Compressor multi-dimensional detection comprehensive evaluation data processing method and system

Abstract

The invention relates to the technical field of digital data processing, in particular to a compressor multi-dimensional detection comprehensive evaluation data processing method and a compressor multi-dimensional detection comprehensive evaluation data processing system. The multi-source data comprises an environment temperature signal, a compressor cylinder body cooling water temperature signal, a power exhaust temperature signal, a user side heating temperature signal and a circulation pipeline flow signal; the multi-source data is transmitted to an intelligent controller, a waste heat recovery and distribution strategy is judged based on a preset priority rule, and the priority rule comprises the steps that high-temperature waste heat is preferentially and directly supplied for heating, and medium and low-temperature waste heat is stored in a phase change heat storage unit in a classified mode; and a control instruction is generated according to the priority rule, and the opening degree of a heat exchange bypass valve, the rotating speed of a circulating pump and the start-stop state of a heat storage unit are adjusted through digital electric signals, so that the waste heat recovery amount, the stored heat release amount and the heating requirement are dynamically matched. The problem that a traditional waste heat utilization system lacks self-adaptive regulation and control capacity is solved.

Description

Technical Field

[0001] The present application relates to the technical field of digital data processing, and in particular to a method and system for processing data of multi-dimensional detection and comprehensive evaluation of compressors. Background Art

[0002] Gas reciprocating compressors, as core equipment for gas gathering, transmission, and production in oil and gas fields, generate significant amounts of waste heat during operation (such as liner cooling water and exhaust heat). Traditional waste heat treatment methods often rely on direct discharge or simple recovery, which not only wastes energy but also increases carbon emissions. With the increasing demand for energy conservation and emission reduction, efficient recovery and intelligent utilization of waste heat have become important research areas.

[0003] At present, some waste heat recovery systems adopt a fixed mode of data collection and processing. For example, waste heat temperature information is obtained through a single temperature sensor, and the start and stop of the heat exchanger is controlled based on a preset threshold.

[0004] Existing waste heat data processing methods lack the ability to comprehensively analyze multi-source data (such as ambient temperature, user needs, and compressor operating conditions), and their control logic is rigid, making it impossible to adjust the waste heat recovery strategy according to real-time operating conditions, which greatly restricts the utilization rate of waste heat. Summary of the Invention

[0005] In order to solve at least one of the above technical problems, the present application provides a method and system for processing data of multi-dimensional detection and comprehensive evaluation of compressors.

[0006] In a first aspect, the present application provides a method for processing data from a multi-dimensional inspection and comprehensive evaluation of a compressor, which adopts the following technical solutions: Collect multi-source data in real time through a sensor network, including ambient temperature signals, compressor cylinder cooling water temperature signals, power exhaust temperature signals, user-end heating temperature signals, and circulation pipeline flow signals; The multi-source data is transmitted to the intelligent controller, and the waste heat recovery and distribution strategy is determined based on preset priority rules, wherein the priority rules include prioritizing high-temperature waste heat for direct heating and hierarchical storage of medium and low-temperature waste heat in phase change heat storage units; Control instructions are generated according to the priority rules, and the opening of the heat exchange bypass valve, the speed of the circulation pump and the start and stop status of the heat storage unit are adjusted through digital electrical signals to achieve dynamic matching of waste heat recovery, heat storage release and heating demand.

[0007] By adopting the above technical solution, multi-source data (including ambient temperature, compressor cooling water temperature, exhaust temperature, user-end temperature and flow signals) is collected in real time through the sensor network, and combined with preset priority rules (such as direct supply of high-temperature waste heat and storage of medium and low-temperature waste heat), digital electrical signals are used to dynamically adjust the valve opening, pump speed and heat storage unit status, solving the problem of the traditional waste heat utilization system's lack of adaptive control capabilities.

[0008] Specifically, the synergy of real-time multi-source data transmission and priority rules enables the system to quickly respond to changes in ambient temperature and fluctuations in user demand, avoiding excess or insufficient heat. For example, when the ambient temperature drops sharply, high-temperature waste heat is prioritized for direct supply to the user end, while medium- and low-temperature waste heat is stored in the phase change unit, significantly increasing waste heat utilization to over 70% (saving 30%-50% compared to traditional systems).

[0009] In addition, the actuator is directly controlled by digital electrical signals to reduce human intervention delays, ensure that the indoor temperature fluctuation range is ≤±1℃, and optimize the user experience.

[0010] In one possible implementation, the priority rule further includes: When the ambient temperature signal is lower than the first threshold, the control instruction preferentially closes the valve of the heat storage unit and increases the speed of the circulation pump to directly deliver the high-temperature waste heat to the user end; When the ambient temperature signal is higher than the second threshold, the control instruction opens the valve of the heat storage unit and reduces the speed of the circulation pump to store the medium and low temperature waste heat in the phase change heat storage unit.

[0011] By adopting the above technical solution, the rigidity of traditional waste heat recovery models is addressed by setting ambient temperature thresholds (first and second thresholds) to hierarchically control the valves of the heat storage units and the speed of the circulation pump. For example, when the ambient temperature falls below the first threshold (e.g., -20°C), the valves of the heat storage units are closed and the pump speed is increased, prioritizing the delivery of high-temperature waste heat to the user end to meet extreme low-temperature demands. When the ambient temperature rises above the second threshold (e.g., 10°C), the valves of the heat storage units are opened and the pump speed is reduced, storing the redundant heat in the phase change material. This dynamic switching logic, based on environmental conditions, prevents the heat storage units from excessively occupying high-temperature waste heat resources in low-temperature environments, while maximizing the utilization of heat storage capacity in medium- and high-temperature environments, significantly reducing the frequency of activation of backup heat sources.

[0012] In one possible implementation, the priority rule further includes: when it is detected that the compressor load change rate exceeds a preset threshold, the intelligent controller generates a graded response instruction, and synchronously adjusts the opening of the heat exchange bypass valve, the circulation pump speed and the opening and closing status of the heat storage unit valve through digital electrical signals to match the waste heat distribution requirements under load fluctuations.

[0013] By adopting the above technical solution, by adding redundant sensors and a dynamic priority adjustment mechanism, the compressor load change signal is captured in real time, and the rapid charging and discharging strategy of the heat storage unit is triggered based on the load fluctuation amplitude. Specifically, when the compressor load suddenly increases, the high-temperature waste heat is preferentially supplied directly to the heating circuit to alleviate the instantaneous demand pressure; when the load suddenly decreases, the heat storage unit valve is immediately opened and the redundant waste heat is stored. At the same time, the bypass valve opening and the circulation pump speed are synchronously adjusted through digital electrical signals to ensure a dynamic balance between heat recovery and distribution. This solves the problem of delayed coordinated response between the waste heat recovery module and the heat storage unit when the compressor load suddenly changes, resulting in reduced heat distribution efficiency.

[0014] In one possible implementation, the generation of the control instruction also includes: real-time monitoring of the heat storage / release rate of the heat storage unit through digital electrical signals; when the rate is lower than a preset threshold, generating a backup heat storage module access instruction, closing the current heat storage unit valve to switch to the backup module, and triggering a maintenance reminder signal.

[0015] This technical solution addresses the issue of decreased heat storage efficiency due to phase change material degradation by monitoring the heat storage and release rates of the thermal storage unit in real time and switching to a backup module when the rate falls below a threshold. For example, when the temperature gradient sensor detects a decrease in heat storage rate (indicating material aging), a digital signal immediately closes the current heat storage valve and switches to the backup module, simultaneously triggering a maintenance reminder. This ensures the long-term stable operation of the thermal storage system and prevents heating efficiency losses caused by material degradation.

[0016] In one possible implementation, the generating of the control instruction further includes: According to the difference between the circulation pipeline flow signal and the user-end heating temperature signal, the opening of the heat exchange bypass valve is adjusted in real time to balance the waste heat recovery efficiency and heating stability.

[0017] By implementing this technical solution, the valve opening is adjusted in real time based on the difference between the circulation pipeline flow signal and the user-end temperature, resolving the issue of insufficient heating stability caused by system response lag. For example, when the flow signal indicates insufficient circulation and the user-end temperature is low, the bypass valve opening is increased via a digital signal to increase waste heat recovery; conversely, the valve opening is reduced to prevent overheating. This closed-loop feedback mechanism balances waste heat recovery efficiency with heating stability, ensuring that indoor temperature fluctuations remain within ±1°C.

[0018] In one possible implementation, the multi-source data also includes outlet temperature signals of each stage of heat exchangers, and the control instructions further include: switching the status of independent pipeline valves through digital electrical signals based on the temperature difference between the high-temperature waste heat and the medium- and low-temperature waste heat circuits, thereby achieving physical isolation and priority allocation of the heat transfer path.

[0019] This technical solution addresses the problem of heat mixing losses in multi-stage heat exchangers by monitoring the temperature difference between the high and low temperature circuits and switching the valves in the independent pipelines. For example, when the high-temperature waste heat circuit temperature is significantly higher than the medium and low temperature circuits, a digital signal closes the mixing valve and activates the independent pipeline, ensuring that the high-temperature waste heat is directly supplied to the user end, while the medium and low temperature waste heat is stored in the phase change unit. This physical isolation design increases the waste heat cascade utilization rate by 15%-20%, reducing ineffective heat loss.

[0020] In one possible implementation, the multi-source data also includes an ambient humidity signal, and the control instruction further includes: when the ambient humidity signal exceeds a preset threshold, controlling the intermittent opening and closing frequency of the heat exchange bypass valve and the speed of the circulation pump through digital electrical signals to suppress condensation and maintain waste heat recovery efficiency.

[0021] By adopting this technical solution, which incorporates an ambient humidity signal and controls the intermittent opening and closing frequency of the heat exchanger bypass valve, the efficiency degradation caused by condensation in high-humidity environments is addressed. For example, when the humidity sensor detects the risk of condensation, a digital signal triggers the rapid opening and closing of the heat exchanger bypass valve, increasing the frequency of airflow to remove condensed water and simultaneously increasing the speed of the circulating pump to accelerate heat transfer. This design maintains waste heat recovery efficiency above 90% of its original level in high-humidity conditions.

[0022] In a second aspect, the present application provides a compressor multi-dimensional detection and comprehensive evaluation data processing system, comprising: The sensor network module is used to collect real-time ambient temperature, compressor cylinder cooling water temperature, power exhaust temperature, user-end heating temperature and circulation pipeline flow signals; an intelligent controller, communicatively connected to the sensor network module, configured to receive the multi-source data and generate control instructions based on preset priority rules, wherein the priority rules include prioritizing high-temperature waste heat for direct heating and hierarchical storage of medium and low-temperature waste heat in phase change thermal storage units; The actuator module includes a heat exchange bypass valve, a circulation pump and a heat storage unit control valve. The actuator module is communicated with the intelligent controller and is used to adjust the valve opening, pump speed and start and stop status of the heat storage unit according to the control instructions to achieve dynamic control of waste heat recovery and heating distribution.

[0023] By adopting this technical solution, a modular design (sensor network, intelligent controller, and actuators) enables dynamic control of waste heat recovery and distribution, addressing the loose structure and poor interoperability of traditional systems. For example, the sensor network module collects multi-source data in real time and transmits it to the controller via a communication link. The controller generates control instructions and drives the actuators (valves, pumps, and heat storage units) via digital electrical signals, forming a closed-loop control chain. This integrated architecture reduces system response time to milliseconds and facilitates expansion and integration with other energy systems (such as solar energy).

[0024] In a third aspect, the present application provides an electronic device comprising a memory and a processor, wherein the memory is used to store computer program code, and the processor is used to execute the computer program code stored in the memory to implement the method in the above-mentioned first aspect and any one of the first aspect, or the above-mentioned second aspect and any possible implementation of the second aspect.

[0025] In a fourth aspect, the present application provides a computer-readable storage medium, which stores a computer program or instruction. When the computer program or instruction is executed, it implements the method in the above-mentioned first aspect and any one of the first aspect, or the above-mentioned second aspect and any possible implementation of the second aspect. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 A flow chart of the method for processing data for multi-dimensional inspection and comprehensive evaluation of a compressor provided in an embodiment of the present application.

[0027] Figure 2 This is a structural diagram of the compressor multi-dimensional detection and comprehensive evaluation data processing system provided in an embodiment of the present application.

[0028] Figure 3 A schematic diagram of the structure of an electronic device provided in an embodiment of the present application. DETAILED DESCRIPTION

[0029] The technical solutions of this application will be described below in conjunction with all the accompanying drawings. Obviously, the embodiments described are only part of the embodiments of this application, not all of them.

[0030] In the description of the embodiments of this application, unless otherwise specified, " / " means "or." For example, A / B can mean A or B. "And / or" in this article is merely a description of an association relationship between associated objects, indicating that three relationships can exist. For example, A and / or B can mean: A exists alone, A and B exist simultaneously, and B exists alone. In addition, in the description of the embodiments of this application, "plurality" or "a plurality" means two or more than two.

[0031] In the following, the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this embodiment, unless otherwise specified, "plurality" means two or more.

[0032] The terms used in the following examples are only for the purpose of describing specific embodiments and are not intended to limit the present application. As used in the specification and appended claims of this application, the singular expressions "a," "an," "said," "above," "the," and "this" are intended to include expressions such as "one or more," unless the context clearly indicates otherwise. It should also be understood that in the following examples of this application, "at least one," "one or more" refer to one, two, or more than two.

[0033] References to "one embodiment" or "some embodiments" in this specification mean that a particular feature, structure, or characteristic described in conjunction with that embodiment is included in one or more embodiments of the present application. Thus, phrases such as "one embodiment," "some embodiments," "another embodiment," and "other embodiments" appearing in various places in this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically stated. The terms "including," "comprising," "having," and variations thereof mean "including but not limited to," unless otherwise specifically stated.

[0034] The embodiment of the present application provides a method for processing data of a multi-dimensional inspection and comprehensive evaluation of a compressor, which is executed by an electronic device, wherein the electronic device can be an independent physical electronic device, or an electronic device cluster or distributed system composed of multiple physical electronic devices, or a cloud electronic device providing cloud computing services. The embodiment of the present application is not limited here, such as Figure 1 As shown, the method includes: S1. Collect multi-source data in real time through sensor networks.

[0035] Among them, multi-source data includes ambient temperature signal, compressor cylinder cooling water temperature signal, power exhaust temperature signal, user-end heating temperature signal and circulation pipeline flow signal.

[0036] Specifically, the deployment of sensor networks and multi-source data collection enable real-time monitoring through distributed hardware. Furthermore, temperature sensors (such as PT100 thermal resistors) and flow sensors (such as electromagnetic flowmeters) are installed at the compressor cylinder cooling water outlet, power exhaust pipe, user-side radiator inlet and outlet, key nodes in the circulation pipeline, and the outdoor environment.

[0037] Sensors connect to the data acquisition module via analog signals or Modbus RTU protocol, transmitting ambient temperature, cooling water temperature, exhaust temperature, user-side temperature, and flow rate signals to the intelligent controller in real time. The PLC communicates with a host computer (such as an industrial personal computer) via Ethernet, forming a closed-loop data link.

[0038] For example, when the outdoor temperature sensor detects a sudden drop in temperature, its signal is transmitted to the PLC via digital electronics, triggering a high-temperature waste heat direct supply instruction. At the same time, the medium and low-temperature waste heat storage signal is sent to the heat storage unit control valve via the bus.

[0039] S2. Transmit multi-source data to the intelligent controller and determine the waste heat recovery and distribution strategy based on preset priority rules.

[0040] Among them, the priority rules include direct supply of high-temperature waste heat for heating, and graded storage of medium and low-temperature waste heat in phase change heat storage units.

[0041] Specifically, the intelligent controller's priority rule logic enables dynamic decision-making through modular programming and hardware interfaces. Furthermore, the PLC's built-in function blocks (such as FB1) have a pre-set priority rule library, including thresholds for direct supply of high-temperature waste heat (e.g., exhaust temperature ≥ 150°C), thresholds for storing medium- and low-temperature waste heat (e.g., cooling water temperature 80-120°C), and ambient temperature classification conditions (e.g., -20°C ≤ T ≤ 10°C).

[0042] Among them, when multi-source data is input through the I / O module, the PLC generates control instructions according to the rule base and sends digital electrical signals to the actuator through the digital output module.

[0043] For example, when the ambient temperature is below -20°C and the user-end temperature is lower than the set value, the PLC outputs a high-level signal to the circulation pump inverter (such as ABB ACS550), increasing the pump speed to 80% of the rated value. At the same time, it sends a pulse signal to close the electric valve of the heat storage unit (such as AUMA SAR actuator), ensuring that high-temperature waste heat is directly supplied to the user end.

[0044] S3. Generate control instructions according to priority rules, and adjust the opening of the heat exchange bypass valve, the speed of the circulation pump, and the start and stop status of the heat storage unit through digital electrical signals to achieve dynamic matching of waste heat recovery, heat storage release and heating demand.

[0045] Specifically, dynamic control of the actuators achieves precise operation through digital electrical signals and mechanical linkage. Furthermore, the heat exchange bypass valve (such as an electric butterfly valve) and circulation pump are controlled via digital output signals from the PLC. Valve opening is adjusted by a PWM signal (e.g., 0-10V corresponds to 0-100% opening), while the circulation pump speed is controlled by an analog input (4-20mA) from the frequency converter. The heat storage unit control valve (such as an electric ball valve) is opened and closed via Modbus TCP commands.

[0046] For example, when the PLC detects that the capacity of the heat storage unit is insufficient, it sends a switching signal to the relay of the backup heat storage module, triggering the valve switching action, and simultaneously notifies the gas boiler controller through the CAN bus to start the preheating process, ensuring seamless connection of the heat source.

[0047] In this embodiment, multi-source data (including ambient temperature, compressor cooling water temperature, exhaust temperature, user-end temperature and flow signals) is collected in real time through a sensor network, and combined with preset priority rules (such as direct supply of high-temperature waste heat and storage of medium and low-temperature waste heat), digital electrical signals are used to dynamically adjust the valve opening, pump speed and heat storage unit status, thus solving the problem of the traditional waste heat utilization system lacking adaptive control capabilities.

[0048] Specifically, the synergy between the real-time transmission of multi-source data and priority rules enables the system to quickly respond to changes in ambient temperature and fluctuations in user demand, avoiding excess or insufficient heat.

[0049] For example, when the ambient temperature drops sharply, high-temperature waste heat is directly supplied to the user end first, while medium and low-temperature waste heat is stored in the phase change unit, significantly improving the waste heat utilization rate to more than 70% (saving 30%-50% energy compared to traditional systems).

[0050] In addition, the actuator is directly controlled by digital electrical signals to reduce human intervention delays, ensure that the indoor temperature fluctuation range is ≤±1℃, and optimize the user experience.

[0051] In some embodiments, the priority rules in S2 further include: S201. When the ambient temperature signal is lower than a first threshold, the control instruction preferentially closes the valve of the heat storage unit and increases the speed of the circulation pump to directly deliver the high-temperature waste heat to the user end.

[0052] Specifically, when the ambient temperature is below a first threshold, the priority rule is linked to the actuator through sensor signals to achieve direct supply of high-temperature waste heat. Furthermore, ambient temperature sensors are installed at key outdoor locations and connected to the analog input module of the intelligent controller via 4-20mA analog signals.

[0053] When the sensor detects a temperature ≤ -20°C (the first threshold), the PLC sends a high-level signal to the thermal storage unit's electric valve via the digital output module, closing the valve and blocking the thermal storage circuit. Simultaneously, the PLC sends a 4-20mA signal to the circulating pump's inverter via the analog output module, increasing the pump speed to 80% of its rated value. This drives high-temperature waste heat (e.g., exhaust temperature ≥ 150°C) directly to the user's radiator through independent pipes.

[0054] For example, in extremely low temperature scenarios, the system receives the load status signal from the compressor PLC in real time through the RS485 bus. If a sudden increase in load is detected, the PLC will simultaneously increase the circulation pump speed to 100% to ensure sufficient instantaneous supply of high-temperature waste heat.

[0055] S202: When the ambient temperature signal is higher than a second threshold, the control instruction opens the valve of the heat storage unit and reduces the speed of the circulation pump to store the medium and low temperature waste heat in the phase change heat storage unit.

[0056] Specifically, when the ambient temperature exceeds the second threshold, priority rules enable storage of medium- and low-temperature waste heat through valve switching and pump speed control. Furthermore, when the ambient temperature sensor detects a temperature ≥10°C (the second threshold), the PLC sends an open command to the electric valve of the heat storage unit via the Modbus TCP protocol, and the circulating pump inverter reduces its speed to 30% of its rated value. Medium- and low-temperature waste heat (such as cylinder cooling water temperatures of 80-120°C) is recovered by the plate heat exchanger and transported to the phase change heat storage unit via independent pipelines.

[0057] The PLC communicates with the temperature transmitter of the heat storage unit via the Profibus DP protocol to monitor the heat storage status in real time. If the temperature of the heat storage unit is lower than the melting point of the phase change material (e.g., 60°C), the PLC sends a pulse signal to adjust the bypass valve opening to 50%, diverting some heat to the buffer water tank.

[0058] For example, during the nighttime low electricity price period, the system uses digital electrical signals to regularly open the heat storage valve and reduce the pump speed to 20%, maximizing the storage of redundant waste heat and reducing the frequency of gas boiler activation during the day.

[0059] This dynamic switching logic based on environmental conditions avoids excessive occupation of high-temperature waste heat resources by heat storage units in low-temperature environments, while maximizing the utilization of heat storage capacity in medium and high-temperature environments, significantly reducing the frequency of activation of backup heat sources.

[0060] In some embodiments, the priority rules in S2 further include: S203. When it is detected that the compressor load change rate exceeds a preset threshold, the intelligent controller generates a graded response instruction and synchronously adjusts the heat exchange bypass valve opening, the circulation pump speed and the opening and closing status of the heat storage unit valve through digital electrical signals to match the waste heat distribution requirements under load fluctuations.

[0061] Specifically, a graded response to sudden changes in compressor load achieves dynamic waste heat distribution through the collaboration of multiple sensors and actuators. Furthermore, a vibration sensor (such as a piezoelectric accelerometer) is installed on the compressor's power shaft and connected to the intelligent controller's high-speed input module via a 4-20mA analog signal.

[0062] When the load change rate is detected to exceed a preset threshold (e.g., 10% / s), the PLC sends a graded instruction through the digital output module: If the load increases suddenly, a pulse signal is sent to increase the opening of the heat exchange bypass valve to 70%, and a 4-20mA signal is simultaneously sent to the circulating pump inverter through the analog output module to increase the speed to 90% of the rated value.

[0063] If the load drops suddenly, a low-level signal is sent to close the valve of the heat storage unit, and the pump speed is reduced to 30% through the RS485 bus instruction.

[0064] For example, in the event of sudden changes in oil and gas field gathering and transportation conditions, the system receives real-time power signals from the compressor PLC through the CAN bus. If the load fluctuation continues to exceed the limit, the PLC automatically switches to the backup control strategy and directly drives the valves and pumps through hard-wired signals to ensure that the waste heat distribution response time is ≤200ms.

[0065] This design can ensure a dynamic balance between heat recovery and distribution, and solve the problem in existing systems where, when the compressor load suddenly changes, there is a delay in the coordinated response of the waste heat recovery module and the heat storage unit, resulting in reduced heat distribution efficiency.

[0066] Furthermore, the vibration sensor adopts a dual-redundancy design (the primary and backup sensors are connected to the PLC's DI module and distributed I / O station respectively). When the primary sensor signal is abnormal (such as noise interference), the PLC automatically switches to the backup signal and sends a fault code to the on-site alarm module, triggering a buzzer alarm.

[0067] The heat exchange bypass valve and circulation pump control adopts a master-slave dual link. When a sudden load change causes a delay in the main link, the slave link directly sends a switch signal to the valve and pump through the emergency output terminal of the PLC, ensuring uninterrupted execution of the control instructions. At the same time, the host computer is notified via Ethernet to record the event log for subsequent maintenance and analysis.

[0068] Furthermore, the valves of the heat storage unit (such as electric ball valves) communicate with the PLC through an independent RS485 bus. When a sudden load drop is detected, the PLC sends a shutdown command and switches to a bypass circuit to temporarily store the redundant waste heat in a buffer water tank.

[0069] At the same time, the circulation pump speed is linked to the valve opening through an analog signal (0-10V): if the load change rate exceeds 20% / s, the PLC sends a high-priority instruction, forcing the pump speed to increase to 100% and fully open the bypass valve to ensure that high-temperature waste heat is instantly supplied directly to the user end.

[0070] For example, when the compressor starts and stops frequently, the system dynamically adjusts the opening and closing frequency of the heat storage unit valve through digital electrical signals (such as 2-5 times per second), combined with the capacity feedback signal of the buffer water tank, to achieve a smooth transition of heat fluctuations and avoid temperature fluctuations at the user end exceeding ±1°C.

[0071] In some embodiments, the generation of the control instruction in S3 further includes: S301. Monitor the heat storage / release rate of the heat storage unit in real time through digital electrical signals. When the rate is lower than a preset threshold, generate a backup heat storage module access instruction, close the valve of the current heat storage unit to switch to the backup module, and trigger a maintenance reminder signal.

[0072] Specifically, thermal storage unit performance degradation monitoring and backup module switching enable efficient maintenance through multi-sensor collaboration and redundant communication links. Furthermore, a temperature gradient sensor (such as a K-type thermocouple array) is installed within the thermal storage unit and connected to the analog input module of the intelligent controller via analog signals.

[0073] The PLC calculates the heat storage / release rate (such as the temperature change value ΔT / Δt per unit time) in real time. When the rate is lower than the preset threshold (such as ΔT / Δt < 2°C / min), the PLC sends a switch signal through the digital output module to close the electric valve of the current heat storage unit, and simultaneously sends an access instruction to the relay of the backup heat storage module through the Modbus TCP protocol.

[0074] For example, in the scenario of phase change material aging, the PLC receives the capacity feedback signal of the backup module through the RS485 bus. If it confirms that the backup module is ready, it switches the valve to the backup circuit and simultaneously triggers the sound and light alarm of the on-site alarm module through the CAN bus to prompt maintenance personnel to carry out maintenance.

[0075] Specifically, by real-time monitoring of the heat storage / release rate of the heat storage unit and switching to the backup module when the rate is lower than the threshold, the problem of decreased heat storage efficiency caused by the attenuation of phase change material performance is solved.

[0076] For example, when the temperature gradient sensor detects a decrease in heat storage rate (indicating material aging), it immediately closes the current heat storage valve and connects the backup module via a digital signal, simultaneously triggering a maintenance reminder. This ensures the long-term stable operation of the heat storage system and avoids a drop in heating efficiency due to material degradation.

[0077] Furthermore, the generation and transmission of maintenance reminder signals utilizes multi-protocol redundant communication to ensure timely response. The PLC sends the maintenance reminder signal (e.g., a JSON-formatted message) to the host monitoring system via Ethernet, and simultaneously activates the control cabinet's red warning light and buzzer via a hard-wired relay.

[0078] Among them, the host computer pushes the alarm information to the cloud operation and maintenance platform through the OPC UA protocol to generate a work order record.

[0079] For example, when it is detected that the heat storage rate is lower than the threshold for three consecutive times, the PLC sends a shutdown request signal to the compressor control system through the Profibus DP protocol, forcing it to enter maintenance mode to avoid heating interruption due to heat storage failure.

[0080] Furthermore, seamless switching of the backup heat storage module ensures system continuity through an independent control circuit and physical isolation design. The backup heat storage module is connected in parallel with the main circuit via an independent pipeline, with an electric three-way valve installed at the inlet.

[0081] When the PLC sends a switching command, the three-way valve switches to the backup circuit through a PWM signal (e.g. 0-10V corresponds to 0-100% opening), and at the same time starts the circulation pump of the backup module through a hard-wired signal.

[0082] For example, during the switchover process, the PLC uses digital signals to synchronously close the main circuit valves and adjust the backup pump speed to 50Hz, ensuring flow fluctuations of ≤5%. Temperature data from the thermal storage units is collected via dual redundant sensors. If the primary sensor fails, the PLC automatically switches to the backup signal and updates the control logic via the Modbus RTU protocol to maintain a stable switchover process.

[0083] In some embodiments, the generation of the control instruction in S3 further includes: S302. According to the difference between the circulation pipeline flow signal and the user-end heating temperature signal, the opening of the heat exchange bypass valve is adjusted in real time to balance the waste heat recovery efficiency and heating stability.

[0084] Specifically, valve regulation driven by the difference between circulation flow and user-side temperature optimizes heating stability through closed-loop feedback and digital signal linkage. Furthermore, electromagnetic flowmeters are installed at key points in the circulation pipeline, and PT100 temperature sensors are deployed at the inlet and outlet of user-side radiators. These sensors are connected to the intelligent controller's analog input module and communication module via 4-20mA analog signals and Modbus RTU protocol, respectively.

[0085] Among them, the PLC calculates the difference between the flow signal and the user-end temperature in real time (such as ΔQ = actual flow value - set value, ΔT = actual user-end temperature value - set value). When ΔQ and ΔT deviate in the same direction (such as insufficient flow and low temperature), the PLC sends a PWM signal through the digital output module to adjust the opening of the heat exchange bypass valve.

[0086] For example, in a low-temperature scenario, if it detects that the user-end temperature drops by 2°C and the flow rate is 10% lower than the set value, the PLC sends a PWM signal with an 80% duty cycle to the valve, increasing the opening to 60%. Simultaneously, a 4-20mA signal is sent to the circulation pump inverter through the analog output module to increase the speed to 75% to enhance waste heat recovery.

[0087] Specifically, the valve opening is adjusted in real time according to the difference between the circulation pipeline flow signal and the user-end temperature, which solves the problem of insufficient heating stability caused by system response lag.

[0088] This closed-loop feedback mechanism balances waste heat recovery efficiency and heating stability, ensuring that the indoor temperature fluctuation range is ≤±1℃.

[0089] Furthermore, redundant sensors and a dual-link communication design ensure real-time and fault-tolerant control instructions. The flow meter and temperature sensor utilize a primary / standby redundant configuration. The primary sensor communicates with the PLC via Profibus DP, while the backup sensor connects to the distributed I / O station via a hard-wired 4-20mA signal.

[0090] When the primary link signal fails (e.g., a communication timeout), the PLC automatically switches to the backup signal and triggers an alarm relay via the CAN bus, illuminating the yellow warning light on site. Valve control utilizes a master-slave dual output: the master link is Modbus TCP instructions, and the slave link is a hard-wired PWM signal (e.g., 0-10V).

[0091] For example, when extreme load fluctuations cause delays in the main link, the PLC outputs a PWM signal directly to the valve from the link, ensuring an opening adjustment response time of ≤150ms. At the same time, it records event logs via Ethernet for subsequent energy efficiency analysis.

[0092] Furthermore, the coordinated control of valve opening and pump speed achieves dynamic balance through physical isolation and priority allocation. The heat exchange bypass valve and circulation pump are connected via independent control loops: the valve opening is driven by the PLC's PWM output module, while the pump speed is controlled by an analog output module.

[0093] When a continuous deviation between ΔQ and ΔT is detected, the PLC sends a high-priority instruction to force the valve opening and pump speed to be linked according to a preset ratio (for example, for every 10% increase in valve opening, the pump speed increases by 5%).

[0094] For example, if a sudden increase in compressor load results in an excess supply of waste heat, the PLC uses digital signals to reduce the valve opening to 40% and simultaneously reduce the pump speed to 50%, diverting the excess heat to the buffer water tank to prevent overheating at the user end. The buffer water tank capacity signal is fed back to the PLC via an ultrasonic level sensor, dynamically adjusting the control parameters to ensure heating stability within an error of ≤±0.5°C.

[0095] In some embodiments, the multi-source data in S1 also includes outlet temperature signals of heat exchangers at each stage, and the control instructions further include: S101. Based on the temperature difference between the high-temperature waste heat circuit and the medium- and low-temperature waste heat circuit, the states of independent pipeline valves are switched through digital electrical signals to achieve physical isolation and priority allocation of heat transfer paths.

[0096] Specifically, the physical isolation of high-temperature and medium- and low-temperature waste heat circuits enables tiered heat utilization through multi-stage temperature monitoring and valve switching logic. Furthermore, K-type thermocouple sensors are installed at the outlet of high-temperature waste heat circuits (such as the compressor exhaust pipe), and temperature sensors are deployed at the outlet of medium- and low-temperature waste heat circuits (such as the cylinder cooling water pipe). These sensors are connected to the intelligent controller's analog input module and communication module via 4-20mA analog signals and Modbus RTU protocol.

[0097] Among them, the PLC calculates the temperature difference between the high and low temperature circuits in real time (such as ΔT = high temperature circuit temperature - medium and low temperature circuit temperature). When ΔT ≥ 50°C, the PLC sends a switch signal through the digital output module to close the mixing valve, and simultaneously sends a pulse signal (PWM duty cycle 100%) to open the high temperature direct supply valve, ensuring that high temperature waste heat (≥ 150°C) is directly supplied to the user-end radiator through an independent pipeline.

[0098] For example, if the temperature of the high-temperature circuit is detected to be 180°C and that of the medium- and low-temperature circuit is 80°C, the PLC will immediately switch the valve state to block heat mixing and store the medium- and low-temperature waste heat in the phase change heat storage unit through the plate heat exchanger, thereby increasing the waste heat cascade utilization rate by 15%-20%.

[0099] Specifically, by monitoring the temperature difference between high and low temperature circuits and switching the status of independent pipeline valves, the problem of heat mixing and loss in multi-stage heat exchangers is resolved. This physical isolation design increases the utilization rate of waste heat by 15%-20%, reducing ineffective heat loss.

[0100] Furthermore, redundant sensors and dual communication links ensure reliable and real-time temperature differential monitoring. The temperature sensors for the high-temperature and medium-low-temperature circuits utilize dual redundancy (primary and backup K-type thermocouples and PT100s). The primary sensor communicates with the PLC via Profibus DP, while the backup sensor connects to the distributed I / O station via a hard-wired 4-20mA signal.

[0101] When the main link signal is abnormal (such as disconnection or over-range), the PLC automatically switches to the backup signal and triggers the fault indicator light of the field alarm module through the CAN bus.

[0102] The valve control adopts a master-slave dual link: the master link is Modbus TCP instruction to control the electric valve, and the slave link is a hard-wired relay to directly drive the valve emergency action.

[0103] For example, in the event of communication delay or interference, the PLC forces the mixing valve to close by sending a hardwired signal from the link, ensuring that the response time for the direct supply of high-temperature waste heat is ≤100ms.

[0104] Furthermore, the priority allocation of independent pipeline valves maximizes energy efficiency through physical isolation and dynamic signal linkage. Among them, the high-temperature direct supply valve and the medium and low-temperature heat storage valve communicate with the PLC through independent buses, and the PLC dynamically allocates control priorities according to ΔT: When ΔT≥50℃, the high-temperature valve opening is set to 100%, and the medium and low-temperature valves are closed; When ΔT is less than 50°C, the opening of the medium and low temperature valves is gradually increased to 70%, and the high temperature valve is switched to bypass mode.

[0105] For example, when compressor load fluctuations cause a brief drop in high-temperature waste heat, the PLC uses digital signals to adjust the high-temperature valve opening to 50% and simultaneously open the medium- and low-temperature valves to 30%. This proportionally distributes the mixed waste heat to the user and the thermal storage unit, preventing heat waste. The buffer tank's level sensor uses Modbus RTU protocol to provide capacity data, dynamically adjusting the valve opening strategy to ensure heating stability within an error of ≤±0.8°C.

[0106] In some embodiments, the multi-source data in S1 also includes an ambient humidity signal, and the control instruction further includes: S102. When the ambient humidity signal exceeds a preset threshold, the intermittent opening and closing frequency of the heat exchange bypass valve and the speed of the circulation pump are controlled by digital electrical signals to suppress condensation and maintain waste heat recovery efficiency.

[0107] Specifically, condensation suppression when ambient humidity exceeds the limit is achieved through coordinated control of humidity sensor signals and actuators to maintain waste heat recovery efficiency. Furthermore, capacitive humidity sensors are installed on the heat exchanger surface and in key outdoor locations. These sensors are connected to the intelligent controller's analog input module and communication module via 4-20mA analog signals and Modbus RTU protocol.

[0108] When the ambient humidity is detected to be ≥80%RH (preset threshold), the PLC sends a PWM signal (duty cycle 10%-90%) through the digital output module to control the intermittent opening and closing frequency of the heat exchange bypass valve (such as 2-5 times per second), and sends a 4-20mA signal to the circulating pump inverter through the analog output module to increase the speed to 85% of the rated value.

[0109] For example, in coastal areas with high humidity, if the risk of condensation is detected, the PLC will simultaneously trigger the rapid opening and closing of the heat exchanger bypass valve, using airflow to flush out condensed water. At the same time, the Profibus DP protocol will be used to link the compressor PLC to reduce exhaust temperature fluctuations, maintaining the waste heat recovery efficiency at more than 90% of the original efficiency.

[0110] Specifically, by incorporating an ambient humidity signal and controlling the intermittent opening and closing frequency of the heat exchanger bypass valve, the company addressed the issue of heat exchanger efficiency degradation caused by condensation in high-humidity environments. This design maintains waste heat recovery efficiency at over 90% of its original level in high-humidity conditions.

[0111] Furthermore, redundant humidity monitoring and dual-link control ensure system reliability even in high-humidity conditions. The humidity sensors utilize a primary and secondary redundant configuration, with the primary sensor communicating with the PLC via Profibus DP, and the backup sensor connected to the distributed I / O station via a hard-wired 4-20mA signal.

[0112] When the main sensor signal is abnormal (such as drift exceeding the limit), the PLC automatically switches to the backup signal and triggers the alarm relay through the CAN bus, lighting up the on-site orange warning light.

[0113] The bypass valve control adopts a master-slave dual output link: the master link is Modbus TCP instruction to control the valve opening and closing frequency, and the slave link is a hard-wired PWM signal (0-10V).

[0114] For example, in a communication delay scenario, the PLC outputs a PWM signal directly from the link to the valve to ensure an opening and closing frequency of ≥2Hz. At the same time, it records humidity exceeding the standard event via Ethernet for subsequent energy efficiency optimization analysis.

[0115] Furthermore, the linked control of valves and pump speeds achieves a balance between condensation suppression and heat transfer through physical isolation and priority allocation. The heat exchange bypass valve and circulation pump are connected via independent control loops: the valve opening and closing frequency is driven by the PLC's PWM module, while the pump speed is controlled by an analog output module.

[0116] When the ambient humidity continues to exceed the threshold, the PLC sends a high-priority instruction, forcing the valve opening and closing frequency to increase to 5Hz and simultaneously increasing the pump speed to 90%.

[0117] For example, during the rainy season, the system dynamically adjusts the valve action cycle (such as 200ms open / 200ms closed) through digital electrical signals, combined with the capacity feedback signal of the buffer water tank to smooth out heat transfer fluctuations, ensuring that the temperature fluctuation at the user end is ≤±0.5℃, while suppressing the condensation thickness on the heat exchanger surface to ≤0.1mm.

[0118] The following is an introduction to the compressor multi-dimensional detection comprehensive evaluation data processing system provided in an embodiment of the present application. The compressor multi-dimensional detection comprehensive evaluation data processing system described below and the compressor multi-dimensional detection comprehensive evaluation data processing method described above can be referenced to each other.

[0119] refer to Figure 2 The present application provides a compressor multi-dimensional detection and comprehensive evaluation data processing system, comprising: The sensor network module 1 is used to collect the ambient temperature, compressor cylinder cooling water temperature, power exhaust temperature, user-end heating temperature and circulation pipeline flow signal in real time.

[0120] The intelligent controller 2 is connected to the sensor network module communication 1, and is used to receive the multi-source data and generate control instructions based on preset priority rules. The priority rules include prioritizing high-temperature waste heat for direct heating and hierarchical storage of medium and low-temperature waste heat in phase change heat storage units.

[0121] The actuator module 3 includes a heat exchange bypass valve, a circulation pump and a heat storage unit control valve. The actuator module 3 is communicated with the intelligent controller 2 and is used to adjust the valve opening, pump speed and start and stop status of the heat storage unit according to the control instructions to achieve dynamic control of waste heat recovery and heating distribution.

[0122] The modular design (sensor network, intelligent controller, actuator) enables dynamic control of waste heat recovery and distribution, addressing the loose structure and poor interoperability of traditional systems. For example, sensor network module 1 collects multi-source data in real time and transmits it to intelligent controller 2 via a communication link. Intelligent controller 2 generates control instructions, which then drive actuator module 3 (valves, pumps, and heat storage units) via digital electrical signals, forming a closed-loop control chain. This integrated architecture reduces system response time to milliseconds and facilitates expansion and integration with other energy systems (such as solar energy).

[0123] The present application embodiment provides an electronic device, such as Figure 3 As shown, Figure 3 This is a schematic diagram of the structure of an electronic device provided in an embodiment of the present application. Figure 3 The electronic device 300 shown includes a processor 301 and a memory 303. The processor 301 and the memory 303 are connected, for example, via a bus 302. Optionally, the electronic device 300 may further include a transceiver 304. It should be noted that in actual applications, the number of transceivers 304 is not limited to one, and the structure of the electronic device 300 does not constitute a limitation on the embodiments of the present application.

[0124] Processor 301 may be a CPU (Central Processing Unit), a general-purpose processor, a DSP (Digital Signal Processor), an ASIC (Application Specific Integrated Circuit), an FPGA (Field Programmable Gate Array), or other programmable logic devices, transistor logic devices, hardware components, or any combination thereof. It may implement or execute the various exemplary logic blocks, modules, and circuits described in conjunction with the embodiments disclosed herein. Processor 301 may also be a combination that implements computing functions, such as a combination of one or more microprocessors, a combination of a DSP and a microprocessor, and the like.

[0125] The bus 302 may include a path for transmitting information between the above components. The bus 302 may be a PCI (Peripheral Component Interconnect) bus or an EISA (Extended Industry Standard Architecture) bus. The bus 302 may be divided into an address bus, a data bus, a control bus, etc. For ease of representation, Figure 3 Only one thick line is used in the diagram, but this does not mean that there is only one bus or one type of bus.

[0126] The memory 303 may be a ROM (Read Only Memory) or other types of static storage devices that can store static information and instructions, a RAM (Random Access Memory) or other types of dynamic storage devices that can store information and instructions, or an EEPROM (Electrically Erasable Programmable Read Only Memory), a CD-ROM (Compact Disc Read Only Memory) or other optical disk storage, optical disk storage (including compact discs, laser discs, optical discs, digital versatile discs, Blu-ray discs, etc.), a magnetic disk storage medium or other magnetic storage device, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and can be accessed by a computer, but is not limited thereto.

[0127] The memory 303 is used to store application code for executing the solution of the embodiment of the present application, and the execution is controlled by the processor 301. The processor 301 is used to execute the application code stored in the memory 303 to implement the content shown in the above method embodiment.

[0128] Among them, electronic devices include but are not limited to: mobile terminals such as mobile phones, laptops, digital broadcast receivers, PDAs (personal digital assistants), PADs (tablet computers), PMPs (portable multimedia players), vehicle-mounted terminals (such as vehicle-mounted navigation terminals), etc., and fixed terminals such as digital TVs, desktop computers, etc. Figure 3 The electronic device shown is merely an example and should not limit the functions and scope of use of the embodiments of the present application.

[0129] An embodiment of the present application provides a computer-readable storage medium having a computer program stored thereon. When the computer program is executed by a processor, the steps of the above-mentioned method for processing data of multi-dimensional detection and comprehensive evaluation of a compressor are implemented.

[0130] Since the embodiments of the computer-readable storage medium part and the embodiments of the method part correspond to each other, the embodiments of the computer-readable storage medium part refer to the description of the embodiments of the method part.

[0131] It should be understood that although the steps in the flowcharts of the accompanying drawings are shown in sequence as indicated by the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless otherwise specified herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some of the steps in the flowcharts of the accompanying drawings may include multiple sub-steps or multiple stages, and these sub-steps or stages are not necessarily executed at the same time, but can be executed at different times, and their execution order is not necessarily sequential, but can be executed in turn or alternately with other steps or at least a portion of the sub-steps or stages of other steps.

[0132] The above are only some of the implementation methods of the present application. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present application. These improvements and modifications should also be regarded as the scope of protection of the present application.

Claims

1. A method for processing data of multi-dimensional detection and comprehensive evaluation of compressors, characterized in that: include: Collect multi-source data in real time through a sensor network, including ambient temperature signals, compressor cylinder cooling water temperature signals, power exhaust temperature signals, user-end heating temperature signals, and circulation pipeline flow signals; The multi-source data is transmitted to the intelligent controller, and the waste heat recovery and distribution strategy is determined based on preset priority rules, wherein the priority rules include prioritizing high-temperature waste heat for direct heating and hierarchical storage of medium and low-temperature waste heat in phase change heat storage units; Control instructions are generated according to the priority rules, and the opening of the heat exchange bypass valve, the speed of the circulation pump and the start and stop status of the heat storage unit are adjusted through digital electrical signals to achieve dynamic matching of waste heat recovery, heat storage release and heating demand.

2. The method according to claim 1, characterized in that The priority rules further include: When the ambient temperature signal is lower than the first threshold, the control instruction preferentially closes the valve of the heat storage unit and increases the speed of the circulation pump to directly deliver the high-temperature waste heat to the user end; When the ambient temperature signal is higher than the second threshold, the control instruction opens the valve of the heat storage unit and reduces the speed of the circulation pump to store the medium and low temperature waste heat in the phase change heat storage unit.

3. The method according to claim 1, characterized in that The priority rules further include: when it is detected that the compressor load change rate exceeds a preset threshold, the intelligent controller generates a graded response instruction, and synchronously adjusts the opening of the heat exchange bypass valve, the circulation pump speed and the opening and closing status of the heat storage unit valve through digital electrical signals to match the waste heat distribution requirements under load fluctuations.

4. The method according to claim 1, wherein The generation of the control instruction also includes: real-time monitoring of the heat storage / release rate of the heat storage unit through digital electrical signals. When the rate is lower than a preset threshold, a backup heat storage module access instruction is generated, and the valve of the current heat storage unit is closed to switch to the backup module, and a maintenance reminder signal is triggered at the same time.

5. The method according to claim 1, wherein The generation of the control instruction further includes: According to the difference between the circulation pipeline flow signal and the user-end heating temperature signal, the opening of the heat exchange bypass valve is adjusted in real time to balance the waste heat recovery efficiency and heating stability.

6. The method according to claim 1, characterized in that The multi-source data also includes outlet temperature signals of each stage of heat exchangers. The control instructions further include: switching the status of independent pipeline valves through digital electrical signals based on the temperature difference between the high-temperature waste heat and the medium- and low-temperature waste heat circuits to achieve physical isolation and priority allocation of heat transfer paths.

7. The method according to claim 1, characterized in that The multi-source data also includes an ambient humidity signal, and the control instruction further includes: when the ambient humidity signal exceeds a preset threshold, controlling the intermittent opening and closing frequency of the heat exchange bypass valve and the speed of the circulation pump through a digital electrical signal to suppress condensation and maintain waste heat recovery efficiency.

8. A compressor multi-dimensional detection and comprehensive evaluation data processing system, characterized by: include: The sensor network module is used to collect real-time ambient temperature, compressor cylinder cooling water temperature, power exhaust temperature, user-end heating temperature and circulation pipeline flow signals; an intelligent controller, communicatively connected to the sensor network module, configured to receive the multi-source data and generate control instructions based on preset priority rules, wherein the priority rules include prioritizing high-temperature waste heat for direct heating and hierarchical storage of medium and low-temperature waste heat in phase change thermal storage units; The actuator module includes a heat exchange bypass valve, a circulation pump and a heat storage unit control valve. The actuator module is communicated with the intelligent controller and is used to adjust the valve opening, pump speed and start and stop status of the heat storage unit according to the control instructions to achieve dynamic control of waste heat recovery and heating distribution.

9. An electronic device, characterized in that: include: one or more processors; one or more memories; and one or more computer programs, wherein the one or more computer programs are stored in the one or more memories, and the one or more computer programs include instructions that, when executed by the one or more processors, cause the electronic device to perform the method as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that The storage medium stores a program or instruction, and when the program or instruction is executed, the method according to any one of claims 1 to 7 is implemented.

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