Environment-friendly container type digital energy air compression station based on air floating shaft driving

Abstract

The invention relates to an environment-friendly container type digital energy air compression station based on air floating shaft driving, and belongs to the technical field of digital energy air compression stations. A ventilation and heat dissipation module of an air treatment system is designed to comprise an airflow distribution modeling unit, an adjustable fan array, a distributed sensor network and an intelligent control unit; the airflow distribution modeling unit generates an initial airflow distribution diagram in a container body through computational fluid mechanics simulation based on container structure parameters, arranges an adjustable fan array in an airflow distribution non-uniform area in the container body according to the airflow distribution diagram, deploys a vector fan in a dead area, feeds back data in real time in combination with a sensor network, and establishes an airflow distribution model in the container body. A nonlinear relation function of the temperature, the airflow speed and the fan rotating speed is output and established, an airflow dead zone is eliminated, a temperature field in the box is balanced, and the problem that in the prior art, when an axial flow fan and a flow guide plate are arranged for ventilation and heat dissipation, system heat dissipation is insufficient is solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of digital energy air compressor stations, and particularly relates to an environment-friendly container-type digital energy air compressor station driven by an air-floating shaft. Background Art

[0002] Currently, the environment-friendly container-type air compressor station driven by an air-floating shaft mainly consists of an air-floating shaft drive system, container modular integration, an air treatment system, and an energy management system. Among them, the air treatment system realizes its functions through three parts: air conditioning, air humidification, and ventilation and heat dissipation. Air conditioning uses a frequency converter to adjust the speed of the air compressor and combines a PID control algorithm to maintain the stability of the output pressure. Air humidification relies on an external humidifier or a spraying system to adjust the humidity of the compressed air to meet industrial requirements. Ventilation and heat dissipation are achieved by configuring an axial flow fan and a deflector, and using forced air cooling to reduce the temperature inside the box.

[0003] However, the inventor found that there are some problems in the current container-type air compressor station driven by an air-floating shaft during use: Since the container itself is a closed metal box, in a closed operating environment, when ventilating and dissipating heat by configuring an axial flow fan and a deflector, due to the characteristics of the closed metal box of the container and the limited internal space, the air flow distribution in the box may be uneven. The air flow generated by the axial flow fan may not effectively reach every corner of the container, especially the corners and the leeward side, forming an air flow dead zone and resulting in insufficient heat dissipation, causing frequent occurrence of high-temperature hot spots inside the container, and ultimately forcing the equipment to operate at a reduced load. In view of the above problems, an environment-friendly container-type digital energy air compressor station driven by an air-floating shaft is proposed, aiming to optimize system heat dissipation and air flow distribution, and improve the operating efficiency and stability of the equipment. Summary of the Invention

[0004] To solve the above problems existing in the prior art, the present invention provides an environment-friendly container-type digital energy air compressor station driven by an air-floating shaft, which solves the problem of insufficient system heat dissipation when ventilating and dissipating heat by configuring an axial flow fan and a deflector in the prior art.

[0005] The object of the present invention can be achieved by the following technical solutions: An environmentally friendly container-type digital energy air compressor station based on air-floating shaft drive comprises an air-floating shaft drive system, a container modular integration, an air treatment system, an energy management system and a control terminal. The air-floating shaft drive system, the container modular integration, the air treatment system and the energy management system are respectively connected to the control terminal for communication. The ventilation and heat dissipation module of the air treatment system comprises an airflow distribution modeling unit, an adjustable fan array, a distributed sensor network and an intelligent control unit. The airflow distribution modeling unit generates an initial airflow distribution diagram in the box through computational fluid dynamics simulation based on container structural parameters and operating conditions. The adjustable fan array is arranged in an area with uneven airflow distribution in the box according to the airflow distribution diagram. The distributed sensor network is used to monitor the temperature, airflow velocity and fan speed data of each area in the box in real time. The intelligent control unit dynamically adjusts the fan speed and angle based on sensor data and a preset temperature-airflow-speed function relationship model to eliminate airflow dead zones and balance the temperature field in the box.

[0006] As a further solution of the present invention, the airflow distribution modeling unit generates an airflow distribution diagram through the following steps: Step 1: Input the container 3D model, equipment layout and heat source distribution data of the air-floating shaft drive system; Step 2: Combine the ambient temperature and humidity and the air compressor load parameters to build a thermodynamic-fluid mechanics coupling simulation model; Step 3: Determine the initial airflow dead zone position through iterative calculation, and output the fan layout coordinates and recommended power.

[0007] As a further solution of the present invention, in the adjustable fan array, some fans are universal axial flow fans, the air outlet angles of which can be adjusted within a range of ±45°, and dynamic deflection is achieved by servo motor drive.

[0008] As a further solution of the present invention, the distributed sensor network also includes an infrared thermal imager for real-time scanning of the temperature field distribution inside the box and fusing and correcting the data with the temperature sensor data.

[0009] As a further solution of the present invention, the intelligent control unit adopts a fuzzy PID algorithm to dynamically adjust PID parameters to optimize the fan response speed according to the temperature change rate and the air flow velocity deviation value.

[0010] As a further solution of the present invention, a guide baffle is provided on the inner wall of the container, the surface of the guide baffle is covered with a heat insulation coating, and the inclination angle thereof can be adjusted in conjunction with the air outlet direction of the fan.

[0011] As a further solution of the present invention, the intelligent control unit is connected to a remote monitoring platform, supporting real-time visualization of the airflow and temperature distribution status in the box through a digital twin model.

[0012] As a further solution of the present invention, the temperature-airflow-rotation speed function relationship model dynamically corrects the rotation speed of the fan through the following formula: N i =K p ·ΔT i +K i ·∫ΔT i dt+K d ·dΔT i / dt, where N i is the target rotation speed of the i-th fan, ΔT i is the deviation between the measured temperature and the set temperature in the i-th area, and K p , K i , K d are the proportional, integral, and differential coefficients adjusted in real time according to the heat load.

[0013] As a further solution of the present invention, the surface of the container is provided with sensors for monitoring the external wind speed flow, and the sensors for monitoring the external wind speed flow are communicatively connected to the control terminal.

[0014] As a further solution of the present invention, the surface of the container is provided with a plurality of spoiler plates for reducing turbulence.

[0015] The beneficial effects of the present invention are as follows: By designing the ventilation and heat dissipation module of the air treatment system to include an airflow distribution modeling unit, an adjustable fan array, a distributed sensor network, and an intelligent control unit, the airflow distribution modeling unit generates an initial airflow distribution map inside the container through computational fluid dynamics simulation based on the container structure parameters, such as the aspect ratio, equipment layout, and operating conditions. According to the airflow distribution map, the adjustable fan array is arranged in the uneven airflow distribution areas inside the container, and vector fans are deployed in the dead zones, enabling angle adjustment and rotation speed adjustment. Combined with the sensor network, real-time feedback data is provided. The intelligent control unit dynamically adjusts the rotation speed and angle of the fan based on the sensor data and the preset temperature-airflow-rotation speed function relationship model, dynamically matches the fan, outputs a non-linear relationship function establishing temperature, airflow velocity, and fan rotation speed, eliminates the airflow dead zone, and balances the temperature field inside the container, solving the problem of insufficient system heat dissipation in the prior art when ventilating and dissipating heat by configuring axial fans and guide plates. Description of the Drawings

[0016] For the convenience of those skilled in the art to understand, the present invention will be further described below with reference to the accompanying drawings.

[0017] Figure 1 It is the system logic diagram of the present invention. Detailed Embodiments

[0018] To further elaborate on the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the following provides a detailed description of the specific implementation manners, structures, features, and effects of the present invention in conjunction with the accompanying drawings and preferred embodiments.

[0019] Please refer to Figure 1 , this embodiment provides an environmentally friendly containerized digital energy air compressor station based on air bearing drive, including an air bearing drive system, container modular integration, an air treatment system, an energy management system, and a control terminal. The air bearing drive system, container modular integration, air treatment system, and energy management system are respectively communicatively connected to the control terminal. Among them, the core of the air bearing drive system is an air bearing air compressor, which uses an air film to support the rotor, reduces mechanical friction, lowers energy consumption and noise, and is equipped with a high-pressure gas source system to provide a stable air film pressure for the air bearing. Through a non-contact bearing design, mechanical friction losses are reduced, and at the same time, noise pollution is reduced; Container modular integration is achieved by integrating equipment such as air compressor units, gas storage tanks, refrigerated dryers, and filters into standard containers, enabling rapid transportation and deployment. The internal layout of the container is compact, but the design of the heat dissipation channels and pipeline systems is relatively fixed. The container is internally integrated with shock-absorbing bases for equipment and multi-layer noise reduction structures; The energy management system collects operation data (pressure, temperature, energy consumption, etc.) through sensors to achieve local or remote monitoring. The energy management system optimizes the equipment operation mode in real time, combines the potential for renewable energy access, and reduces carbon emissions throughout the life cycle. The ventilation and heat dissipation module of the above air treatment system includes an air flow distribution modeling unit, an adjustable fan array, a distributed sensor network, and an intelligent control unit. The air flow distribution modeling unit generates an initial air flow distribution map inside the container through computational fluid dynamics simulation based on the container structure parameters and operating conditions. According to the air flow distribution map, the adjustable fan array is arranged in the areas with uneven air flow distribution inside the container. The distributed sensor network is used to monitor the temperature, air flow velocity, and fan rotation speed data in each area inside the container in real time. The intelligent control unit dynamically adjusts the fan rotation speed and angle based on the sensor data and the preset temperature-air flow-rotation speed function relationship model to eliminate air flow dead zones and balance the temperature field inside the container, thereby making the temperature field balanced. In addition, the air flow distribution modeling unit in the above text generates the air flow distribution map through the following steps: Step 1: Input the three-dimensional model of the container, equipment layout, and heat source distribution data of the air bearing drive system; Step 2: Combine the environmental temperature and humidity, air compressor load parameters to construct a thermodynamics-fluid mechanics coupled simulation model; Step 3: Determine the position of the initial air flow dead zone through iterative calculation, and output the fan layout coordinates and recommended power.

[0020] Currently, when the containerized digital energy air compressor station is in use, since the container itself is a closed metal box, in this airtight operating environment, when ventilating and dissipating heat by configuring an axial flow fan and a deflector, due to the characteristics of the closed metal box of the container, the internal space is limited, which may lead to uneven air flow distribution inside the box. The air flow generated by the axial flow fan may not effectively reach every corner of the container, especially the corners and the leeward side, forming air flow dead zones and resulting in insufficient heat dissipation, causing frequent high-temperature hot spots inside the container, and ultimately forcing the equipment to operate at a reduced load.

[0021] To solve the above problems, in this embodiment, the ventilation and heat dissipation module of the air treatment system is designed to include an air flow distribution modeling unit, an adjustable fan array, a distributed sensor network, and an intelligent control unit. The air flow distribution modeling unit generates an initial air flow distribution map inside the box through computational fluid dynamics simulation based on the container structure parameters, such as the length-width-height ratio, equipment layout, and operating conditions. According to the air flow distribution map, the adjustable fan array is arranged in the areas with uneven air flow distribution inside the box, and vector fans are deployed in the dead zones to enable angle adjustment and speed adjustment. Combined with the sensor network, temperature / flow velocity nodes are arranged every 1m 2 to real-time feedback data. The intelligent control unit dynamically adjusts the fan speed and angle based on the sensor data and the preset temperature-air flow-speed function relationship model, dynamically matches the fan output through the PID algorithm, realizes that the standard deviation of the temperature field ≤ 1.5°C, establishes a non-linear relationship function between temperature, air flow velocity, and fan speed, eliminates the air flow dead zones and balances the temperature field inside the box, and solves the problem of insufficient system heat dissipation in the prior art when ventilating and dissipating heat by configuring an axial flow fan and a deflector. Through the three-level cooperation of the adjustable fan array, the distributed sensor, and the intelligent control unit, the system heat dissipation efficiency is improved compared with the traditional axial flow fan scheme, local high-temperature areas are eliminated, and thermal stress damage to the equipment is avoided. In addition, it should be noted that by arranging temperature / flow velocity nodes every 1m 2 it is possible to achieve real-time and fine monitoring of the air flow and temperature inside the box, ensure the accuracy and real-time of the data, and the goal of realizing the standard deviation of the temperature field ≤ 1.5°C is to ensure the uniformity of the temperature field inside the box.

[0022] In order to make the three levels of the adjustable fan array, distributed sensors and intelligent control unit work better together, they can be dynamically adjusted according to actual working conditions to improve adaptability. In this regard, in one embodiment, in the adjustable fan array, several fans are universal axial flow fans, and the adjustable range of their air outlet angles is ±45°, and dynamic deflection is achieved by servo motor drive. The dynamic deflection of the fan is achieved by servo motor drive, and the air outlet angle of the fan can be adjusted in real time to adapt to different working conditions and environmental requirements, thereby improving the operating efficiency and energy efficiency of the entire system. The adjustable range of the air outlet angle is ±45°, so that the fan can flexibly adjust the wind flow direction according to actual needs, and is suitable for complex working conditions. In addition, by adjusting the air outlet angle of the fan, the air flow distribution can be better controlled to avoid local airflow being too strong or too weak, improve the quality of compressed air, and avoid the fan working in a non-optimal state, thereby reducing overall energy consumption.

[0023] In order to more accurately monitor and evaluate the temperature conditions of various parts in the box and improve the accuracy of temperature monitoring, in one embodiment, the distributed sensor network also includes an infrared thermal imager for real-time scanning of the temperature field distribution in the box and fusing and correcting it with the temperature sensor data. The infrared thermal imager can provide more comprehensive and intuitive temperature distribution information, which helps to understand the operating status of the equipment more accurately. By improving energy efficiency and reducing equipment failures, this design helps to reduce energy waste and environmental pollution.

[0024] In order to further improve energy efficiency and response speed, and enhance temperature and airflow control at the same time, in this regard, in one embodiment, the intelligent control unit adopts a fuzzy PID algorithm, and dynamically adjusts the PID parameters according to the temperature change rate and the airflow speed deviation value to optimize the fan response speed. The inner wall of the container is provided with a guide baffle, and the surface of the guide baffle is covered with a thermal insulation coating, and its inclination angle can be adjusted in conjunction with the air outlet direction of the fan. The intelligent control unit is connected to the remote monitoring platform, and supports real-time visualization of the airflow and temperature distribution state in the box through the digital twin model. By adopting the fuzzy PID algorithm intelligent control unit, the PID parameters can be dynamically adjusted according to the temperature change rate and the airflow speed deviation, thereby optimizing the response speed and energy efficiency of the fan, so that the air compressor station can maintain efficient operation under different working conditions. The inner wall of the container is provided with a guide baffle, and the surface is covered with a thermal insulation coating, which can effectively isolate the influence of the external environment temperature on the internal airflow and temperature, and maintain a stable internal environment. The inclination angle of the guide baffle can be adjusted in conjunction with each other, and adjusted according to the air outlet direction of the fan, further enhancing the airflow control and ensuring uniform airflow distribution.

[0025] It is worth mentioning that, since traditional heat dissipation control mostly adopts fixed speed or simple on-off control, it cannot dynamically adapt to load changes and local temperature fluctuations. It takes a long time to trigger the fan response after the temperature deviation appears, and the risk of local overheating is high. It is difficult to completely eliminate the temperature deviation, resulting in uneven temperature fields after long-term operation. To better solve this problem, in one embodiment, the temperature-airflow-speed function relationship model dynamically corrects the fan speed through the following formula: N i =K p ·ΔT i +K i ·∫ΔT i dt+K d ·dΔT i / dt, where N i is the target speed of the i-th fan, ΔT i is the deviation between the measured temperature and the set temperature in the i-th area, and K p , K i , K d are the proportional, integral, and differential coefficients adjusted in real time according to the heat load. During precise dynamic adjustment, the proportional term K p ·ΔT i can quickly respond to the temperature deviation and directly reduce the current temperature difference. The integral term K i ·∫ΔT i dt eliminates the historical cumulative error. The differential term K d ·dΔT i / dt predicts the temperature change trend and adjusts the fan speed in advance to avoid overshoot. Combining with the fuzzy logic algorithm, the values of K p , K i , and K d are optimized in real time according to the heat load (such as the load rate of the air compressor). For example, K p is increased under high load to improve the response speed, and K i is reduced under low load to reduce energy consumption.

[0026] In actual use, considering the influence of the external environment on the internal flow field, strong winds or sudden airflow may interfere with the internal airflow distribution through the gaps or openings of the container, resulting in fluctuations in the heat dissipation efficiency. Moreover, the right-angle structure on the surface of the container is prone to generating turbulence, increasing wind resistance and affecting the stability of the equipment. To address this, in one embodiment, sensors for monitoring the external wind speed and flow are provided on the surface of the container. The sensors for monitoring the external wind speed and flow are communicatively connected to the control terminal. A number of flow spoilers for reducing turbulence are provided on the surface of the container. The sensors for monitoring the external wind speed and flow are arranged on the surface of the container to monitor the external wind speed and direction data in real time and transmit them to the control terminal. When strong winds are detected, the intelligent control unit dynamically adjusts the rotational speed of the internal fan and the angle of the guiding baffle to counteract the external airflow disturbance. When there is an external headwind, the output power of the fan is increased to maintain the stability of the internal airflow pressure. Installing aerodynamically optimized flow spoilers at specific positions on the surface of the container can guide the external airflow to flow smoothly around the container, reducing the wind resistance on the surface of the container and preventing external turbulence from invading the container through the ventilation openings and interfering with the heat dissipation airflow path.

[0027] It should be noted that, in order to better maximize the heat dissipation efficiency and minimize the energy consumption through closed-loop control, the ventilation and heat dissipation control method of the digital energy air compressor station adopted needs to include the following steps: Step S1: Based on the initial airflow distribution map, start the fan array and operate it at a preset rotational speed; generate the airflow distribution map in advance through CFD simulation to guide the fan to start according to the optimal layout and avoid dead zones caused by blind layout. Step S2: Collect real-time temperature, airflow speed, and humidity data through the sensor network; the distributed sensor network provides high-resolution data to support precise regulation. Step S3: If it is detected that the local temperature exceeds the threshold or the airflow speed is lower than the set value, then trigger the fan regulation instruction; actively monitor and trigger adjustments to avoid local overheating. Step S4: According to the temperature-airflow-rotational speed function relationship model, calculate the required rotational speed of the fan and the adjustment amount of the angle in the target area; based on the temperature-airflow-rotational speed function model, scientifically calculate the fan parameters to ensure the optimality of the adjustment. Step S5: Drive the fan to execute the adjustment and continuously monitor until the uniformity of the temperature field reaches the preset requirements.

[0028] The above are only the preferred embodiments of the present invention, and do not impose any form of limitation on the present invention. Although the present invention has been disclosed above with the preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some changes or modifications to equivalent embodiments with equivalent changes within the scope of the technical solution of the present invention. However, as long as it does not depart from the content of the technical solution of the present invention, any brief modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. An environmentally friendly containerized digital energy air compressor station based on air-floating shaft drive, comprising an air-floating shaft drive system, a container modular integration, an air treatment system, an energy management system and a control terminal, wherein the air-floating shaft drive system, the container modular integration, the air treatment system and the energy management system are respectively connected to the control terminal in communication, characterized in that: The ventilation and heat dissipation module of the air handling system includes an airflow distribution modeling unit, an adjustable fan array, a distributed sensor network and an intelligent control unit. The airflow distribution modeling unit generates an initial airflow distribution map in the box through computational fluid dynamics simulation based on the container structure parameters and operating conditions. The adjustable fan array is arranged in the area with uneven airflow distribution in the box according to the airflow distribution map. The distributed sensor network is used to monitor the temperature, airflow velocity and fan speed data of each area in the box in real time. The intelligent control unit dynamically adjusts the fan speed and angle based on the sensor data and the preset temperature-airflow-speed function relationship model to eliminate the airflow dead zone and balance the temperature field in the box.

2. According to claim 1, an environmentally friendly container-type digital energy air compressor station based on air floating shaft drive is characterized in that: The airflow distribution modeling unit generates an airflow distribution diagram by the following steps: Step 1: Input the container 3D model, equipment layout and heat source distribution data of the air-floating shaft drive system; Step 2: Combine the ambient temperature and humidity and the air compressor load parameters to build a thermodynamic-fluid mechanics coupling simulation model; Step 3: Determine the initial airflow dead zone position through iterative calculation, and output the fan layout coordinates and recommended power.

3. According to claim 1, an environmentally friendly container-type digital energy air compressor station based on air floating shaft drive is characterized in that: In the adjustable fan array, several fans are universal axial flow fans, the air outlet angles of which can be adjusted within a range of ±45°, and dynamic deflection is achieved through servo motor drive.

4. According to claim 1, an environmentally friendly container-type digital energy air compressor station based on air floating shaft drive is characterized in that: The distributed sensor network also includes an infrared thermal imager for real-time scanning of the temperature field distribution in the box and fusing and correcting the temperature sensor data.

5. According to claim 1, an environmentally friendly container-type digital energy air compressor station based on air floating shaft drive is characterized in that: The intelligent control unit adopts a fuzzy PID algorithm to dynamically adjust PID parameters according to the temperature change rate and the air flow speed deviation value to optimize the fan response speed.

6. The environmentally friendly containerized digital energy air compressor station based on air floating shaft drive according to claim 1 is characterized in that: The inner wall of the container is provided with a guide baffle, the surface of the guide baffle is covered with a heat insulation coating, and the inclination angle of the guide baffle can be adjusted in conjunction with the air outlet direction of the fan.

7. The environmentally friendly containerized digital energy air compressor station based on air floating shaft drive according to claim 1 is characterized in that: The intelligent control unit is connected to a remote monitoring platform, and supports real-time visualization of the airflow and temperature distribution status in the box through a digital twin model.

8. The environmentally friendly containerized digital energy air compressor station based on air floating shaft drive according to claim 1 is characterized in that: The temperature-airflow-speed function relationship model dynamically corrects the fan speed through the following formula: i =K p ΔT i +K i ∫ΔT i dt+K d ·dΔT i / dt, where N i is the target speed of the i-th fan, ΔT i is the deviation between the measured temperature and the set temperature of the i-th area, K p , K i , K d The proportional, integral and differential coefficients are adjusted in real time according to the heat load.

9. The environmentally friendly containerized digital energy air compressor station based on air floating shaft drive according to claim 8 is characterized in that: A sensor for monitoring external wind speed flow is provided on the surface of the container, and the sensor for monitoring external wind speed flow is communicatively connected with the control terminal.

10. The environmentally friendly containerized digital energy air compressor station based on air floating shaft drive according to claim 9 is characterized in that: The surface of the container is provided with a plurality of spoilers for reducing turbulence.

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