Real-time monitoring method and device for Compair compressor

Abstract

The invention discloses a real-time monitoring method and device for a Compair air compressor, and relates to the technical field of air compressor control. The real-time monitoring method comprises the steps that a monitoring signal of the air compressor is received; the received monitoring signals are transmitted to a central monitoring system through a remote communication system; according to the received temperature and pressure signals, air compressor protection parameters are calculated; judging the operation state of the air compressor based on the calculation result; and a control instruction is sent to the air compressor according to the monitoring result. According to the real-time monitoring method for the Compair compressor, all the protection parameters and the change trend of the protection parameters are comprehensively analyzed, potential faults can be found in time before the air compressor is abnormal, unnecessary shutdown caused by equipment misoperation or faults is avoided, and production continuity and stability are improved. The central monitoring system can provide historical data trend analysis and help maintainers to accurately position a fault source, so that the efficiency of fault maintenance is improved, and the downtime is shortened.

Description

Technical Field

[0001] The invention relates to the technical field of air compressor control, and in particular to a real-time monitoring method and device for a Compair air compressor. Background Art

[0002] In the traditional Compair air compressor monitoring system, temperature measurement points (such as motor winding and motor bearing temperature) are only displayed by the temperature controller of the on-site control cabinet and participate in the control of the air compressor. Once the temperature exceeds the set value, the air compressor will trigger the trip protection. However, due to the poor stability of the secondary instrumentation in the existing system, the air compressor often trips by mistake, affecting the normal operation of the air compressor. At the same time, the existing on-site control system can only display the high temperature alarm, and cannot accurately find the cause of the fault, which brings great difficulties to the maintenance personnel and cannot effectively support fault diagnosis and maintenance work. Therefore, the equipment fault handling efficiency of the air compressor is low, resulting in unstable operation of the unit.

[0003] In addition, the traditional monitoring system can only provide real-time temperature signals, but cannot fully monitor the various operating parameters of the air compressor. This single monitoring method makes the system unable to fully reflect the actual operating status of the air compressor, and it is easy to miss other risk factors that may cause failures, such as abnormal changes in parameters such as pressure, vibration, and current, thus affecting the safety and long-term stable operation of the equipment. Summary of the invention

[0004] In view of the above-mentioned problems, the present invention is proposed.

[0005] Therefore, the technical problems solved by the present invention are: first, since the monitoring signal is limited to that provided by the on-site instrument, the timeliness of data transmission and monitoring is poor, and it is impossible to provide real-time comprehensive fault analysis. Secondly, a single alarm mechanism cannot cope with complex equipment failures, and often cannot accurately judge the operating status of the air compressor, which easily leads to problems such as false alarms and wrong shutdowns. Furthermore, fault detection and positioning rely on manual inspections, and automation and remote monitoring cannot be achieved, resulting in maintenance personnel being unable to respond quickly, delaying maintenance work. Finally, due to the lack of long-term recording and analysis of equipment operation data, traditional systems are unable to achieve comprehensive monitoring and trend prediction of the air compressor status, nor can they provide an early warning mechanism before a failure occurs, thereby failing to effectively reduce the failure rate and downtime of the equipment.

[0006] In order to solve the above technical problems, the present invention provides the following technical solutions: a real-time monitoring method of a Compair air compressor, comprising:

[0007] Receive monitoring signals from air compressors;

[0008] Transmitting the received monitoring signals to the central monitoring system via the remote communication system;

[0009] Calculate the air compressor protection parameters based on the received temperature and pressure signals;

[0010] Display the operating status and protection parameters of the air compressor in the central monitoring system;

[0011] Determine the operating status of the air compressor based on the calculation results;

[0012] Send control instructions to the air compressor based on the monitoring results.

[0013] As a preferred solution of the real-time monitoring method of the Compair air compressor described in the present invention, wherein: the monitoring signal includes a temperature signal, a pressure signal, a vibration signal, a current signal and a speed signal;

[0014] The signal is acquired in real time through sensors installed at key locations of the air compressor.

[0015] As a preferred solution of the real-time monitoring method of the Compair air compressor of the present invention, wherein: the calculating of the air compressor protection parameter includes calculating the overheat protection parameter of the air compressor based on the received temperature signal, and comparing the protection parameter with the set overheat protection threshold;

[0016] Based on the received pressure signal, a low-pressure protection parameter of the air compressor is calculated, and the protection parameter is compared with a set low-pressure protection threshold;

[0017] Based on the received current signal, an overload protection parameter of the air compressor is calculated, and the protection parameter is compared with a set overload protection threshold;

[0018] Based on the air compressor speed signal, determine whether the air compressor speed is abnormal.

[0019] As a preferred solution of the real-time monitoring method of the Compair air compressor of the present invention, wherein: the judging of the operating state of the air compressor includes judging whether the calculated protection parameter exceeds the set threshold value;

[0020] If any protection parameter exceeds the set threshold, it is judged that the air compressor is in abnormal operation state, and a shutdown command is issued to the air compressor or a command to start the standby air compressor is issued;

[0021] If the air compressor is in normal working condition, continue to monitor the operation of the air compressor to ensure that the air compressor operates within a safe range;

[0022] Send alarm information to the DCS system and trigger corresponding maintenance or repair operations.

[0023] As a preferred solution of the real-time monitoring method of the Compair air compressor of the present invention, wherein: the issuing of a control instruction to the air compressor includes issuing an emergency stop instruction to shut down the power supply of the air compressor if the protection parameter of the air compressor exceeds a set threshold value;

[0024] If the outlet pressure of the air compressor is lower than the set value, the standby air compressor will be automatically started and a start command will be sent to the control system;

[0025] If the vibration signal of the air compressor is abnormal, it will trigger equipment inspection and automatically slow down and stop to prevent equipment damage.

[0026] As a preferred solution of the real-time monitoring method of the Compair air compressor described in the present invention, the control instructions of the air compressor are generated by the central monitoring system through the real-time transmitted monitoring data, and the monitoring signals are collected according to the set time intervals.

[0027] As a preferred solution of the real-time monitoring method of the Compair air compressor of the present invention, if the outlet pressure of the air compressor is lower than 0.6MPa, it is determined whether to issue a start instruction according to preset conditions, including:

[0028] If the air compressor is in standby mode and no other air compressor is running, a start command is automatically issued;

[0029] If the air compressor is in standby mode and no other air compressor starts within 6 seconds, issue the start command again;

[0030] If there is air compressor load and the outlet pressure is still lower than 0.6MPa, an emergency start command is issued and the start status is confirmed through the control system.

[0031] Another object of the present invention is to provide a real-time monitoring device for a Compair air compressor, which can solve the problems of false alarms and missed detections caused by a single monitoring parameter in the existing air compressor monitoring system by constructing a real-time monitoring device for the air compressor.

[0032] In order to solve the above technical problems, the present invention provides the following technical solutions: A real-time monitoring device for a Compair air compressor, comprising: a data acquisition module for receiving monitoring signals of the air compressor; a data transmission module for transmitting the received monitoring signals to a central monitoring system through a remote communication system; a parameter calculation module for calculating the protection parameters of the air compressor according to the received temperature and pressure signals; a parameter display module for displaying the operating status and protection parameters of the air compressor in the central monitoring system; a status judgment module for judging the operating status of the air compressor based on the calculation results. An instruction control module for issuing control instructions to the air compressor according to the monitoring results. A computer device, comprising a memory and a processor, wherein the memory stores a computer program, and when the processor executes the computer program, the steps of the real-time monitoring method for a Compair air compressor as described above are implemented.

[0033] A computer-readable storage medium stores a computer program, which, when executed by a processor, implements the steps of the real-time monitoring method for a Compair air compressor as described above.

[0034] Beneficial effects of the present invention: The real-time monitoring method of the Compair air compressor provided by the present invention can detect potential faults in time before the air compressor becomes abnormal by comprehensively analyzing various protection parameters and their changing trends, thereby avoiding unnecessary shutdowns due to equipment misoperation or failures and improving the continuity and stability of production. The central monitoring system can provide historical data trend analysis to help maintenance personnel accurately locate the source of the fault, thereby improving the efficiency of fault repair and reducing downtime. By optimizing the issuance of control instructions, the standby air compressor can be automatically started or other emergency measures can be taken according to actual conditions, ensuring the high availability and safety of the air compressor system. At the same time, the implementation of remote monitoring reduces the operating burden of the staff, improves the level of automated management of equipment, reduces the frequency of manual inspections, and thereby improves the level of automation and informatization of the entire production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0036] Figure 1 An overall flow chart of a real-time monitoring method for a Compair air compressor provided by one embodiment of the present invention.

[0037] Figure 2A conventional air compressor control flow chart of a real-time monitoring method for a Compair air compressor provided by one embodiment of the present invention.

[0038] Figure 3 An overall structural diagram of a real-time monitoring device for a Compair air compressor provided in one embodiment of the present invention. DETAILED DESCRIPTION

[0039] In order to make the above-mentioned purposes, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the drawings of the specification. Obviously, the described embodiments are part of the embodiments of the present invention, but not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary persons in the art without creative work should fall within the scope of protection of the present invention.

[0040] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0041] Example 1

[0042] Reference Figure 1-Figure 2 , as an embodiment of the present invention, provides a real-time monitoring method for a Compair air compressor, comprising:

[0043] Receive monitoring signals from air compressors;

[0044] Transmitting the received monitoring signals to the central monitoring system via the remote communication system;

[0045] Calculate the air compressor protection parameters based on the received temperature and pressure signals;

[0046] Display the operating status and protection parameters of the air compressor in the central monitoring system;

[0047] Determine the operating status of the air compressor based on the calculation results;

[0048] Send control instructions to the air compressor based on the monitoring results.

[0049] The monitoring signals include temperature signal, pressure signal, vibration signal, current signal and speed signal;

[0050] The signal is acquired in real time through sensors installed at key locations of the air compressor.

[0051] Specifically, the monitoring signals include temperature signals, pressure signals, vibration signals, current signals and speed signals, which are obtained in real time through sensors installed at key parts of the air compressor. The temperature signal is obtained by temperature sensors at the compressor cylinder, exhaust pipe and intake pipe, the pressure signal is obtained by pressure sensors at the intake and exhaust ports, the vibration signal is obtained by vibration sensors on rotating parts and bearings, the current signal is obtained by the motor current sensor, and the speed signal is obtained by the speed sensor.

[0052] Furthermore, high-precision sensors are used in various key parts of the air compressor to ensure the accuracy and real-time performance of signal acquisition. The temperature sensor uses a highly sensitive thermocouple sensor, and the pressure sensor uses a model with a sensor accuracy of ±0.1% FS to ensure the reliability of the system under different working conditions. The vibration signal is collected using a high-frequency vibration sensor, which improves the response speed to abnormal vibration through signal filtering and sampling.

[0053] Furthermore, all collected monitoring signals are transmitted to the central control system via the field bus, and the wireless communication module is used to upload the data to the remote monitoring system in real time. During the data transmission process, encryption and verification mechanisms are used to ensure the security and data integrity of the monitoring signals during transmission, avoiding monitoring failures caused by signal loss or mistransmission.

[0054] Calculating the air compressor protection parameter includes calculating an overheat protection parameter of the air compressor based on the received temperature signal, and comparing the protection parameter with a set overheat protection threshold;

[0055] Based on the received pressure signal, a low-pressure protection parameter of the air compressor is calculated, and the protection parameter is compared with a set low-pressure protection threshold;

[0056] Based on the received current signal, an overload protection parameter of the air compressor is calculated, and the protection parameter is compared with a set overload protection threshold;

[0057] Based on the air compressor speed signal, determine whether the air compressor speed is abnormal.

[0058] Specifically, when calculating the overheat protection parameters of the air compressor, based on the temperature signal, an algorithm is used to calculate the temperature change trend of each component, and a judgment is made based on the load of the air compressor. If the temperature exceeds the set threshold, the overheat protection mechanism is triggered. Based on the pressure signal, the low-pressure protection parameters of the air compressor are calculated. If the outlet pressure of the air compressor is lower than the set threshold, the standby air compressor is started to ensure stable air supply in the system.

[0059] Furthermore, the calculation of overheat protection parameters uses a thermal balance model, which accurately predicts the risk of temperature overrun by performing real-time analysis of temperature change trends under different working conditions. The calculation of low-pressure protection parameters is based on the workload and intake pressure of the air compressor, combined with historical operating data, to ensure that the protection mechanism can be judged and activated in a timely manner even when the compressor load changes significantly.

[0060] Furthermore, the current signal is used to calculate the overload protection parameters. By real-time monitoring of the motor current and combining the load conditions, it is possible to determine in real time whether an overload has occurred. When the current exceeds the set threshold, the system will automatically stop the air compressor and issue a fault alarm to avoid equipment damage due to overload operation.

[0061] Judging the operating status of the air compressor includes judging whether the calculated protection parameters exceed the set threshold value;

[0062] If any protection parameter exceeds the set threshold, it is judged that the air compressor is in abnormal operation state, and a shutdown command is issued to the air compressor or a command to start the standby air compressor is issued;

[0063] If the air compressor is in normal working condition, continue to monitor the operation of the air compressor to ensure that the air compressor operates within a safe range;

[0064] Send alarm information to the DCS system and trigger corresponding maintenance or repair operations.

[0065] First, based on the received temperature, pressure, current, speed signals, and calculated protection parameters such as overheating, low pressure, and overload, the operating status of the air compressor is analyzed in real time. The specific steps are as follows:

[0066] After receiving the monitoring signal, the monitoring data is smoothed by a time series analysis algorithm (such as the sliding average method or the weighted regression method), the fluctuation range of the current signal and the historical data is calculated, and the signal is judged to have abnormal fluctuations in combination with the set threshold. For example, if a protection parameter (such as temperature or current) deviates from the historical average value by more than the set fluctuation range, the signal is considered to have an abnormal trend and further enters the fault judgment stage.

[0067] Next, based on the calculation results of each protection parameter, a comprehensive analysis is performed using a multi-dimensional anomaly detection model. These models include autoencoders and decision trees. Specifically, the system uses the autoencoder to train historical data of the air compressor under normal working conditions, learn its characteristics, and form a low-dimensional compressed representation. When a real-time signal is received, the autoencoder calculates the reconstruction error of the signal. If the error exceeds the set threshold, it is determined to be an abnormal signal. In addition, the system uses a decision tree to analyze the combined characteristics of the signal, determine the relationship between different signals, and evaluate whether it conforms to known fault modes, such as overload, low voltage or overheating. If it matches, the fault mode is output and the fault type is determined.

[0068] Once an abnormality is detected through the multi-dimensional detection model, the system will continue to analyze the mutual influence between the various protection parameters to determine whether there is a risk of multiple failure modes overlapping. For example, if the temperature and current are abnormal at the same time, the air compressor is judged to be in a serious fault state, and the emergency response measures of the air compressor are determined according to the severity of the fault mode. These emergency response measures include: issuing an emergency shutdown command to cut off the power supply of the air compressor; if the system needs to ensure continuous operation, start the backup air compressor; send an alarm message to the DCS system to trigger the corresponding repair or maintenance process to ensure the safe and stable operation of the air compressor.

[0069] If the air compressor is judged to be operating normally, the system will continue routine monitoring and adjust the monitoring threshold in real time to adapt to changes in the environment or load. In particular, when the air compressor is in normal operation for a long time, the system will dynamically adjust the risk threshold according to the fluctuation trend of historical data, thereby optimizing the protection parameters, avoiding overly sensitive false alarms, and ensuring that the air compressor always operates within a safe range.

[0070] Sending control instructions to the air compressor includes issuing an emergency stop instruction to shut down the power supply of the air compressor if the protection parameter of the air compressor exceeds the set threshold;

[0071] If the outlet pressure of the air compressor is lower than the set value, the standby air compressor will be automatically started and a start command will be sent to the control system;

[0072] If the vibration signal of the air compressor is abnormal, it will trigger equipment inspection and automatically slow down and stop to prevent equipment damage.

[0073] Specifically, if the protection parameter of the air compressor exceeds the set threshold, the system will send an emergency stop command to the air compressor, disconnect the power supply, and stop the operation of the air compressor. If the outlet pressure of the air compressor is lower than the set value, the system will automatically start the backup air compressor and send a start command to the control system to ensure that the air compressor system will not experience air supply interruption.

[0074] Furthermore, when the system determines that the air compressor is operating abnormally, it not only relies on the set values ​​of the protection parameters, but also conducts a comprehensive assessment of the working status of the air compressor based on historical operating data and real-time environmental conditions. If a serious failure of the equipment is detected, the system will immediately perform an emergency shutdown operation and perform fault self-diagnosis within a preset time.

[0075] Furthermore, when the vibration signal of the air compressor is abnormal, the system will issue a deceleration and shutdown command according to the changes in vibration intensity and frequency, gradually reducing the air compressor speed to a safe range to avoid equipment damage caused by strong vibration. At the same time, the system will start the self-check function to check each key component of the air compressor, confirm the cause of the fault and provide timely feedback to the operator.

[0076] The control instructions of the air compressor are generated by the central monitoring system through the real-time transmission of monitoring data, and the monitoring signals are collected according to the set time intervals.

[0077] Specifically, the central monitoring system generates control instructions through real-time transmitted monitoring data and collects data according to the set sampling frequency. The system has a built-in intelligent algorithm to process the received sensor data and generate corresponding control instructions based on the operating status of the air compressor. The collection frequency can be dynamically adjusted according to the workload of the air compressor to ensure the real-time and accuracy of instruction generation.

[0078] Furthermore, during the data collection process, the central monitoring system not only considers the immediate operating status of the air compressor, but also considers external factors such as ambient temperature and humidity to ensure that the air compressor works in the best condition. The system will compare the current operating data and historical data of the air compressor in real time to evaluate whether the operating parameters need to be adjusted to ensure the safety and economy of the air compressor.

[0079] Furthermore, through intelligent control algorithms, the system can calculate the possible failure trend of the air compressor based on monitoring data and issue early warning signals. The system can also automatically generate maintenance instructions based on preset conditions to ensure that the air compressor is promptly inspected or maintained before a failure occurs, greatly improving the operating reliability of the equipment.

[0080] If the outlet pressure of the air compressor is lower than 0.6MPa, the system will determine whether to issue a start command based on the preset conditions, including:

[0081] If the air compressor is in standby mode and no other air compressor is running, a start command is automatically issued;

[0082] If the air compressor is in standby mode and no other air compressor starts within 6 seconds, issue the start command again;

[0083] If there is air compressor load and the outlet pressure is still lower than 0.6MPa, an emergency start command is issued and the start status is confirmed through the control system.

[0084] Specifically, when the outlet pressure of the air compressor is lower than the set value, the system will determine whether to issue a start command based on the preset conditions. If the air compressor is in standby mode and no other air compressor is running, the system will automatically issue a start command to start the standby air compressor. If the air compressor does not start within 6 seconds, the start command will be issued again to ensure that the equipment can resume normal operation as soon as possible.

[0085] Furthermore, when the air compressor is in standby mode and other air compressors have been started, the system will determine whether the standby air compressor needs to be started based on the change in outlet pressure. If the air compressor load is too large and the outlet pressure is lower than the set threshold, the system will trigger an emergency start command to start the standby air compressor and ensure stable air supply.

[0086] Furthermore, when the air compressor outlet pressure is lower than the set value and the system fails to start the standby air compressor within the scheduled time, the system will automatically diagnose the current working mode and adjust the control strategy. The system calculates the load changes in real time and determines whether the operation strategy needs to be adjusted based on the air compressor's working conditions and historical data to avoid the air compressor being in a non-working state for a long time.

[0087] Figure 2 For the air compressor control flow chart, all the temperature and pressure signals of the compressor are transmitted remotely, including the measuring point air compressor coil temperature, bearing temperature, host temperature, air compressor exhaust temperature and exhaust pressure. All the control signals and alarm signals of the air compressor are displayed and controlled by the host computer, including fan power failure alarm, emergency stop alarm, start command, stop command, load command, and unload command. All the control logic of the original local control panel is changed to remote control interlock protection, which saves the annual maintenance cost of the control panel. At the same time, the local control panel is changed to an electrical control circuit.

[0088] The first step: When the power switch K1 is closed, the contactor KM1 is energized and closed, and the normally closed contact of KM1-1 is disconnected. When the power switch K1 loses power, the normally closed contact of KM1-1 is closed, which will trigger the power failure alarm signal, and the alarm signal is sent to the DCS screen.

[0089] Step 2: When the DCS issues a start command, contactor KM2 is energized and closed, the normally open contact of KM2-1 is closed, and contactor KM5 is energized and closed. After the normally closed contact of contactor KM3 is electrified (which serves as an interlocking function), the normally open contact KM5-1 is closed to start the power supply fan (which serves as a self-locking function).

[0090] Step 3: When the KM2-2 contact is closed and the KM5-2 contact is closed, start the air compressor power supply command and send the start command to the electrical.

[0091] Step 4: When the DCS issues a stop command, the contactor KM3 is energized and closed, the normally open contact KM3-1 is closed, and a stop command is issued. The command is sent to the electrical system to stop the power supply of the air compressor. When the normally closed contact KM1-2 is closed, a stop command is also sent.

[0092] Step 5: When the emergency stop button of the air compressor is pressed locally, the KM3 switch is closed, the contactor KM4 is energized and closed, the normally open contact KM4-2 is closed, and an emergency stop signal is sent to the DCS. The normally open contact KM4-3 is closed, and an emergency stop signal is sent to the electrical system.

[0093] Step 6: When the load / unload instruction is issued, the contactor KM6 is energized and closed, the normally open contact KM6-1 is closed, the loading solenoid valve is activated, the normally open contact KM6-2 is closed, and the discharge solenoid valve is activated.

[0094] When the air compressor is under remote control, when the air compressor outlet pressure is lower than 0.7Mpa, DCS automatically issues a loading command; when the air compressor outlet pressure is higher than 0.82Mpa, DCS automatically issues an unloading command.

[0095] When the air compressor is put into standby 1, an automatic start command is issued when any air compressor trips or the outlet pressure is lower than 0.6MPa when any air compressor is loaded.

[0096] When the air compressor is put into standby 2, if there is no air compressor running or the outlet pressure is still lower than 0.6MPa 6 seconds after any air compressor trips, an automatic start command will be issued.

[0097] When the DCS receives a power failure alarm signal, the logic will automatically send a stop command to the air compressor.

[0098] Example 2

[0099] Reference Figure 3 , as one embodiment of the present invention, provides a real-time monitoring device for a Compair air compressor, comprising:

[0100] The data acquisition module 100 is used to receive the monitoring signal of the air compressor;

[0101] The data transmission module 200 is used to transmit the received monitoring signal to the central monitoring system via the remote communication system;

[0102] The parameter calculation module 300 is used to calculate the air compressor protection parameters according to the received temperature and pressure signals;

[0103] The parameter display module 400 is used to display the operating status and protection parameters of the air compressor in the central monitoring system;

[0104] A state judgment module 500 is used to judge the operating state of the air compressor based on the calculation result;

[0105] The command control module 600 is used to issue control commands to the air compressor according to the monitoring results.

[0106] Example 3

[0107] An embodiment of the present invention is different from the first two embodiments in that:

[0108] If the functions are implemented in the form of software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art or the part of the technical solution, can be embodied in the form of a software product. The computer software product is stored in a storage medium, including several instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the methods described in each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk, etc., which can store program codes.

[0109] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as an ordered list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by an instruction execution system, device or apparatus (such as a computer-based system, a system including a processor, or other system that can fetch instructions from an instruction execution system, device or apparatus and execute instructions), or in conjunction with such instruction execution systems, devices or apparatuses. For the purposes of this specification, "computer-readable medium" can be any device that can contain, store, communicate, propagate or transmit a program for use by an instruction execution system, device or apparatus, or in conjunction with such instruction execution systems, devices or apparatuses.

[0110] More specific examples of computer-readable media (a non-exhaustive list) include the following: an electrical connection with one or more wires (electronic device), a portable computer disk case (magnetic device), a random access memory (RAM), a read-only memory (ROM), an erasable and programmable read-only memory (EPROM or flash memory), an optical fiber device, and a portable compact disk read-only memory (CDROM). In addition, the computer-readable medium may even be a paper or other suitable medium on which the program is printed, since the program may be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, deciphering or, if necessary, processing in another suitable manner, and then stored in a computer memory.

[0111] It should be understood that the various parts of the present invention can be implemented by hardware, software, firmware or a combination thereof. In the above-mentioned embodiments, a plurality of steps or methods can be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, it can be implemented by any one of the following technologies known in the art or their combination: a discrete logic circuit having a logic gate circuit for implementing a logic function for a data signal, a dedicated integrated circuit having a suitable combination of logic gate circuits, a programmable gate array (PGA), a field programmable gate array (FPGA), etc.

[0112] Example 4

[0113] As an embodiment of the present invention, a real-time monitoring method for a Compair air compressor is provided. In order to verify the beneficial effects of the present invention, a scientific demonstration is carried out through simulation experiments.

[0114] The experiment was conducted at an industrial air compressor station, and the equipment used was a Compair C140 air compressor. The experiment was divided into two groups: a traditional method group and an inventive method group. The sensors used in the experiment can monitor key parameters such as temperature, pressure, current, vibration, and speed. The data acquisition frequency is once per second, and the monitoring is continuous for 24 hours.

[0115] In the traditional method, only the temperature control instrument of the field control cabinet is used to monitor the temperature of the air compressor, and the overheat protection threshold is set to 80°C. When the temperature exceeds this value, the system will trigger an alarm and trip. This method can only monitor the temperature and cannot determine the status of other parameters of the air compressor, which is easy to cause false alarms and shutdowns.

[0116] The method of the present invention integrates multiple sensors, including real-time acquisition of temperature, pressure, vibration, current and speed signals. The system analyzes various parameters in real time through the central monitoring platform and sets multiple protection thresholds: the temperature overheating protection threshold is 85°C, the standby unit is started when the pressure is lower than 0.6MPa, and the overload protection threshold is 120% of the rated current. When a protection parameter exceeds the set value, the system will automatically issue a command to shut down or start the standby air compressor and trigger an alarm.

[0117] In order to test the system's responsiveness, two fault conditions were introduced during the experiment: Pressure drop: simulating the situation where the pressure is too low (lower than 0.6MPa) during the operation of the air compressor. Current overload: simulating the situation where the current is overloaded (more than 120% of the rated current) when the air compressor is running under high load.

[0118] All data are collected in real time by sensors and recorded by data recorders. The performance difference between the traditional method and the method of the present invention is evaluated by comparing the reaction time, downtime, number of false alarms and other indicators after the fault occurs. The experimental results are shown in Table 1.

[0119] Table 1 Comparison of experimental results

[0120]

[0121]

[0122] First of all, traditional air compressor monitoring systems often monitor only through temperature signals, and trigger alarms or shutdowns based on temperature anomalies. However, air compressor failures are not solely caused by temperature anomalies. Abnormalities in other parameters such as pressure, current, vibration, etc. may also cause failures. Monitoring methods that rely solely on temperature signals are prone to incomplete fault diagnosis, resulting in equipment tripping, wrong shutdowns, or missed detection of other fault risks. In contrast, the present invention uses a multi-dimensional monitoring method, combined with multiple key parameters such as temperature, pressure, current, vibration, etc. for comprehensive analysis, fundamentally avoiding misdiagnosis caused by a single signal. Through real-time monitoring of multiple parameters, the technical solution can identify multiple fault risks in advance and issue early warnings in a timely manner, thereby effectively reducing false alarms and wrong shutdowns, and improving the operating reliability and stability of the air compressor.

[0123] Secondly, the traditional air compressor monitoring system relies on manual inspection and manual judgment, and the timeliness of fault diagnosis and maintenance decision-making is poor. Manual inspection is inefficient and easily affected by human factors, which may lead to delays in fault diagnosis and increase downtime. The present invention adopts an automated real-time monitoring system, which can automatically diagnose and judge faults according to changes in various monitoring parameters, and issue control instructions in a timely manner, such as automatic shutdown, activation of standby air compressors, etc. This improvement greatly improves the fault response speed and decision-making accuracy of the air compressor system, avoids errors in manual judgment, ensures that equipment failures can be handled quickly, significantly shortens downtime, and improves the safety and stability of equipment operation.

[0124] In addition, traditional monitoring systems are usually unable to provide long-term operation data recording and analysis of equipment, and lack an early warning mechanism for equipment trends. The present invention not only monitors the operating status of the equipment in real time, but also can predict potential equipment failures in advance through long-term recording and trend analysis of various types of data. This prediction mechanism can issue an early warning before equipment failure occurs, and perform maintenance or replace parts in a timely manner, further reducing the failure rate of the equipment and extending the service life of the air compressor.

[0125] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A real-time monitoring method for a Compair air compressor, characterized in that: include: Receive monitoring signals from air compressors; Transmitting the received monitoring signals to the central monitoring system via the remote communication system; Calculate the air compressor protection parameters based on the received temperature and pressure signals; Display the operating status and protection parameters of the air compressor in the central monitoring system; Determine the operating status of the air compressor based on the calculation results; Send control instructions to the air compressor based on the monitoring results.

2. The real-time monitoring method of Compair air compressor according to claim 1, characterized in that: The monitoring signals include temperature signals, pressure signals, vibration signals, current signals and rotation speed signals; The signal is acquired in real time through sensors installed at key locations of the air compressor.

3. The real-time monitoring method of Compair air compressor according to claim 2, characterized in that: The calculating of the air compressor protection parameter includes calculating an overheat protection parameter of the air compressor based on the received temperature signal, and comparing the protection parameter with a set overheat protection threshold; Based on the received pressure signal, a low-pressure protection parameter of the air compressor is calculated, and the protection parameter is compared with a set low-pressure protection threshold; Based on the received current signal, an overload protection parameter of the air compressor is calculated, and the protection parameter is compared with a set overload protection threshold; Based on the air compressor speed signal, determine whether the air compressor speed is abnormal.

4. The real-time monitoring method of Compair air compressor according to claim 3, characterized in that: The determining of the operating state of the air compressor includes determining whether the calculated protection parameter exceeds a set threshold value; If any protection parameter exceeds the set threshold, it is judged that the air compressor is in abnormal operation state, and a shutdown command is issued to the air compressor or a command to start the standby air compressor is issued; If the air compressor is in normal working condition, continue to monitor the operation of the air compressor to ensure that the air compressor operates within a safe range; Send alarm information to the DCS system and trigger corresponding maintenance or repair operations.

5. The real-time monitoring method of Compair air compressor according to claim 4, characterized in that: The issuing of a control command to the air compressor includes issuing an emergency stop command to shut down the power supply of the air compressor if the protection parameter of the air compressor exceeds a set threshold; If the outlet pressure of the air compressor is lower than the set value, the standby air compressor will be automatically started and a start command will be sent to the control system; If the vibration signal of the air compressor is abnormal, it will trigger equipment inspection and automatically slow down and stop to prevent equipment damage.

6. The real-time monitoring method of Compair air compressor according to claim 5, characterized in that: The control instructions of the air compressor are generated by the central monitoring system through the monitoring data transmitted in real time, and the monitoring signals are collected according to the set time intervals.

7. The real-time monitoring method of Compair air compressor according to claim 6, characterized in that: If the outlet pressure of the air compressor is lower than 0.6MPa, the system will determine whether to issue a start command based on the preset conditions, including: If the air compressor is in standby mode and no other air compressor is running, a start command is automatically issued; If the air compressor is in standby mode and no other air compressor starts within 6 seconds, issue the start command again; If there is air compressor load and the outlet pressure is still lower than 0.6MPa, an emergency start command is issued and the start status is confirmed through the control system.

8. A device using the real-time monitoring method of a Compair air compressor as claimed in any one of claims 1 to 7, characterized in that: include: A data acquisition module (100), used for receiving a monitoring signal of an air compressor; A data transmission module (200), used for transmitting the received monitoring signal to a central monitoring system via a remote communication system; A parameter calculation module (300), used for calculating air compressor protection parameters according to the received temperature and pressure signals; A parameter display module (400), used to display the operating status and protection parameters of the air compressor in the central monitoring system; A state judgment module (500), used for judging the operating state of the air compressor based on the calculation result; The command control module (600) is used to issue a control command to the air compressor according to the monitoring result.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, wherein: When the processor executes the computer program, the steps of the real-time monitoring method of the Compair air compressor described in any one of claims 1 to 7 are implemented.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the real-time monitoring method of the Compair air compressor described in any one of claims 1 to 7 are implemented.

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