A safe and energy-saving power system for air compressor stations driven by air-floating shafts

Abstract

The present invention discloses a safe and energy-saving electricity consumption system for an air compressor station driven by an air floating shaft, which relates to the technical field of air compressor stations. The operating parameters of various devices in the air compressor station are monitored in real time through a data acquisition module, and the operating status of the air compressor can be adjusted through a frequency conversion drive module according to real-time gas demand, thereby avoiding unnecessary energy consumption. The pressure of the pipeline network is monitored by a pressure sensor, and the output air pressure of the air compressor is controlled within an optimal range, thereby avoiding energy waste caused by excessive pressure; the waste heat generated during the operation of the air compressor is recovered and utilized through an energy recovery module, thereby reducing the energy demand of other links; when multiple air compressors are running, the system automatically distributes the load through a linkage control module, ensuring that each device operates in an efficient range, thereby balancing the load; the safety protection module automatically triggers a protection mechanism under abnormal circumstances, effectively ensuring the safety of equipment and personnel; the control strategy of the control center ensures that the air compressor station equipment always remains stable during operation.

Description

Technical Field

[0001] The present invention relates to the technical field of air compressor stations, and in particular to a safe and energy-saving electricity system for air compressor stations driven by an air floating shaft. Background Art

[0002] Compressed air, as the most environmentally friendly power source in industrial production, is widely used in various industries such as medicine, food, machinery, and electronics. Compared with voltage and oil pressure, air pressure has its unique advantages. It is inexhaustible. Basically, every factory is equipped with an air compressor station. The air bearing driven air compressor station is an air compressor station that uses air bearing technology. Since the air bearing spindle has no mechanical contact during operation, the degree of wear is extremely low, which can ensure that the accuracy remains stable. It has the advantages of no friction, high precision, and long life.

[0003] However, in the existing air compressor station based on air floating shaft drive, since the air compressor generates a lot of heat when working, manual inspection poses a safety hazard, resulting in the inability to directly monitor the operating status of the equipment in the air compressor station. It is necessary to collect the working parameters of the air compressor equipment through electrical equipment for monitoring. In addition, there are multiple air compressor equipment installed in the air compressor station. How to balance the operation of multiple air compressor equipment to achieve energy saving and consumption reduction while meeting actual usage needs is also a problem that technical personnel in this field urgently need to solve. Summary of the Invention

[0004] To solve the above problems, the present invention provides a safe and energy-saving power consumption system for an air compressor station driven by an air floating shaft, which replaces the traditional manual on-site operation monitoring of the air compressor equipment. It not only realizes the balanced deployment of multiple air compressors, but also achieves the purpose of energy saving and consumption reduction.

[0005] To achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a safe and energy-saving power system for an air compressor station driven by an air floating shaft; comprising:

[0006] A control center, wherein the control center is connected to the monitoring and management module and the control subsystem respectively. The control subsystem includes a variable frequency drive module, a data acquisition module, an energy recovery module, a safety protection module and a linkage control module. The control subsystem is connected to multiple air compressors in the air compression station;

[0007] The control center includes a programmable logic controller (PLC) for real-time monitoring of the operating status of the air compressor station and automatic adjustment of the start and stop and load of the air compressor according to gas demand to avoid no-load or overload operation;

[0008] The variable frequency drive module includes a frequency converter (VFD) for adjusting the output power according to the actual gas consumption, reducing the motor speed at low load and reducing power consumption;

[0009] The data acquisition module is used to collect the pressure, flow and operating status data of the air compressor station pipe network in real time;

[0010] The energy recovery module is used to convert the waste heat generated by the air compressor into hot water or steam, which is then used in other production processes.

[0011] The safety protection module is used to control the automatic shutdown of the equipment in the air compressor station when it is found that the equipment is abnormal, the system automatically switches to the backup equipment, and sends an alarm signal to avoid accidents;

[0012] The linkage control module is used to automatically start, stop or switch the air compressor according to gas demand, optimize load distribution, ensure that each device in the air compression station operates in a high-efficiency range, and avoid long-term high-load operation of a single device.

[0013] Preferably, the monitoring and management module realizes remote monitoring through the Internet of Things (IoT) technology, and checks the operating status and energy consumption data of each device in the air compressor station in real time, realizes remote early warning and remote diagnosis, and improves maintenance efficiency; the monitoring and management module is also connected to the cloud platform to upload the operating data of the equipment in the air compressor station to the cloud platform for storage.

[0014] Preferably, the control center analyzes the current gas demand based on the data collected by the data acquisition module and the preset control strategy, determines whether the air compressor needs to be started or stopped, and sends start-stop or speed regulation instructions to each air compressor; when receiving the signal from the safety protection module, the faulty equipment is automatically switched to the backup equipment and an alarm signal is issued.

[0015] More preferably, the control strategy specifically includes:

[0016] By setting a target pressure range; when the network pressure of the air compressor station is lower than the lower limit, one or more air compressors are started; when the network pressure reaches the upper limit, some air compressors are stopped;

[0017] Set a priority for each air compressor and start and stop them in order. Specifically, start the air compressor with the shortest running time first to balance the wear of each device.

[0018] When multiple air compressors are running, the load of each device is dynamically adjusted to ensure that all devices operate in the high-efficiency range;

[0019] For air compressors equipped with frequency converters, the motor speed is adjusted according to gas demand, increasing the motor speed at high loads and reducing the motor speed at low loads, thereby reducing power consumption and achieving precise gas supply.

[0020] Preferably, the data acquisition module includes a pressure sensor, a flow sensor, a current sensor, a humidity sensor and a timer, which are used to collect real-time information about the air compressor station pipeline pressure, the air flow in the pipeline, the real-time current of the air compressor equipment and the humidity of the nearby working environment, as well as the operating time of the air compressor equipment, and send the data to the control center.

[0021] Preferably, the safety protection module monitors the operating status of the air compressor to ensure stable operation of the system;

[0022] The specific steps include:

[0023] By collecting the working current and voltage of the air compressor in real time and comparing them with the rated working current and voltage, when the real-time working current is greater than the rated working current or the real-time working voltage is greater than the rated working voltage and the running time is greater than the preset time t, it is determined that the current operating state of the air compressor equipment is an overload state;

[0024] When the real-time working current is much greater than the rated working current and the real-time working voltage is much less than the rated working voltage and the running time is greater than the preset time t, the current operating state of the air compressor equipment is determined to be a short-circuit state;

[0025] When it is determined that the current equipment fails, a signal is sent to the control center.

[0026] Preferably, the linkage control module designates one air compressor as the master and the rest as slaves, wherein the master controls the start and stop of the slaves according to gas demand, and the linkage control module balances equipment wear by regularly rotating the master and slave roles of the air compressors;

[0027] When multiple air compressors are running at the same time, the master and slave roles of each device are dynamically adjusted according to the total gas demand in cooperation with the control center to balance the load.

[0028] More preferably, the regular rotation of the master-slave roles of each air compressor includes:

[0029] Combining multiple factors such as time, load, and fault status, the rotation strategy is dynamically adjusted, specifically including the collected data and real-time status prediction of the optimal rotation timing.

[0030] More preferably, the optimal rotation timing is calculated as follows:

[0031]

[0032] Among them, T represents the time when the device will be rotated to the host next time, N represents the average annual workload of the device, and T B Indicates the number of days the equipment is down due to failure, T brepresents the number of days the device is not scheduled to work, X represents the number of days the device works as a host, M represents the workload of the device when it worked as a host last time, and η represents the average working efficiency of the device.

[0033] Preferably, a PID controller is provided to adjust the output of the air compressor by adjusting the frequency converter VFD in real time, and the specific steps include:

[0034] The current pressure of the air compression station pipe network is collected through the pressure sensor:

[0035] Then calculate the deviation between the current pressure and the expected output pressure;

[0036] Calculate the control output u(t) based on the PID ratio and deviation;

[0037] The variable frequency drive module adjusts the motor speed or start / stop state of the air compressor according to u(t);

[0038] Continuously monitor the pipeline pressure and repeat the above steps to ensure stable pressure output.

[0039] The beneficial effects of the present invention are as follows: through the air-floating shaft-driven safe and energy-saving power consumption system of the air compressor station of the present invention, the operating parameters of each device in the air compressor station are monitored in real time through the data acquisition module, and the operating status of the air compressor can be adjusted according to the real-time gas demand, thereby avoiding unnecessary energy consumption. The pipeline pressure is monitored by a pressure sensor, and the output of the air compressor is controlled by PID to control the air pressure of the air compressor within the optimal range, thereby avoiding energy waste caused by excessive pressure; the waste heat generated during the operation of the air compressor is recovered and utilized by the energy recovery module to reduce the energy demand of other links; when multiple air compressors are running, the system automatically distributes the load through the linkage control module to ensure that each device operates in the high-efficiency range, so that the load is balanced; the safety protection module automatically triggers the protection mechanism under abnormal circumstances to effectively ensure the safety of equipment and personnel; the control strategy of the control center can effectively ensure the effective operation of each device in the air compressor station, ensure that the equipment always remains stable during operation, and at the same time avoid the failure of a certain device causing other devices to be affected, thereby affecting the overall operating performance of the air compressor station. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 This is a block diagram of a safe and energy-saving electricity system for an air compressor station driven by an air floating shaft according to the present invention. DETAILED DESCRIPTION

[0041] See also Figure 1 As shown, the present invention relates to a safe and energy-saving power system for an air compressor station driven by an air floating shaft as follows:

[0042] It includes a control center, which is respectively connected to the monitoring and management module and the control subsystem. The control subsystem includes a variable frequency drive module, a data acquisition module, an energy recovery module, a safety protection module and a linkage control module. The control subsystem is connected to multiple air compressors in the air compression station;

[0043] The control center includes a programmable logic controller (PLC), which is used to monitor the operating status of the air compressor station in real time and automatically adjust the start and stop and load of the air compressor according to gas demand to avoid no-load or overload operation;

[0044] The data acquisition module is used to collect real-time data on the air compressor station pipe network pressure, flow, and air compressor operating status;

[0045] The programmable logic controller (PLC) acts as the core control unit through a preset program, responsible for coordinating the operation of multiple air compressors. It connects each air compressor to the main controller via an industrial bus or Ethernet to achieve data exchange and command transmission. Each air compressor is also equipped with a data acquisition module, including a pressure sensor, a flow sensor, a current sensor, a humidity sensor and a timer, which are used to collect real-time information about the air compressor station pipeline pressure, the air flow in the pipeline, the real-time current of the air compressor equipment and the humidity of the nearby working environment, as well as the operating time of the air compressor equipment, and send the data to the control center via wireless communication.

[0046] Based on the data collected by the data acquisition module and the preset control strategy, the control center analyzes the current gas demand, determines whether the air compressor needs to be started or stopped, and sends start, stop or speed regulation instructions to each air compressor; when receiving the signal from the safety protection module, the faulty equipment is automatically switched to the backup equipment and an alarm signal is issued.

[0047] The control strategies specifically include:

[0048] By setting a target pressure range; when the network pressure of the air compressor station is lower than the lower limit (output is insufficient), start one or more air compressors; when the network pressure reaches the upper limit (output is excessive), stop some air compressors;

[0049] Taking into account multiple factors such as time, load, and fault status, the rotation strategy is dynamically adjusted to set a priority for each air compressor, and start and stop them in sequence. Specifically, the air compressor with the shortest running time is started first to balance the wear of each device.

[0050] When multiple air compressors are running, the load of each device is dynamically adjusted to ensure that all devices operate in the high-efficiency range; ensure that each air compressor is within the rated working range and does not operate under overload.

[0051] For air compressors equipped with frequency converters, the motor speed is adjusted according to gas demand, increasing the motor speed at high loads and reducing the motor speed at low loads, thereby reducing power consumption and achieving precise gas supply.

[0052] The variable frequency drive module includes a frequency converter (VFD), which is used to adjust the output power according to the actual gas consumption, reduce the motor speed at low load, and reduce power consumption;

[0053] Since the pressure sensor is set at the pipe network, the output of the air compressor can be effectively measured. 实际 With the expected output P 目标 Compare and find the deviation:

[0054] Deviation e(t) = P 目标 -P 实际

[0055] Then the control output u(t) is calculated according to the PID control formula;

[0056]

[0057] where K p、 K i、 K d They represent the proportional, integral, and differential coefficients respectively. Then the variable frequency drive module adjusts the motor speed or start / stop status of the air compressor according to u(t).

[0058] Assume that the target pressure of the pipe network of an air compressor station is 0.7 MPa and the current pressure is 0.65 MPa. The PID parameters are: =2; = 0.1; =0.5,

[0059] Calculation deviation

[0060] e(t) = 0.7 - 0.65 = 0.05 ,

[0061] Calculating PID output

[0062] Assumption: The historical cumulative value of the integral item is 0.02.

[0063] The differential term (rate of change of deviation) is -0.01.

[0064] but:

[0065] u(t)=2⋅0.05+0.1⋅0.02+0.5⋅(−0.01)=0.1+0.002−0.005=0.097,

[0066] If u(t) = 0.097 is positive, it means that the air compressor output needs to be increased.

[0067] Assume the control output range is 0 to 1, corresponding to the motor speed is 0% to 100%.

[0068] Adjust the motor speed to 9.7% of the current speed.

[0069] The pressure of the pipeline network is continuously monitored by the pressure sensor, and the above calculation and adjustment are repeated until the pressure stabilizes at 0.7 MPa.

[0070] The energy recovery module is used to convert the waste heat generated by the air compressor into hot water or steam, which can be used in other production links.

[0071] Since the air compressor generates a large amount of heat when working, a heat recovery heat exchanger is installed at the compressor outlet to recover the compressor exhaust heat through water circulation, or to exchange heat with cold water to be heated through the heat exchanger to heat the cold water to a certain temperature for heating or domestic water use; or to convert water into steam through the heat exchanger and send the steam to the steam generator set to generate electricity.

[0072] The setting of the energy recovery module can improve energy utilization efficiency and convert waste heat into useful electrical energy.

[0073] When the air compressor is working, the heat discharged is higher than the ambient temperature and higher than a preset threshold, and T is calculated in real time. out Indicates the outlet water temperature of the heat exchanger, T in Indicates the heat exchanger inlet water temperature:

[0074]

[0075] in, Indicates the design water temperature difference flowing through the heat exchanger, W re Indicates the minimum proportion of heat exchanger to the energy cost of air compressor operation, the first amount of water W generated by the air compressor due to compressed air 1， The second amount of water W2 discharged from the air compression tank, It represents the residual heat design coefficient and can be obtained based on actual test results. T represents the ambient temperature. When T out When the temperature is greater than the first threshold, the heat exchanger exchanges heat with the cold water to be heated, heating the cold water to a certain temperature for heating or domestic water use; when T out When the temperature is greater than the second threshold, excess heat energy will be generated through the heat exchanger, turning water into steam, which will be sent to the steam generator set to generate electricity.

[0076] The safety protection module is used to control the automatic shutdown of the equipment in the air compressor station when an abnormal situation is found. The system automatically switches to the backup equipment and sends an alarm signal to avoid accidents.

[0077] The safety protection module monitors the operating status of the air compressor to ensure stable operation of the system;

[0078] The specific steps include:

[0079] By collecting the working current and voltage of the air compressor in real time and comparing them with the rated working current and voltage, when the real-time working current is greater than the rated working current or the real-time working voltage is greater than the rated working voltage and the running time is greater than the preset time t, it is determined that the current operating state of the air compressor equipment is an overload state;

[0080] When the real-time working current is much greater than the rated working current and the real-time working voltage is much less than the rated working voltage and the running time is greater than the preset time t, the current operating state of the air compressor equipment is determined to be a short-circuit state;

[0081] Assume the current working voltage is , rated working voltage is , the working current is , rated operating current is , by setting the interval range and ,

[0082] when The difference between and and The difference between , when the running time is greater than the preset t time, it is determined that the current running state of the air compressor equipment is an overload state;

[0083] when and The difference between them is greater than 0 and much greater than I b When U d When the value is close to the power supply voltage, it is judged that the current operating state of the air compressor equipment is short-circuit state.

[0084] In addition, when a bearing of the equipment is worn out, its vibration frequency and amplitude will show a specific change pattern, and its current harmonics will become abnormal:

[0085]

[0086] in, represents the correlation of current harmonic disturbance signal, U(t) represents the decomposition result of harmonic disturbance signal, t is the operation time of the equipment, k represents the vibration amplitude, z represents the vibration frequency, I k Indicates the energy coefficient of the current harmonic disturbance signal;

[0087] When the rotor is unbalanced, anomalies appear in its vibration spectrum:

[0088]

[0089] Among them, f r Indicates the actual rotation frequency of the motor, n indicates the motor speed, represents the vibration severity factor coefficient, d represents the diameter of the electronic rotor, Indicates the time required for the rotor to make one rotation.

[0090] When the current harmonic disturbance signal correlation When the vibration intensity factor is greater than the preset threshold, it is judged that the bearing of the current equipment is worn and needs to be replaced. When it is greater than the preset threshold, it is determined that the rotor of the current device is unbalanced.

[0091] When it is determined that the current device has failed, the device will be stopped immediately and a signal will be sent to the control center. If the air compressor is the master, the next master will be enabled according to the order of the control strategy. If the air compressor is the slave, the standby air compressor (also as a slave) will be enabled to avoid affecting the normal operation of the air compression station.

[0092] Abnormal vibration patterns of equipment are detected. Once potential failure signs are detected, the operation and maintenance team can be notified in time to take measures to reduce unplanned downtime.

[0093] The linkage control module is used to automatically start, stop or switch air compressors according to gas demand, optimize load distribution, ensure that each device in the air compression station operates in the high-efficiency range, and avoid long-term high-load operation of a single device.

[0094] The linkage control module designates one air compressor as the master and the rest as slaves. The master controls the start and stop of the slaves based on gas demand. The linkage control module also balances equipment wear by regularly rotating the master and slave roles of the air compressors.

[0095] When multiple air compressors are running at the same time, the master and slave roles of each device are dynamically adjusted according to the total gas demand in cooperation with the control center to balance the load.

[0096] The master and slave roles of each air compressor are rotated regularly, including:

[0097] Combining multiple factors such as time, load, and fault status, the rotation strategy is dynamically adjusted, specifically including the collected data and real-time status prediction of the optimal rotation timing.

[0098] In actual operation, there are several rotation methods:

[0099] 1. Time rotation

[0100] Set a running time threshold for each air compressor, such as 8 hours. When the running time of the master air compressor reaches the threshold, the system automatically switches to the next air compressor.

[0101] 2. Load rotation

[0102] Monitor the load of each air compressor and switch to a lower-loaded device when the load on one device is too high.

[0103] In load rotation, the operating status of the air compressor and its speed are dynamically adjusted by combining PID control.

[0104] 3. Fault-first rotation

[0105] Monitor the operating status of each air compressor, including temperature, vibration, fault records, etc. When rotating, give priority to the air compressor in the best condition.

[0106] The rotation steps are as follows: First, the operating data of each air compressor in the air compression station needs to be collected, including operating time, load, status, temperature, vibration, fault records, etc.; then, according to the selected rotation strategy, the next air compressor is selected as the output host, and the load of the current main control device is gradually reduced. At the same time, the next output host device is started, and the status of each air compressor device in the air compression station is continuously monitored to ensure a smooth switching process. Finally, the rotation history data is recorded and the rotation strategy is optimized.

[0107] The calculation method of the best rotation opportunity of the present invention is as follows:

[0108]

[0109] Among them, T represents the time when the device will be rotated to the host next time, N represents the average annual workload of the device, and T B Indicates the number of days the equipment is down due to failure, T b = represents the number of days the equipment is not scheduled to work, X represents the number of days the equipment has worked as the main machine, M represents the workload of the equipment during the last operation as the main machine, η represents the average working efficiency of the equipment, 1.442 is the deviation coefficient, which is used to adjust the deviation of the air compressor's working hours based on working hours when it is used as the main machine under high load and overtime, and 0.225 is the adjustment parameter used to adjust and compensate for the operating time of the air compressor when it is used as the main machine due to high load.

[0110] By calculating the next time when each air compressor in the air compressor station will rotate as the output host, they will be used as the output host in ascending order of time.

[0111] The calculation method for the optimal rotation timing provided by the present invention can accurately calculate the time when each air compressor will next rotate to become the main machine (main output), which can balance the operating time, reduce the wear of individual equipment, and effectively extend the life of the equipment; through rotation operation, it can effectively ensure that each equipment is in good condition, balance wear and tear, reduce failure rate, and reduce maintenance needs and costs.

[0112] The present invention is also provided with a monitoring and management module, which realizes remote monitoring through the Internet of Things (IoT) technology. Through remote monitoring, the operating status and energy consumption data of each device in the air compressor station can be viewed in real time, remote early warning and remote diagnosis can be achieved, and maintenance efficiency is improved. In a feasible implementation method, the management personnel can change the output of the air compressor or manually change the master-slave role of each air compressor in the remote control center through the monitoring and management module. The monitoring and management module is also connected to the cloud platform to upload the operating data of the equipment in the air compressor station to the cloud platform for permanent storage.

[0113] The above formulas are all calculated by removing dimensions and taking their numerical values. The formula is a formula that is closest to the actual situation obtained by collecting a large amount of data and performing software simulation. The preset parameters and preset thresholds in the formula are set by technicians in this field according to actual conditions or obtained by simulating a large amount of data.

[0114] Those skilled in the art can clearly understand that, for the convenience and brevity of description, only the division of the above-mentioned functional units and modules is used as an example for illustration. In actual applications, the above-mentioned functions can be distributed and completed by different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiment can be integrated into one processing unit, or each unit can exist physically alone, or two or more units can be integrated into one unit. The above-mentioned integrated unit can be implemented in the form of hardware or in the form of software functional units. In addition, the specific names of the functional units and modules are only for the convenience of distinguishing each other, and are not used to limit the scope of protection of this application. The specific working process of the units and modules in the above-mentioned system can refer to the corresponding process in the aforementioned method embodiment, and will not be repeated here.

[0115] In the above embodiments, the description of each embodiment has its own focus. For parts that are not described or recorded in detail in a certain embodiment, reference can be made to the relevant description of other embodiments.

[0116] Those skilled in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professionals and technicians can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the present invention.

[0117] In the embodiments provided by the present invention, it should be understood that the disclosed devices / terminal equipment and methods can be implemented in other ways. For example, the device / terminal equipment embodiments described above are merely illustrative. For example, the division of modules or units is merely a logical function division. In actual implementation, there may be other division methods, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of devices or units, which can be electrical, mechanical or other forms.

[0118] Units described as separate components may or may not be physically separate, and components shown as units may or may not be physical units, that is, they may be located in one place or distributed across multiple network units. Some or all of these units may be selected to achieve the purpose of this embodiment according to actual needs.

[0119] In addition, the functional units in the various embodiments of the present invention may be integrated into a single processing unit, each unit may exist physically separately, or two or more units may be integrated into a single unit. The aforementioned integrated units may be implemented in the form of hardware or software functional units.

[0120] If the integrated module / unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the present invention implements all or part of the process in the above-mentioned embodiment method, and can also be completed by instructing the relevant hardware through a computer program. The computer program can be stored in a computer-readable storage medium, and when the computer program is executed by the processor, it can implement the steps of each of the above-mentioned method embodiments. Among them, the computer program includes computer program code, which can be in source code form, object code form, executable file or some intermediate form. The computer-readable medium may include: any entity or device capable of carrying computer program code, recording medium, USB flash drive, mobile hard disk, magnetic disk, optical disk, computer memory, read-only memory (ROM), random access memory (RAM), electric carrier signal, telecommunication signal and software distribution medium. It should be noted that the content contained in the computer-readable medium can be appropriately increased or decreased according to the requirements of legislation and patent practice in the jurisdiction. For example, in some jurisdictions, according to legislation and patent practice, computer-readable media does not include electric carrier signals and telecommunication signals.

[0121] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention, and should all be included in the scope of protection of the present invention.

[0122] The foregoing description is merely a preferred embodiment of the present disclosure. Although the present disclosure has been described in conjunction with the accompanying drawings, this is not intended to limit the present disclosure. Various variations and modifications are possible for those skilled in the art. Any modifications, substitutions, and improvements made within the spirit and principles of the present disclosure shall be included within the scope of protection of the present disclosure.

Claims

1. A safe and energy-saving power system for an air compressor station driven by an air-floating shaft, characterized in that: include: A control center, wherein the control center is connected to the monitoring and management module and the control subsystem respectively. The control subsystem includes a variable frequency drive module, a data acquisition module, an energy recovery module, a safety protection module and a linkage control module. The control subsystem is connected to multiple air compressors in the air compression station; The control center includes a programmable logic controller (PLC) for real-time monitoring of the operating status of the air compressor station and automatic adjustment of the start and stop and load of the air compressor according to gas demand to avoid no-load or overload operation; The variable frequency drive module includes a frequency converter (VFD) for adjusting the output power according to the actual gas consumption and reducing the motor speed when the load is low; The data acquisition module is used to collect the pressure, flow and operating status data of the air compressor station pipe network in real time; The energy recovery module is used to convert the waste heat generated by the air compressor into hot water or steam, which is then used in other production processes. The safety protection module is used to control the automatic shutdown of the equipment in the air compressor station when it is found that the equipment is abnormal, the system automatically switches to the backup equipment, and sends an alarm signal to avoid accidents; The linkage control module is used to automatically start, stop or switch the air compressor according to gas demand, optimize load distribution, ensure that each device in the air compression station operates in the high-efficiency range, and avoid long-term high-load operation of a single device; The linkage control module designates one air compressor as the master and the rest as slaves, where the master controls the start and stop of the slaves according to gas demand. The linkage control module balances equipment wear by regularly rotating the master and slave roles of each air compressor. When multiple air compressors are running at the same time, the master and slave roles of each device are dynamically adjusted according to the total gas demand in cooperation with the control center to balance the load; The regular rotation of the master and slave roles of each air compressor includes: Dynamically adjust the rotation strategy based on multiple factors such as time, load, and fault status, specifically including the collected data and real-time status prediction for the optimal rotation timing; The optimal rotation timing is calculated as follows: ， Where T is the time when the device will next rotate as the host, N is the average annual workload of the device, TB is the number of days the device is down due to failure, Tb is the number of days the device is not scheduled to work, X is the number of days the device works as the host, M is the workload of the device when it last worked as the host, and η is the average work efficiency of the device.

2. The air-floating shaft driven air compressor station safety and energy-saving power system according to claim 1 is characterized in that: The monitoring and management module realizes remote monitoring through the Internet of Things (IoT) technology, and checks the operating status and energy consumption data of each device in the air compressor station in real time; the monitoring and management module is also connected to the cloud platform to upload the operating data of the equipment in the air compressor station to the cloud platform for storage.

3. The air-floating shaft driven air compressor station safety and energy-saving power system according to claim 1 is characterized in that: The control center analyzes the current gas demand based on the data collected by the data acquisition module and the preset control strategy, determines whether the air compressor needs to be started or stopped, and sends start-stop or speed regulation instructions to each air compressor; when receiving the signal from the safety protection module, the faulty equipment is automatically switched to the backup equipment and an alarm signal is issued.

4. The air-floating shaft driven air compressor station safety and energy-saving power system according to claim 3 is characterized in that: The control strategy specifically includes: By setting a target pressure range; when the network pressure of the air compressor station is lower than the lower limit, one or more air compressors are started; when the network pressure reaches the upper limit, some air compressors are stopped; Set a priority for each air compressor and start and stop them in order. Specifically, start the air compressor with the shortest running time first to balance the wear of each device. When multiple air compressors are running, the load of each device is dynamically adjusted to ensure that all devices operate in the high-efficiency range; For air compressors equipped with frequency converters, the motor speed is adjusted according to the gas demand, increasing the motor speed when the load is high and reducing the motor speed when the load is low.

5. The air-floating shaft driven air compressor station safety and energy-saving power system according to claim 1 is characterized in that: The data acquisition module includes a pressure sensor, a flow sensor, a current sensor, a humidity sensor and a timer, which are used to collect real-time pressure of the air compressor station pipeline, air flow in the pipeline, real-time current of the air compressor equipment and humidity of the nearby working environment, as well as the operating time of the air compressor equipment, and send the data to the control center.

6. The air-floating shaft driven air compressor station safety and energy-saving power system according to claim 1 is characterized in that: The safety protection module monitors the operating status of the air compressor to ensure stable operation of the system; The specific steps include: By collecting the working current and voltage of the air compressor in real time and comparing them with the rated working current and voltage, when the real-time working current is greater than the rated working current or the real-time working voltage is greater than the rated working voltage and the running time is greater than the preset time t, it is determined that the current operating state of the air compressor equipment is an overload state; When the real-time working current is much greater than the rated working current and the real-time working voltage is much less than the rated working voltage and the running time is greater than the preset time t, the current operating state of the air compressor equipment is determined to be a short-circuit state; When it is determined that the current equipment fails, a signal is sent to the control center.

7. The air-floating shaft driven air compressor station safety and energy-saving power system according to claim 1 is characterized in that: By setting a PID controller, the output of the air compressor is adjusted by adjusting the frequency converter VFD in real time. The specific steps include: The current pressure of the air compression station pipe network is collected through the pressure sensor: Then calculate the deviation between the current pressure and the expected output pressure; Calculate the control output u(t) based on the PID ratio and deviation; The variable frequency drive module adjusts the motor speed or start / stop state of the air compressor according to u(t); Continuously monitor the pipeline pressure and repeat the above steps to ensure stable pressure output.

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