flow of the cold dryer. This optimization is based on the accurate prediction and real-time adjustment of the system load. In this way, the system can improve operating efficiency and reduce energy consumption.

[0152] The controller first uses a model based on historical load data to predict the upcoming load. This prediction model is described by Equation 4:

[0153]

[0154] This formula is an autoregressive model where:

[0155] Indicates the current time The predicted load.

[0156] It is the current moment Before Historical load data.

[0157] It is the model coefficient obtained by learning historical data, which represents the influence weight of historical load data on current load prediction.

[0158] It is the error term, which represents the deviation between the predicted value and the actual value. It is usually caused by random factors and can be provided based on statistical data or experience.

[0159] Once the load is predicted, the controller uses the next formula to determine the optimal inlet flow of the dryer:

[0160]

[0161] in, is a regulation function that is dynamically adjusted according to the variance of historical load changes, given by Formula 6:

[0162]

[0163] here, and is a preset constant, Is the historical load data The variance of To reflect the impact of historical load fluctuations.

[0164] is a function adjusted based on the standard deviation of historical loads and is defined by Equation 7:

[0165]

[0166] in and is a constant, Is the historical load data The standard deviation of To adapt to load variability.

[0167] Finally, the actual import flow The adjustment is done by the following formula:

[0168]

[0169] in:

[0170] , is the change in load.

[0171] It is the difference feedback between predicted load and actual load, which is used to fine-tune the response of the controller and ensure the stability of the system.

[0172] , and It is an adjustment coefficient, which is set through system adjustment or experience to balance the impact of different control factors.

[0173] Through this mathematical model and regulation mechanism, the controller can control the operation of the refrigerated dryer very accurately, ensuring that the air compression station can achieve optimal energy efficiency and performance under various operating conditions.

[0174] The cold dryer 103 is used to adjust the opening degree of the cold dryer inlet ball valve according to the received control signal to adjust the cold dryer inlet flow rate so that the dew point temperature of the compressed air is maintained within a specified range.

[0175] The cold dryer 103 plays a key role in the intelligent control system of the air compressor station based on the dew point sensor. It is the component in the system that directly responds to the control signal to adjust the operating parameters to maintain the dew point temperature of the compressed air within the optimized range. By receiving the signal from the controller 102, the cold dryer adjusts the opening degree of the inlet ball valve to accurately control the flow of compressed air into the cold dryer, thereby effectively managing the drying process and dew point temperature of the compressed air.

[0176] The main function of the refrigerated dryer 103 is to remove water vapor from the compressed air by cooling it, thereby preventing the water vapor from condensing in the compressed air system. The equipment condenses the water vapor into liquid water by lowering the air temperature to below its dew point, and then removes it through a separation system. This process is essential to protect the pipes and other components of the compressed air system from corrosion and damage, especially in applications that require high-quality compressed air.

[0177] The dryer 103 is equipped with a highly sensitive control system designed to receive and accurately respond to signals from the controller 102. These control signals include the degree of opening of the dryer inlet ball valve that needs to be adjusted, which directly affects the amount of compressed air processed by the dryer. Based on the instructions of the control signal, the dryer can adjust the degree of opening of the ball valve to increase or decrease the amount of air flowing through the dryer to optimize the dew point temperature of the air.

[0178] The inlet ball valve of the cold dryer is a key mechanical component responsible for regulating the flow of compressed air entering the cold dryer. The design of the ball valve allows it to accurately adjust the opening angle when receiving a control signal, thereby controlling the flow rate and flow of the compressed air. By adjusting these parameters, the cold dryer can more effectively control the cooling degree of the compressed air and ensure that the air reaches the appropriate dew point temperature when passing through the cold dryer.

[0179] The technical implementation of the refrigerated dryer includes advanced mechanical and electronic systems that enable it to reliably perform complex control tasks. These systems include, but are not limited to, automated electronic control units, sophisticated flow control devices, and efficient cooling systems. In addition, the design of the refrigerated dryer takes into account the need for easy maintenance and long-term operation, and its components and structure are designed to facilitate and quickly carry out routine inspections, cleaning, and necessary repairs.

[0180] In terms of system integration, the refrigerated dryer 103 works closely with other components of the air compression station, such as the compressor and piping system, to ensure the quality and safety of compressed air throughout the system. The refrigerated dryer is also equipped with various safety measures, such as overload protection, temperature monitoring and automatic fault diagnosis, to prevent and respond to potential operating problems.

[0181] Furthermore, the air compression station intelligent control system also includes a waste heat recovery unit, which recovers and converts the heat discharged by the air compressor and the cold dryer through a heat exchanger controlled by the controller.

[0182] In the intelligent control system of air compressor station based on dew point sensor, a component - waste heat recovery unit is introduced. This unit is the key technology to improve system efficiency. It significantly improves the energy utilization rate and the environmental sustainability of the overall system by recovering and utilizing the heat energy generated by air compressor and cold dryer during operation.

[0183] The waste heat recovery unit includes a heat exchanger that is specially designed to capture and convert the heat emitted by air compressors and refrigerated dryers during the compression and cooling process. During the air compression process, the temperature of the gas increases significantly as it is compressed, generating a large amount of heat energy. Similarly, refrigerated dryers also emit heat during the dehumidification process. Traditionally, this heat is often regarded as waste heat and is not effectively used, resulting in energy waste.

[0184] The waste heat recovery unit captures and converts this waste heat into usable energy through its built-in high-efficiency heat exchanger. The heat exchanger is designed with high thermal conductivity materials and has excellent heat transfer efficiency, which can quickly absorb heat from the exhaust gas of the compressor and the dryer. After that, this heat can be used to heat the factory, preheat the air entering the compressor or other industrial processes, thereby reducing the demand for external energy and optimizing energy consumption.

[0185] The controller plays a vital role in the waste heat recovery unit. It is responsible for monitoring not only the dew point sensor, ambient temperature and humidity data, but also the efficiency of the heat exchanger and the exhaust temperature in real time. Based on this data, the controller automatically adjusts the operating parameters of the heat exchanger, such as adjusting the flow rate of the heat exchange medium or changing the exposure of the heat exchange surface, to maximize the heat recovery efficiency.

[0186] In addition, the controller can dynamically optimize the waste heat recovery strategy based on the compressed air usage demand and external environmental conditions. For example, when the external temperature is low, the controller can increase heat recovery for heating, while when the heat demand is low, the controller will reduce heat recovery to maintain the overall energy efficiency of the system.

[0187] Waste heat recovery units are designed for low maintenance and high durability, but regular inspection and maintenance are key to ensuring their long-term effective operation. Operators need to regularly check the cleanliness of the heat exchanger and the integrity of the piping to ensure there is no risk of heat loss. At the same time, the controller's software may also need to be updated to adapt to new energy efficiency standards or operational requirements.

[0188] By adding a waste heat recovery unit to the intelligent control system of the air compressor station, it not only improves energy efficiency, but also helps reduce operating costs and environmental impact. The implementation of this system provides an effective way to save energy and reduce emissions for industrial applications, and also demonstrates the great potential of integrating intelligent control and energy recovery technology in modern industrial systems.

[0189] Furthermore, the air compressor station intelligent control system also includes a digital monitoring subsystem, which is used to collect, store and display air compressor station operation data, wherein the air compressor station operation data includes pressure, flow, temperature and energy consumption.

[0190] An advanced digital monitoring subsystem is introduced into the intelligent control system of the air compressor station based on the dew point sensor. This subsystem is the information and data hub of the entire control system, responsible for collecting, storing and displaying key operating data of the air compressor station, including pressure, flow, temperature and energy consumption. By monitoring these parameters in real time, the subsystem not only enhances the operational efficiency and transparency of the air compressor station, but also improves the overall safety and reliability of the system.

[0191] The main function of the digital monitoring subsystem is to collect operating data from various key points of the air compressor station. This includes pressure and flow data from the compressor outlet, temperature readings from the cold dryer and other processing equipment, and energy consumption data for the entire system. This data is collected in real time through sensors installed on various key components. Sensor types include pressure sensors, flow meters, temperature sensors, and energy metering devices.

[0192] The collected data is transmitted to the server or controller in the control center via a wired or wireless network. During the data transmission process, advanced data encryption and security protocols are applied to ensure the security of the data and prevent any unauthorized access. Once these real-time data are transmitted and received, they are further processed for monitoring and control decisions.

[0193] In the control center, the digital monitoring subsystem uses powerful data processing software to analyze and process the collected data. The software can organize, analyze and visualize the data, allowing operators to intuitively view operating data in the form of charts, trend lines and real-time dashboards. This information is crucial for discovering potential problems, optimizing operating parameters and predicting maintenance needs in advance.

[0194] All collected data is stored in a secure data warehouse, which allows long-term storage and data traceability. Data storage solutions typically include highly reliable servers and database systems that are configured with data backup and recovery mechanisms to prevent data loss or system failure. This allows the operations team to review historical data, analyze long-term trends and performance fluctuations, and optimize operations and reduce energy consumption.

[0195] The digital monitoring subsystem is also designed with user-friendliness and ease of maintenance in mind. The system’s user interface (UI) is simple and intuitive, supporting multiple languages ​​and operating habits, ensuring that operators with different technical backgrounds can easily manage it. The system also provides automatic fault diagnosis and alarm functions, which can help operators quickly respond to any abnormalities and minimize downtime.

[0196] By implementing this digital monitoring subsystem, the management of the air compressor station becomes more efficient and scientific. Operators can obtain comprehensive data support and make more accurate decisions, ultimately improving the economy and reliability of the system.

[0197] Although the present application is disclosed as above in the form of a preferred embodiment, it is not intended to limit the present application. Any technical personnel in this field may make possible changes and modifications without departing from the spirit and scope of the present application. Therefore, the scope of protection of the present application shall be based on the scope defined by the claims of the present application.

Claims

1. An intelligent control system for an air compressor station based on a dew point sensor, characterized in that: include: Dew point sensor, used to detect the dew point temperature of compressed air and send the detection result to the controller; A controller, used for generating a control signal according to the ambient temperature, ambient humidity, output pressure of the air compressor and the dew point temperature sent by the dew point sensor; and sending the generated control signal to the cold dryer; The cold dryer is used to adjust the opening degree of the cold dryer inlet ball valve according to the received control signal to adjust the cold dryer inlet flow rate so that the dew point temperature of the compressed air is maintained within the specified range; The controller calculates the optimal opening degree of the cold dryer inlet ball valve through a mathematical model; wherein the mathematical model is expressed by the following formula (1): Among them, ΔQ is the adjustment amount of the opening of the cold dryer inlet ball valve; T d is the dew point temperature detected by the dew point sensor; T d,set is the target dew point temperature; θ is the ambient temperature; H is the ambient humidity; P is the compressor output pressure data; α, β, γ, δ and ∈ are adjustment coefficients; f(T d ,T d,set ,θ,H) is the environmental adaptability dew point adjustment function, which is implemented using the following formula (2): Among them, a1, a2, a3 and b1 are adjustment parameters; g(P,θ,H) is the pressure response function, which is implemented using the following formula (3): g(P,θ,H)=c1·P+c2·θ 2 +c3·sin(b2H) (3) Among them, c1, c2, c3 and b2 are adjustment parameters.

2. The intelligent control system for air compression station according to claim 1 is characterized in that: It also includes a waste heat recovery unit, which recovers and converts the heat discharged by the air compressor and the cold dryer through a heat exchanger controlled by the controller.

3. The intelligent control system for air compression station according to claim 1 is characterized in that: It also includes a digital monitoring subsystem, which is used to collect, store and display air compression station operation data, wherein the air compression station operation data includes pressure, flow, temperature and energy consumption.

4. The intelligent control system for air compression station according to claim 1 is characterized in that: The controller also includes a user interface having a graphical dashboard that displays the dew point temperature, ambient temperature, ambient humidity and compressor output pressure of the compressed air in real time, wherein each dashboard is configured with dynamic color coding, and the color change is automatically adjusted according to the degree of deviation of the real-time data relative to a preset threshold value to provide an intuitive system status warning.

5. The intelligent control system for air compression station according to claim 1 is characterized in that: The user interface of the controller includes an interactive control module, which allows the user to adjust the α, β, γ, δ and ∈ parameters in the mathematical model through intuitive drag and drop operations; after the user adjusts the parameters, the interface instantly displays a prediction diagram of the effect after the parameter adjustment, so that the user can optimize the system settings according to the expected operation results.

6. The intelligent control system for air compression station according to claim 1 is characterized in that: It also includes a remote control module, which is used to receive control instructions from a remote terminal to achieve remote monitoring and operation of the air compressor station.

7. The intelligent control system for air compression station according to claim 1 is characterized in that: The controller optimizes and adjusts the inlet flow of the cold dryer according to historical operation data and a load prediction model to improve the operation efficiency and energy-saving effect of the air compression station.

8. The intelligent control system for air compression station according to claim 7 is characterized in that: The controller is specifically used for: Based on the following formula (4), the predicted load L(t) is calculated: Where L(t–i) is the load data at the i-th moment before the current moment t; w i is the model coefficient, learned from historical data; e(t) is the error term; According to the following formula (5), the optimal inlet flow rate Q of the cold dryer is calculated: opt (t): Q opt (t)=k(t)·L(t)+m(t) (5) Among them, k(t) and m(t) are adjustment functions; k(t) is implemented using the following formula (6): Among them, k0 and λ are preset constants; Var(L hist (t)) is the historical load data L in the past period of time hist The variance of (t); m(t) is realized using the following formula (7): m(t)=m0+ξ·Std (L his (t)) (7) Where m0 and ξ are preset constants; Std(L hist (t)) is the historical load data L in the past period of time his (t) standard deviation; According to the following formula (8), calculate the inlet flow rate Q(t) of the cold dryer: Q(t)=α1·Q opt (t)+α2·ΔL(t)+α3·R(t) (8) Among them, ΔL(t) is the load change L(t)–L(t–1), where L(t–1) is the load data at the first moment before the current moment t; R(t) represents the difference feedback between the predicted load and the actual load; α1, α2, and α3 are adjustment coefficients.

9. The intelligent control system for air compression station according to claim 1 is characterized in that: The dew point sensor is a high-precision dew point sensor.

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