Air compressor fault detection system

Abstract

The invention relates to the technical field of air compressor detection, and discloses an air compressor fault detection system which comprises an oil-gas separator pressure data acquisition unit and a lubricating oil level sensing unit. According to the air compressor fault detection system, the inlet pressure value when gas generated in the working process of the air compressor enters the oil-gas separator, the outflow pressure value when the gas flows out of the oil-gas separator, oil level real-time data and the real-time gas temperature when gas is discharged from the gas outlet position of the air compressor are obtained in real time; the data are processed and analyzed, whether an oil-gas separator of the air compressor breaks down or a filter element of the oil-gas separator is aged or not is judged, corresponding signals are generated, and operation and maintenance personnel maintain or repair the air compressor according to the corresponding signals, so that the air compressor is detected in real time; whether the air compressor is in a normal state is judged timely.

Description

Technical Field

[0001] The present invention relates to the technical field of air compressor detection, in particular to an air compressor fault detection system. Background Art

[0002] Air compressors are categorized as air-cooled, oil-cooled, and oil-free. In oil-lubricated air compressors, the oil-air mixture generates high temperatures during compression, and the lubricating oil helps cool and lubricate the compressor components. However, this also causes some lubricating oil to be carried away by the compressed air. To prevent oil mist from entering downstream equipment or affecting air quality, an oil-air separator is required to capture these droplets, delivering clean air to the point of use while recovering the lubricating oil for recycling.

[0003] During the long-term operation of the air compressor, due to wear, aging, environmental factors and other reasons, its oil-gas separator and its filter element gradually age, clog and damage as the air compressor is used, which in turn causes the air compressor to malfunction. Currently, only when the air compressor malfunctions can the oil-gas separator be disassembled to determine whether there is an abnormality in the oil-gas separator or the filter element. It is impossible to analyze the oil-gas separator based on the various data generated by the air compressor during operation to determine whether it is in a normal state. Summary of the Invention

[0004] (1) Technical problems solved In response to the deficiencies in the prior art, the present invention provides an air compressor fault detection system, which has the advantages of obtaining in real time the inlet pressure value of the gas generated by the air compressor when it enters the oil-gas separator, the outlet pressure value of the gas flowing out of the oil-gas separator, the real-time oil level data, and the real-time gas temperature of the air at the outlet position of the air compressor during operation, and processing and analyzing these data to determine whether the air compressor has an oil-gas separator failure or an oil-gas separator filter aging, and generate corresponding signals. Operation and maintenance personnel maintain or repair the air compressor according to the corresponding signals, thereby realizing real-time detection of the air compressor and timely judgment of whether the air compressor is in a normal state, etc., thereby solving the above-mentioned problems.

[0005] (2) Technical solution To achieve the above object, the present invention provides the following technical solutions: an air compressor fault detection system, comprising an oil-gas separator pressure data acquisition unit, a lubricating oil level sensing unit, an exhaust temperature sensing unit, a data analysis unit, and a fault alarm unit; The oil-gas separator pressure data acquisition unit is used to acquire the inlet pressure value of the gas entering the oil-gas separator and the outlet pressure value of the gas flowing out of the oil-gas separator, and send the acquired multiple inlet pressure values ​​and multiple outlet pressure values ​​to the data analysis unit; The lubricating oil level sensing unit is used to collect real-time oil level data of the lubricating oil of the air compressor and send the collected multiple real-time oil level data to the data analysis unit; The exhaust temperature sensing unit is used to collect the real-time gas temperature of the exhaust gas at the air outlet of the air compressor, and send the collected multiple real-time gas temperatures to the data analysis unit; The data analysis unit performs corresponding data cleaning on the plurality of inlet pressure values ​​and the plurality of outflow pressure values ​​to obtain an inlet pressure cleaning value and an outflow pressure cleaning value, respectively, and the data analysis unit calculates an inlet and outlet pressure difference based on the pressure cleaning value and the outflow pressure cleaning value; The data analysis unit calculates lubricating oil consumption based on real-time data; The data analysis unit calculates the gas temperature growth rate based on the multiple real-time gas temperatures; When the data analysis unit calculates the inlet and outlet pressure difference, lubricating oil consumption, and gas temperature growth rate, and judges whether each value is abnormal according to the corresponding threshold value, and judges whether the air compressor has an oil-gas separator failure or an oil-gas separator filter aging based on the abnormal value, and generates an oil-gas separation failure signal or a filter aging signal accordingly, the data analysis unit sends the generated oil-gas separation failure signal or filter aging signal to the fault alarm unit; The fault alarm unit issues a corresponding early warning after receiving an oil-gas separation fault signal or a filter element aging signal.

[0006] Preferably, the plurality of inlet pressure values ​​are respectively expressed as , the multiple outflow pressure values ​​are respectively expressed as: , multiple real-time oil level data are represented as The real-time gas temperature at the time of gas outlet is expressed as , and multiple inlet pressure values, multiple outflow pressure values, multiple oil level real-time data, and multiple real-time gas temperatures at gas outlet are in the same collection cycle.

[0007] Preferably, the calculation expression of the entry pressure cleaning value is as follows: In the formula, Expressed as the entry pressure cleaning value, Indicates the sum of all incoming pressure values ​​within this acquisition cycle. Indicates the summed result divided by the number of all inlet pressure values The result is the pressure cleaning value .

[0008] Preferably, the outflow pressure cleaning value calculation expression is as follows: In the formula, Expressed as outflow pressure cleaning value, Indicates the sum of all outflow pressure values ​​within this collection cycle. Indicates the sum of the results divided by the total number of outflow pressure values The result is the outflow pressure cleaning value .

[0009] Preferably, the inlet and outlet pressure difference calculation expression is as follows: In the formula, Indicates the difference in inlet and outlet pressure. Indicates the difference between the outflow pressure cleaning value and the inflow pressure cleaning value.

[0010] Preferably, the lubricating oil consumption calculation expression is as follows: In the formula, Indicates lubricating oil consumption, Indicates the last real-time oil level data in this collection cycle and first oil level real-time data The difference between the two values ​​is the lubricating oil consumption of the oil-gas separator during this collection period. .

[0011] Preferably, the gas temperature growth rate calculation expression is as follows: In the formula, represents the gas temperature growth rate, Indicates the difference between the real-time gas temperature at the last gas outlet and the real-time gas temperature at the first gas outlet in this collection cycle. The result of dividing this difference by the real-time gas temperature at the first gas outlet is the gas temperature growth rate. .

[0012] Preferably, the inlet and outlet pressure difference threshold is expressed as: , the lubricating oil consumption threshold is expressed as: , the gas temperature growth rate threshold is expressed as: .

[0013] Preferably, when the inlet and outlet pressure difference Greater than the inlet and outlet pressure difference threshold When the inlet and outlet pressure difference is determined Abnormality occurs when the lubricating oil consumption Greater than the lubricating oil consumption threshold When the lubricating oil consumption is Abnormality occurs when the gas temperature increases Greater than the gas temperature growth rate threshold When the gas temperature increases An exception occurred.

[0014] Preferably, when only the inlet and outlet pressure difference occurs When abnormal, it is determined that the filter element of the oil-gas separator is clogged and needs to be replaced; When lubricant consumption occurs Abnormal and gas temperature increase When abnormal, it is determined that the filter element of the oil-gas separator is damaged and needs to be replaced; When the gas temperature increases Abnormal, lubricating oil consumption Abnormal and inlet and outlet pressure differences When abnormal, it is determined that the oil-gas separator is faulty.

[0015] Compared with the prior art, the present invention provides an air compressor fault detection system with the following beneficial effects: The present invention obtains in real time the inlet pressure value of the gas generated by the air compressor when it enters the oil-gas separator during operation, the outlet pressure value of the gas flowing out of the oil-gas separator, the real-time data of the oil level, and the real-time gas temperature of the air outlet position of the air compressor when the gas is discharged, and processes and analyzes these data to determine whether the air compressor has an oil-gas separator failure or an oil-gas separator filter aging, and generates a corresponding signal. The operation and maintenance personnel maintain or repair the air compressor according to the corresponding signal, thereby realizing real-time detection of the air compressor and timely judgment of whether the air compressor is in a normal state. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Schematic diagram of the system flow of the present invention. DETAILED DESCRIPTION

[0017] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0018] See also Figure 1 , an air compressor fault detection system, which consists of an oil-gas separator pressure data acquisition unit, a lubricating oil level sensing unit, an exhaust temperature sensing unit, a data analysis unit and a fault alarm unit.

[0019] The oil-gas separator pressure data acquisition unit is used to collect the inlet pressure value of the gas entering the oil-gas separator and the outlet pressure value of the gas flowing out of the oil-gas separator, and send the collected multiple inlet pressure values ​​and multiple outlet pressure values ​​to the data analysis unit. The lubricating oil level sensor unit is used to collect the real-time oil level data of the lubricating oil of the air compressor, and send the collected multiple real-time oil level data to the data analysis unit. The exhaust temperature sensor unit is used to collect the real-time gas temperature of the air compressor outlet position when the air is discharged, and send the collected multiple real-time gas temperatures to the data analysis unit.

[0020] Multiple inlet pressure values ​​are expressed as , multiple outflow pressure values ​​are expressed as: , multiple oil level real-time data are expressed as , the real-time gas temperature at multiple outlets is expressed as .

[0021] It should be noted that multiple inlet pressure values, multiple outflow pressure values, multiple real-time oil level data, and multiple real-time gas temperatures at gas outlet belong to the same collection period.

[0022] The data analysis unit performs corresponding data cleaning on multiple inlet pressure values ​​and multiple outflow pressure values ​​to obtain an inlet pressure cleaning value and an outflow pressure cleaning value, respectively. The algorithm expressions are as follows: The calculation expression for the pressure cleaning value is as follows: In the formula, Expressed as the entry pressure cleaning value, Indicates the sum of all incoming pressure values ​​within this acquisition cycle. Indicates the summed result divided by the number of all inlet pressure values The result is the pressure cleaning value .

[0023] The calculation expression of outflow pressure cleaning value is as follows: In the formula, Expressed as outflow pressure cleaning value, Indicates the sum of all outflow pressure values ​​within this collection cycle. Indicates the sum of the results divided by the total number of outflow pressure values The result is the outflow pressure cleaning value .

[0024] After the inlet pressure cleaning value and the outlet pressure cleaning value are calculated, the data analysis unit calculates the inlet and outlet pressure difference based on the pressure cleaning value and the outlet pressure cleaning value. The calculation expression is as follows: In the formula, Indicates the difference in inlet and outlet pressure. Indicates the difference between the outflow pressure cleaning value and the inflow pressure cleaning value.

[0025] The data analysis unit calculates the lubricating oil consumption based on real-time data. The specific expression is as follows: In the formula, Indicates lubricating oil consumption, Indicates the last real-time oil level data in this collection cycle and first oil level real-time data The difference between the two values ​​is the lubricating oil consumption of the oil-gas separator during this collection period. .

[0026] The data analysis unit calculates the gas temperature growth rate based on multiple real-time gas temperatures. The specific expression is as follows: In the formula, represents the gas temperature growth rate, Indicates the difference between the real-time gas temperature at the last gas outlet and the real-time gas temperature at the first gas outlet in this collection cycle. The result of dividing this difference by the real-time gas temperature at the first gas outlet is the gas temperature growth rate. .

[0027] When the data analysis unit calculates the inlet and outlet pressure difference, lubricating oil consumption and gas temperature growth rate, it judges whether the corresponding values ​​are abnormal according to the corresponding thresholds, and judges whether the air compressor has an oil-gas separator failure or oil-gas separator filter aging based on the abnormal values. Among them, the inlet and outlet pressure difference threshold is expressed as: , the lubricating oil consumption threshold is expressed as: , the gas temperature growth rate threshold is expressed as: .

[0028] The specific judgment is as follows: When the inlet and outlet pressure difference Greater than the inlet and outlet pressure difference threshold When the inlet and outlet pressure difference is determined An abnormality occurs; When lubricating oil consumption Greater than the lubricating oil consumption threshold When the lubricating oil consumption is An abnormality occurs; When the gas temperature increases Greater than the gas temperature growth rate threshold When the gas temperature increases An abnormality occurs; When only the inlet and outlet pressure difference occurs When abnormal, it is determined that the filter element of the oil-gas separator is clogged and needs to be replaced, and a filter element aging signal is generated; When lubricant consumption occurs Abnormal and gas temperature increase When abnormal, it is determined that the filter element of the oil-gas separator is damaged and needs to be replaced, and a filter element aging signal is generated; When the gas temperature increases Abnormal, lubricating oil consumption Abnormal and inlet and outlet pressure differences When abnormal, the oil-gas separator is judged to be faulty and an oil-gas separation fault signal is generated; The data analysis unit sends the generated oil-gas separation fault signal or filter element aging signal to the fault alarm unit. After receiving the oil-gas separation fault signal or filter element aging signal, the fault alarm unit issues a corresponding early warning. The operation and maintenance personnel maintain and repair the air compressor according to the early warning output by the fault alarm unit.

[0029] By obtaining in real time the inlet pressure value of the gas generated by the air compressor when it enters the oil-gas separator, the outlet pressure value of the gas flowing out of the oil-gas separator, the real-time oil level data, and the real-time gas temperature of the air at the outlet position of the air compressor during operation, and processing and analyzing these data, it is determined whether the air compressor has an oil-gas separator failure or an oil-gas separator filter aging, and generating corresponding signals. The operation and maintenance personnel maintain or repair the air compressor according to the corresponding signals, thereby realizing real-time detection of the air compressor and timely determining whether the air compressor is in normal condition.

[0030] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An air compressor fault detection system, characterized in that: It includes oil-gas separator pressure data acquisition unit, lubricating oil level sensing unit, exhaust temperature sensing unit, data analysis unit and fault alarm unit; The oil-gas separator pressure data acquisition unit is used to acquire the inlet pressure value of the gas entering the oil-gas separator and the outlet pressure value of the gas flowing out of the oil-gas separator, and send the acquired multiple inlet pressure values ​​and multiple outlet pressure values ​​to the data analysis unit; The lubricating oil level sensing unit is used to collect real-time oil level data of the lubricating oil of the air compressor and send the collected multiple real-time oil level data to the data analysis unit; The exhaust temperature sensing unit is used to collect the real-time gas temperature of the exhaust gas at the air outlet of the air compressor, and send the collected multiple real-time gas temperatures to the data analysis unit; The data analysis unit performs corresponding data cleaning on the plurality of inlet pressure values ​​and the plurality of outflow pressure values ​​to obtain an inlet pressure cleaning value and an outflow pressure cleaning value, respectively, and the data analysis unit calculates an inlet and outlet pressure difference based on the pressure cleaning value and the outflow pressure cleaning value; The data analysis unit calculates lubricating oil consumption based on real-time data; The data analysis unit calculates the gas temperature growth rate based on the multiple real-time gas temperatures; When the data analysis unit calculates the inlet and outlet pressure difference, lubricating oil consumption, and gas temperature growth rate, and judges whether each value is abnormal according to the corresponding threshold value, and judges whether the air compressor has an oil-gas separator failure or an oil-gas separator filter aging based on the abnormal value, and generates an oil-gas separation failure signal or a filter aging signal accordingly, the data analysis unit sends the generated oil-gas separation failure signal or filter aging signal to the fault alarm unit; The fault alarm unit issues a corresponding early warning after receiving an oil-gas separation fault signal or a filter element aging signal.

2. An air compressor fault detection system according to claim 1, characterized in that: The plurality of inlet pressure values ​​are respectively expressed as , the multiple outflow pressure values ​​are respectively expressed as: , multiple real-time oil level data are represented as The real-time gas temperature at the time of gas outlet is expressed as , and multiple inlet pressure values, multiple outflow pressure values, multiple oil level real-time data, and multiple real-time gas temperatures at gas outlet are in the same collection cycle.

3. An air compressor fault detection system according to claim 2, characterized in that: The calculation expression of the entry pressure cleaning value is as follows: In the formula, Expressed as the entry pressure cleaning value, Indicates the sum of all incoming pressure values ​​within this acquisition cycle. Indicates the summed result divided by the number of all inlet pressure values The result is the pressure cleaning value .

4. An air compressor fault detection system according to claim 3, characterized in that: The outflow pressure cleaning value calculation expression is as follows: In the formula, Expressed as outflow pressure cleaning value, Indicates the sum of all outflow pressure values ​​within this collection cycle. Indicates the sum of the results divided by the total number of outflow pressure values The result is the outflow pressure cleaning value .

5. An air compressor fault detection system according to claim 4, characterized in that: The calculation expression of the inlet and outlet pressure difference is as follows: In the formula, Indicates the difference in inlet and outlet pressure. Indicates the difference between the outflow pressure cleaning value and the inflow pressure cleaning value.

6. An air compressor fault detection system according to claim 5, characterized in that: The lubricating oil consumption calculation expression is as follows: In the formula, Indicates lubricating oil consumption, Indicates the last real-time oil level data in this collection cycle and first oil level real-time data The difference between the two values ​​is the lubricating oil consumption of the oil-gas separator during this collection period. .

7. An air compressor fault detection system according to claim 6, characterized in that: The gas temperature growth rate calculation expression is as follows: In the formula, represents the gas temperature growth rate, Indicates the difference between the real-time gas temperature at the last gas outlet and the real-time gas temperature at the first gas outlet in this collection cycle. The result of dividing this difference by the real-time gas temperature at the first gas outlet is the gas temperature growth rate. .

8. An air compressor fault detection system according to claim 7, characterized in that: The inlet and outlet pressure difference threshold is expressed as: , the lubricating oil consumption threshold is expressed as: , the gas temperature growth rate threshold is expressed as: .

9. An air compressor fault detection system according to claim 8, characterized in that: When the inlet and outlet pressure difference Greater than the inlet and outlet pressure difference threshold When the inlet and outlet pressure difference is determined Abnormality occurs when the lubricating oil consumption Greater than the lubricating oil consumption threshold When the lubricating oil consumption is Abnormality occurs when the gas temperature increases Greater than the gas temperature growth rate threshold When the gas temperature increases An exception occurred.

10. The air compressor fault detection system according to claim 1, characterized in that: When only the inlet and outlet pressure difference occurs When abnormal, it is determined that the filter element of the oil-gas separator is clogged and needs to be replaced; When lubricant consumption occurs Abnormal and gas temperature increase When abnormal, it is determined that the filter element of the oil-gas separator is damaged and needs to be replaced; When the gas temperature increases Abnormal, lubricating oil consumption Abnormal and inlet and outlet pressure differences When abnormal, it is determined that the oil-gas separator is faulty.

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