A mobile multi-functional nitrogen generator and its intelligent control system

Abstract

This invention provides a mobile, multifunctional nitrogen generator and its intelligent control system. The device includes a housing with lifting components on both sides and a moving component at the bottom. Internally, it houses a primary gas compressor, an air-cooled module, a liquid-cooled module, a dehydration module, a nitrogen separation membrane, a pipeline and valve integration module, and a secondary gas compressor, connected in series. The generator outputs either high-purity, low-pressure nitrogen or high-pressure, low-purity nitrogen. It also includes an intelligent pressure control unit, a remote online monitoring unit, an intelligent leak detection unit, a predictive maintenance unit, and a main control module for coordinating the operation of all units. This device is easy to transport and carry, generates high-purity nitrogen without the risk of over-pressurization, and can also generate high-pressure nitrogen. It can collect pressure, temperature, and flow rate data in real time, enabling intelligent pressure control and remote monitoring and early warning functions.

Description

Technical Field

[0001] This invention relates to the field of nitrogen generation technology, and in particular to a mobile multifunctional nitrogen generation device and intelligent control system. Background Technology

[0002] A nitrogen generator is a device that uses air as raw material and separates oxygen and nitrogen in it using physical methods to obtain nitrogen gas. Currently, when performing nitrogen filling and pressure holding operations on air conditioning pipelines or when using it for welding protection, workers need to carry heavy and potentially dangerous high-pressure nitrogen cylinders. This is inconvenient for workers to carry and poses a certain degree of danger.

[0003] Nitrogen purging and pressurization of air conditioning pipes requires high-pressure, low-purity nitrogen, while welding protection requires low-pressure, high-purity nitrogen. Existing nitrogen cylinders cannot switch between these pressures and purities and lack monitoring and early warning functions. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a mobile, multifunctional nitrogen generator and intelligent control system. This device is easy to transport and carry, and can generate high-purity nitrogen gas without the risk of over-pressurization. It can also generate high-pressure nitrogen gas and can collect data such as pressure, temperature, and flow rate in real time, enabling intelligent pressure control and remote monitoring and early warning functions.

[0005] To solve the above problems, the technical solution adopted by the present invention is as follows:

[0006] A mobile multi-functional nitrogen generator includes a housing, with lifting components on both sides and a moving component at the bottom. Inside the housing are a primary gas compressor, an air-cooled module, a liquid-cooled module, a water removal module, a nitrogen separation membrane, a pipeline and valve integrated module, and a secondary gas compressor, which are connected in series.

[0007] Air passes sequentially through a primary gas compressor, an air-cooled module, a liquid-cooled module, a water removal module, a nitrogen separation membrane, and a pipeline and valve integration module before outputting high-purity, low-pressure nitrogen.

[0008] Air passes sequentially through a primary gas compressor, an air-cooled module, a liquid-cooled module, a dehydration module, a nitrogen separation membrane, a pipeline and valve integration module, and a secondary gas compressor before outputting high-pressure, low-purity nitrogen.

[0009] It also includes a control system, which comprises a power hardware control unit, a nitrogen generator software control unit, an intelligent pressure control unit, a remote online monitoring unit, and an intelligent leak detection unit.

[0010] Preferably, the lifting assembly includes handles fixedly installed on the top of the front and rear sides of the equipment housing, and a pull rod is rotatably connected to the front end of the equipment housing. The moving assembly includes two pairs of moving wheels installed at the bottom of the equipment housing, the front pair of moving wheels being universal wheels and the rear pair of moving wheels being directional wheels.

[0011] Preferably, a pair of intake fans are installed on the rear side of the equipment housing, and cooling fans are provided on the front side, both sides of the equipment housing, and the primary gas compressor.

[0012] Preferably, the compressor filter element of the primary gas compressor is exposed on the outside of the equipment housing, and the cylinder heads of the inlet and outlet ends of the secondary gas compressor are covered with air guide shrouds, with cooling fans installed at the openings of the air guide shrouds.

[0013] Preferably, the air-cooled module consists of a spiral heat dissipation pipe and an air-cooled fan. The air outlet end of the spiral heat dissipation pipe is also equipped with an air-cooled module temperature sensor, and the air outlet end of the liquid-cooled module is equipped with a liquid-cooled module temperature sensor.

[0014] Preferably, the dehydration module includes an air source dryer, a primary micron-sized sieve, and a secondary nano-sized sieve connected in series. The cooled compressed air passes through the air source dryer, the primary micron-sized sieve, and the secondary nano-sized sieve in sequence before being output as dry air. A low-pressure sensor is installed at the air outlet of the dehydration module.

[0015] Preferably, one end of the nitrogen separation membrane is provided with an oxygen outlet and a nitrogen outlet, and the oxygen outlet is connected to an oxygen storage tank.

[0016] Preferably, the integrated pipeline valve module includes an inlet pipeline, a high-purity low-pressure pipeline, a low-purity high-pressure pipeline, a switching pipeline, an output pipeline, and a detection pipeline. Low-pressure solenoid valves are installed at the connections between the high-purity low-pressure pipeline, the low-purity high-pressure pipeline, and the inlet pipeline. A flow regulating valve is connected in series on the high-purity low-pressure pipeline. The high-purity low-pressure pipeline and the switching pipeline are connected via a connecting pipe. A mesh gas storage pipeline is installed within the low-purity high-pressure pipeline. The outlet of the mesh gas storage pipeline is connected to the secondary gas compressor via an exhaust pipe. High-pressure low-purity nitrogen output from the secondary gas compressor enters the switching pipeline through a one-way valve. A pair of first high-pressure solenoid valves are installed on the switching pipeline. Second high-pressure solenoid valves are installed on both the output pipeline and the detection pipeline. A nitrogen outlet is provided at the end of the output pipeline.

[0017] Preferably, a pressure relief valve and a high-pressure sensor are installed on the output pipeline, and a humidity sensor and a nitrogen purity sensor are connected in series on the detection pipeline.

[0018] Preferably, the top of the equipment housing is equipped with a UI interface and a button / parameter setting function module, which allows users to manually set the pipeline nitrogen filling pressure value based on their manual calculation experience.

[0019] The remote online monitoring unit automatically collects the working time, nitrogen purity, humidity and dew point parameters during pipeline welding and nitrogen pressure holding operations. After completion, it connects to a smart pressure gauge with 4G positioning function to remotely monitor and warn of pipeline pressure anomalies in real time on the Internet of Things platform.

[0020] After vacuuming, the intelligent leak detection unit can perform negative pressure leak detection on the pipeline. Alternatively, after nitrogen purging and pressure maintenance, it can collect and calculate data using pressure and temperature sensors to determine whether there is any abnormal leakage in the pipeline.

[0021] The present invention also provides an intelligent control system for a mobile multifunctional nitrogen generator, including an intelligent pressure control unit, a remote online monitoring unit, an intelligent leak detection unit, a predictive maintenance unit, and a main control module for coordinating the collaborative work of each unit, wherein each unit is electrically connected to the main control module;

[0022] The intelligent pressure control unit includes a parameter input module, a sensor group one, an algorithm processing module one, and a pressure regulation execution module. The parameter input module includes a mobile APP mini-program interaction module and a UI interface and button interaction module, used to receive air conditioning system parameters input by the user or manually set pressure values. The sensor group one includes a flow sensor, a pressure sensor, and a temperature sensor, used to collect gas temperature, ambient temperature, and pipeline flow parameters. The algorithm processing module one is used to calculate the pipeline capacity and determine the target pressure holding value based on the parameters received by the parameter input module or the parameters collected by the sensor group one. The pressure regulation execution module is used to control the pressurization action of the nitrogen generator according to the target pressure holding value, and automatically stops pressurization when the pressure reaches the target pressure holding value.

[0023] The remote online monitoring unit includes a 4G positioning module, a data acquisition module, a smart pressure gauge communication module, and an IoT platform interaction module. The 4G positioning module is used to acquire the location information of the nitrogen generator. The data acquisition module is used to collect the working time, nitrogen purity, humidity and dew point parameters during pipeline welding and nitrogen pressure holding operations. The smart pressure gauge communication module is used to establish a communication connection with a smart pressure gauge with 4G positioning function. The IoT platform interaction module is used to upload the collected location information, operation parameters, and pipeline pressure data fed back by the smart pressure gauge to the IoT platform to realize remote real-time monitoring and pressure anomaly early warning.

[0024] The intelligent leak detection unit includes a negative pressure detection module, a second sensor group, and a second algorithm processing module. The negative pressure detection module is used to detect negative pressure leaks in the pipeline after vacuuming. The second sensor group includes a pressure sensor and a temperature sensor, which are used to collect pipeline pressure and ambient temperature data after nitrogen purging and pressurization. The second algorithm processing module is used to calculate and analyze the data collected by the second sensor group to determine whether there is a leak in the pipeline.

[0025] The predictive maintenance unit includes a life calibration module, a sensor group three, an anomaly analysis module, and an early warning module. The life calibration module is used to calibrate the life parameters of key components and vulnerable parts of the nitrogen generator. The sensor group three includes a pressure sensor, a temperature sensor, a flow sensor, a purity sensor, and a humidity sensor, which are used to monitor the working status parameters of each component in real time. The anomaly analysis module is used to analyze and determine abnormal modules and components based on the parameters collected by the sensor group three and the life calibration data. The early warning module includes a UI interface prompt module and an IoT platform early warning module, which are used to display abnormal codes through the UI interface and send abnormal early warning information to the IoT platform.

[0026] The beneficial effects of this invention are as follows:

[0027] 1. The equipment is easy to move with its design of 2 omnidirectional wheels + 2 fixed wheels + pull rod. The front and rear ends are designed with handles with a spacing of about 0.6m, which makes it easy for a single person to carry. The outer shell and frame of the equipment are made of lightweight metals such as aluminum alloy or high-polymer composite materials such as carbon fiber, which greatly reduces the weight of the equipment to less than 50kg. By integrating the pipes and valves, the size of the equipment is greatly reduced, and the weight of the equipment is also reduced.

[0028] 2. Air sequentially passes through a primary gas compressor, an air-cooled module, a liquid-cooled module, a dehumidification module, a nitrogen separation membrane, and a pipeline valve integration module before outputting high-purity, low-pressure nitrogen. High-purity nitrogen with a purity ≥99.5% is produced through membrane separation. Air also sequentially passes through a secondary gas compressor, air-cooled module, liquid-cooled module, dehumidification module, nitrogen separation membrane, pipeline valve integration module, and a secondary gas compressor before outputting high-pressure, low-purity nitrogen. High-pressure nitrogen with a purity ≥85% and a pressure ≥4.5 MPa is produced through a high-pressure compressor. The equipment utilizes multiple condensation processes (air-cooled module + liquid-cooled module) to ensure the output nitrogen dew point reaches below -25℃ and -40℃.

[0029] 3. The target pressure can be set through the UI interface and button / parameter setting function module. When the pressure reaches the set value, the equipment will automatically stop pressurizing to prevent excessive pressure from damaging the pipeline, and no personnel monitoring is required. The equipment is equipped with a safety pressure relief valve, which will automatically release pressure when the equipment is powered off or the pressure exceeds the safe range to protect the safety of personnel and equipment.

[0030] 4. Dual-mode nitrogen and oxygen production: oxygen is stored simultaneously while nitrogen is being produced. When the pressure in the oxygen storage tank reaches the set value, it is filled into the oxygen cylinder through a booster.

[0031] 5. The compressor and solenoid valves in the equipment generate heat, and overheating will greatly reduce the service life of the equipment. By designing the air duct so that the equipment has air intake on one side and air outlet on three sides, and placing the heat-generating components at the air outlet, the rate of temperature rise of the equipment can be effectively reduced.

[0032] 6. The remote online monitoring unit automatically collects parameters such as working time, nitrogen purity, humidity, and dew point during pipeline welding and nitrogen pressurization operations. After completion, it connects to a smart pressure gauge with 4G positioning function to remotely monitor pipeline pressure anomalies and issue warnings in real time on the Internet of Things platform. The intelligent leak detection unit can perform negative pressure leak detection on the pipeline after vacuuming operations, or after nitrogen pressurization, it can collect and calculate data through pressure sensors and temperature sensors to determine whether there are any abnormal leaks in the pipeline. Attached Figure Description

[0033] Figure 1 This is a front perspective view of the present invention;

[0034] Figure 2 This is a rear perspective view of the present invention;

[0035] Figure 3 This is a perspective view of the intake fan of the present invention;

[0036] Figure 4 This is a three-dimensional schematic diagram of the internal structure of the present invention;

[0037] Figure 5 This is a front view of the present invention;

[0038] Figure 6 This is a front perspective view of the pipeline valve integration module proposed in this invention;

[0039] Figure 7 This is a rear perspective view of the pipeline valve integrated module proposed in this invention;

[0040] Figure 8 This is a cross-sectional view of the low-purity high-pressure pipeline proposed in this invention;

[0041] Figure 9 This is a three-dimensional view of the first-stage gas compressor proposed in this invention;

[0042] Figure 10 This is a perspective view of the air-cooled module proposed in this invention;

[0043] Figure 11 This is a perspective view of the liquid cooling module proposed in this invention;

[0044] Figure 12This is a three-dimensional view of the water removal module proposed in this invention;

[0045] Figure 13 This is a three-dimensional view of the nitrogen separation membrane proposed in this invention;

[0046] Figure 14 This is a three-dimensional view of the two-stage gas compressor proposed in this invention;

[0047] Figure 15 This is a flowchart illustrating the design process of the present invention.

[0048] Figure 16 This is a block diagram of the intelligent control system of the present invention.

[0049] In the diagram: 1. Equipment housing; 2. UI interface and button / parameter setting function module; 3. Pipeline and valve integration module; 31. Nitrogen outlet; 32. Low-purity high-pressure pipeline; 33. Output pipeline; 34. Low-pressure solenoid valve; 35. Flow regulating valve; 36. Exhaust pipe; 37. Connecting pipe; 38. Check valve; 39. First high-pressure solenoid valve; 310. Inlet pipeline; 311. Conversion pipeline; 312. Second high-pressure solenoid valve; 313. Pressure relief valve; 314. Detection pipeline; 315. Humidity sensor; 316. Nitrogen purity sensor; 317. High-purity low-pressure pipeline; 4. Handle; 5. Pull rod; 6. Casters; 7. Suction fan. 8. Cooling Fan, 9. Primary Gas Compressor, 91. Compressor Filter, 10. Air-Cooled Module, 101. Air-Cooled Module Temperature Sensor, 11. Liquid-Cooled Module, 111. Liquid-Cooled Module Temperature Sensor, 12. Dehydration Module, 121. Gas Source Dryer, 122. Primary Micron-Grade Sieve, 123. Secondary Nano-Grade Sieve, 124. Low-Pressure Sensor, 13. Nitrogen Separation Membrane, 131. Nitrogen Exhaust Port, 132. Oxygen Exhaust Port, 14. Power Hardware Control Unit, 15. Nitrogen Generator Software Control Unit, 16. Secondary Gas Compressor, 161. Cooling Fan, 162. Air Guide Cover. Detailed Implementation

[0050] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0051] Reference Figure 1-15 A mobile multifunctional nitrogen generator and intelligent control system includes a housing 1, with lifting components on both sides and a moving component at the bottom. Inside the housing 1 are installed a primary gas compressor 9, an air-cooled module 10, a liquid-cooled module 11, a water removal module 12, a nitrogen separation membrane 13, a pipeline valve integration module 3, and a secondary gas compressor 16, which are connected in series.

[0052] Specifically, the lifting assembly includes handles 4 fixedly installed on the top of the front and rear sides of the equipment housing 1. A pull rod 5 is also rotatably connected to the front end of the equipment housing 1. The moving assembly includes two pairs of moving wheels 6 installed at the bottom of the equipment housing 1. The front pair of moving wheels 6 are omnidirectional wheels, and the rear pair of moving wheels 6 are directional wheels. The equipment is easy to move through the design of 2 omnidirectional wheels + 2 directional wheels + pull rod. The front and rear ends are designed with handles 4, with a spacing of about 0.6m, which is convenient for single-person handling. The equipment housing 1 and frame are made of lightweight metals such as aluminum alloy or high-polymer composite materials such as carbon fiber, which greatly reduces the weight of the equipment, making the equipment weight <50kg.

[0053] Furthermore, a pair of intake fans 7 are installed on the rear side of the equipment housing 1, and cooling fans 8 are equipped on the front side, both sides of the equipment housing 1, and the primary gas compressor 9. The compressor and solenoid valves in the equipment generate heat, and overheating will greatly reduce the service life of the equipment. Through the design of the air duct, the equipment can take in air from one side through the intake fan 7 and exhaust air from three sides through the cooling fans 8. The components with high heat generation are placed at the air outlet, which can effectively reduce the temperature rise rate of the equipment.

[0054] Furthermore, the compressor filter element 91 of the primary gas compressor 9 is exposed on the outside of the equipment housing 1 for easy replacement, and the cylinder heads of the secondary gas compressor 16 at both the inlet and outlet are covered with air guide shrouds 162, with cooling fans 161 installed at the opening of the air guide shrouds 162.

[0055] Specifically, the air-cooled module 10 consists of a spiral heat dissipation pipe and an air-cooled fan. The air outlet end of the spiral heat dissipation pipe is also equipped with an air-cooled module temperature sensor 101. The air outlet end of the liquid-cooled module 11 is equipped with a liquid-cooled module temperature sensor 111. The dehydration module 12 includes an air source dryer 121, a primary micron-sized sieve 122, and a secondary nano-sized sieve 123 connected in series. The cooled compressed air passes through the air source dryer 121, the primary micron-sized sieve 122, and the secondary nano-sized sieve 123 in sequence before being output as dry air. The air outlet end of the dehydration module 12 is equipped with a low-pressure sensor 124. The temperature sensor is an RS485. Through multiple condensation processes of the air-cooled module and the liquid-cooled module, the equipment enables the dew point of the output nitrogen to reach below -25℃ and -40℃.

[0056] Furthermore, one end of the nitrogen separation membrane 13 is provided with an oxygen outlet 132 and a nitrogen outlet 131. The oxygen outlet 132 is connected to an oxygen storage tank, and oxygen is stored simultaneously when nitrogen is produced. When the pressure of the oxygen storage tank reaches the set value, it is filled into the oxygen cylinder through a booster.

[0057] Specifically, the pipeline valve integration module 3 includes an intake pipeline 310, a high-purity low-pressure pipeline 317, a low-purity high-pressure pipeline 32, a switching pipeline 311, an output pipeline 33, and a detection pipeline 314. Low-pressure solenoid valves 34 are installed at the connections between the high-purity low-pressure pipeline 317, the low-purity high-pressure pipeline 32, and the intake pipeline 310. A flow regulating valve 35 is connected in series on the high-purity low-pressure pipeline 317. The high-purity low-pressure pipeline 317 and the switching pipeline 311 are connected by a connecting pipe 37. A mesh gas storage pipeline is installed inside the low-purity high-pressure pipeline 32. The outlet end of the mesh gas storage pipeline is connected to the secondary gas compressor 16 through the exhaust pipe 36. The high-pressure low-purity nitrogen output from the secondary gas compressor 16 enters the conversion pipeline 311 through the one-way valve 38. A pair of first high-pressure solenoid valves 39 are installed on the conversion pipeline 311. Second high-pressure solenoid valves 312 are installed on both the output pipeline 33 and the detection pipeline 314. A nitrogen outlet 31 is provided at the end of the output pipeline 33.

[0058] Furthermore, a pressure relief valve 313 and a high-pressure sensor are installed on the output pipeline 33, and a humidity sensor 315 and a nitrogen purity sensor 316 are connected in series on the detection pipeline 314. To detect the purity and humidity of the output nitrogen, simply open the corresponding second high-pressure solenoid valve 312 to allow some gas to enter the detection pipeline 314, and the purity and humidity are detected by the humidity sensor 315 and the nitrogen purity sensor 316, respectively.

[0059] Reference Figure 16 The present invention also provides an intelligent control system for a mobile multifunctional nitrogen generator, including an intelligent pressure control unit, a remote online monitoring unit, an intelligent leak detection unit, a predictive maintenance unit, and a main control module for coordinating the collaborative work of each unit, wherein each unit is electrically connected to the main control module;

[0060] The intelligent pressure control unit includes a parameter input module, a sensor group one, an algorithm processing module one, and a pressure regulation execution module. The parameter input module includes a mobile APP mini-program interaction module, a UI interface, and a button interaction module, used to receive air conditioning system parameters input by the user or manually set pressure values. The sensor group one includes a flow sensor, a pressure sensor, and a temperature sensor, used to collect gas temperature, ambient temperature, and pipeline flow parameters. The algorithm processing module one is used to calculate the pipeline capacity and determine the target pressure holding value based on the parameters received by the parameter input module or the parameters collected by the sensor group one. The pressure regulation execution module is used to control the pressurization action of the nitrogen generator according to the target pressure holding value, and automatically stops pressurization when the pressure reaches the target pressure holding value.

[0061] The remote online monitoring unit includes a 4G positioning module, a data acquisition module, a smart pressure gauge communication module, and an IoT platform interaction module. The 4G positioning module is used to acquire the location information of the nitrogen generator. The data acquisition module is used to collect the working time, nitrogen purity, humidity and dew point parameters during pipeline welding and nitrogen pressure holding operations. The smart pressure gauge communication module is used to establish a communication connection with the smart pressure gauge with 4G positioning function. The IoT platform interaction module is used to upload the collected location information, operation parameters and pipeline pressure data fed back by the smart pressure gauge to the IoT platform to realize remote real-time monitoring and pressure anomaly early warning.

[0062] The intelligent leak detection unit includes a negative pressure detection module, a second sensor group, and a second algorithm processing module. The negative pressure detection module is used to detect negative pressure leaks in the pipeline after vacuuming. The second sensor group includes a pressure sensor and a temperature sensor, which are used to collect pipeline pressure and ambient temperature data after nitrogen purging and pressure holding. The second algorithm processing module is used to calculate and analyze the data collected by the second sensor group to determine whether there is a leak in the pipeline.

[0063] The predictive maintenance unit includes a life calibration module, a sensor group three, an anomaly analysis module, and an early warning module. The life calibration module is used to calibrate the life parameters of key components and vulnerable parts of the nitrogen generator. The sensor group three includes a pressure sensor, a temperature sensor, a flow sensor, a purity sensor, and a humidity sensor, which are used to monitor the working status parameters of each component in real time. The anomaly analysis module is used to analyze and identify abnormal modules and components based on the parameters collected by the sensor group three and the life calibration data. The early warning module includes a UI interface prompt module and an IoT platform early warning module, which are used to display anomaly codes through the UI interface and send anomaly early warning information to the IoT platform.

[0064] The intelligent pressure control unit is the core module for achieving precise nitrogen filling and pressure maintenance in the equipment. Through the combination of hardware sensors and software algorithms, it adapts to the pressure control requirements of different scenarios, specifically including:

[0065] 1. Parameter Input Module

[0066] This module supports two parameter input methods:

[0067] Mobile APP / Mini Program Interaction: Users can input parameters such as the size of the air conditioning system (e.g., pipe length, volume) and the number of indoor units through the mobile APP. After clicking "Nitrogen Charging and Pressure Holding", the parameters are transmitted to the equipment control system via wireless communication.

[0068] UI Interface and Button Interaction: The UI interface and button / parameter setting function module 2 on the top of the device housing can directly receive the pipeline nitrogen filling pressure value manually input by the user, which is suitable for scenarios where users set the pressure themselves based on experience.

[0069] 2. Sensor Group One

[0070] Composed of a flow sensor, a high-pressure sensor (on the output pipe 33) and an ambient temperature sensor installed in the pipeline valve integration module 3, it can collect gas temperature (temperature of nitrogen flowing through the pipeline), ambient temperature (temperature of the equipment operating environment) and pipeline flow parameters in real time, providing basic data for pipeline capacity calculation.

[0071] 3. Algorithm Processing Module 1

[0072] Based on the built-in algorithm of the nitrogen generator software control unit 15, this module can calculate the pipeline capacity according to input parameters or sensor data:

[0073] If system parameters are input via a mobile app or UI interface, the algorithm directly matches the preset "system size-capacity-pressure holding value" correspondence to determine the target pressure holding value range (e.g., the pressure holding value for a small air conditioning system is 1.5MPa, and for a large system it is 2.0MPa).

[0074] If data is collected through sensor group one, the pipeline must first be evacuated by a vacuum pump, and then filled with nitrogen to atmospheric pressure. The algorithm combines the ideal gas law (PV=nRT) to calculate the actual volume of the pipeline based on the flow rate, pressure and temperature parameters, and then determines the appropriate pressurization pressure value (e.g., a pipeline with a volume of 5L corresponds to a pressure holding value of 1.8MPa).

[0075] 4. Pressure Regulation Module

[0076] The system is linked with the low-pressure solenoid valve 34 and the first high-pressure solenoid valve 39 in the integrated module 3 of the primary gas compressor 9, secondary gas compressor 16, and pipeline valves: when the pipeline pressure is detected to be below the target holding pressure value, the compressor is started and the corresponding solenoid valve is opened to continuously pressurize; when the high-pressure sensor detects that the pressure has reached the target value, the compressor is immediately shut down and the solenoid valve is closed to stop pressurization and avoid excessive pressurization that could damage the pipeline. Simultaneously, the pressure relief valve 313 on the output pipeline 33 serves as hardware redundancy; if the pressure exceeds the safe range (e.g., exceeding the target value by 1.2 times), it will automatically release pressure to ensure safety.

[0077] The remote online monitoring unit uses IoT technology to achieve remote visual management of equipment status and operational data. Its specific implementation relies on the collaborative interaction between hardware modules and the platform.

[0078] 1.4G positioning module

[0079] Integrated into the equipment control system, it can obtain the geographical location information of the equipment in real time, making it convenient for users to view the distribution and movement trajectory of the equipment through the Internet of Things platform. It is suitable for scenarios where multiple devices work together.

[0080] 2. Data Acquisition Module

[0081] In conjunction with the nitrogen purity sensor 316 and humidity sensor 315 on the detection pipeline 314, and the built-in timing module of the equipment, the following parameters are automatically collected:

[0082] Operating hours: The duration from when the equipment starts producing nitrogen to when it stops;

[0083] Nitrogen purity: Detected using a 316 nitrogen purity sensor, with an accuracy of ±0.1%;

[0084] Humidity dew point: Detected by humidity sensor 315, it can reflect the dryness of nitrogen (e.g., dew point ≤ -25℃).

[0085] 3. Smart pressure gauge communication module

[0086] It uses wireless communication protocols (such as Bluetooth or LoRa) to establish a connection with an external smart pressure gauge with 4G positioning function, and can receive pipeline pressure data (such as pressure change curves during the pressure holding process) fed back by the pressure gauge in real time.

[0087] 4. IoT Platform Interaction Module

[0088] The location information acquired by the 4G positioning module, the operating parameters collected by the data acquisition module, and the pressure data from the smart pressure gauge are uploaded to the IoT platform via the 4G network. The platform can store and analyze the data and trigger alerts in the following scenarios:

[0089] Abnormal pipeline pressure: such as a pressure drop rate exceeding 0.05 MPa / h during the pressure holding process (according to industry standard preset);

[0090] Device offline: The device has not uploaded data to the platform for more than 24 hours;

[0091] Nitrogen purity / humidity does not meet the standards: such as purity below 99.5% (welding protection scenario) or 85% (nitrogen purging and pressure holding scenario).

[0092] The intelligent leak detection unit achieves accurate judgment of pipeline leaks through negative pressure detection and pressure-temperature correlation analysis, specifically including:

[0093] 1. Negative pressure detection module

[0094] Linked with a vacuum pump (external device), after the pipeline is evacuated to -0.1MPa, the vacuum pump and pipeline valves are shut off, and the pipeline pressure change is monitored by the low-pressure sensor 124: if the pressure rises by more than 0.02MPa within 1 hour, it is determined to be a negative pressure leak (such as air seepage caused by a loose pipeline interface), and a "negative pressure leak" message is displayed on the UI interface.

[0095] 2. Sensor Group Two

[0096] Composed of a high-pressure sensor and an ambient temperature sensor within the pipeline valve integration module 3, after nitrogen purging and pressure holding (e.g., pressure holding value 2.0MPa), it continuously collects pipeline pressure (accuracy ±0.01MPa) and ambient temperature (accuracy ±0.5℃) at a frequency of 1 time / 10 minutes.

[0097] 3. Algorithm Processing Module Two

[0098] Based on the leakage detection algorithm of the nitrogen generator software control unit 15, combined with the following logical analysis:

[0099] First, correct the effect of temperature on pressure according to the ideal gas law: If the ambient temperature changes by ΔT (e.g., from 25℃ to 30℃), calculate the theoretical pressure change ΔPtheoretical = P0 × ΔT / T0 (where P0 is the initial holding pressure and T0 is the initial absolute temperature).

[0100] Compare the actual pressure change ΔPactual with ΔPtheoretical: If the absolute value of ΔPactual - ΔPtheoretical exceeds 0.03 MPa / 24h, it is determined that there is a leak in the pipeline (such as nitrogen leakage caused by weld defects), and the leak warning and pressure change curve are displayed through the UI interface.

[0101] Predictive maintenance units provide early warnings of potential failures by monitoring the condition and lifespan of critical equipment components. Specifically, this is achieved as follows:

[0102] 1. Lifetime calibration module

[0103] Preset life parameters for easily worn parts of the equipment (such as the primary gas compressor filter element 91, nitrogen separation membrane 13, and solenoid valve core):

[0104] Compressor filter element 91: Lifespan is 500 hours (cumulative working time);

[0105] Nitrogen separation membrane 13: Lifespan is 10,000 hours (cumulative nitrogen production time);

[0106] Solenoid valves (such as low-pressure solenoid valve 34): lifespan of 10,000 switching operations.

[0107] 2. Sensor Group Three

[0108] Distributed in various key components of the equipment:

[0109] Pressure sensor: Monitors the inlet and outlet pressures of the primary / secondary gas compressor;

[0110] Temperature sensors: including air-cooled module temperature sensor 101 and liquid-cooled module temperature sensor 111, monitor the temperature of the heat dissipation system;

[0111] Flow sensor: monitors nitrogen flow rate in pipelines;

[0112] Purity sensor 316 and humidity sensor 315: indirectly reflect the filtration efficiency of nitrogen separation membrane 13.

[0113] Anomaly Analysis Module

[0114] Based on the fault diagnosis algorithm of the nitrogen generator software control unit 15, the sensor data is analyzed:

[0115] If the pressure difference between the compressor inlet and outlet exceeds the preset value (e.g., the normal pressure difference for a first-stage compressor is 0.5MPa, but the actual measurement is 1.0MPa), combined with the cumulative working time, it is determined that the filter element is clogged.

[0116] If the nitrogen purity remains below 99.5% (in high-purity mode) and the cumulative working time of the separation membrane approaches 10,000 hours, it is determined that the separation membrane is aging.

[0117] If the solenoid valve's switching response time exceeds 0.5 seconds (normally 0.2 seconds), combined with the number of switching cycles, it is determined that the valve core is worn.

[0118] 3. Early Warning Module

[0119] UI interface prompts: The UI interface on the top of the device housing displays the error code (such as "E01" indicating filter blockage, "E02" indicating membrane aging), and provides brief handling suggestions (such as "Please replace the compressor filter").

[0120] IoT platform early warning: Abnormal information (including abnormal components, cumulative working time, and sensor data) is uploaded to the IoT platform, and the platform sends notifications to the device administrators via SMS or APP to facilitate timely maintenance.

[0121] The main control module is centered on the nitrogen generator software control unit 15, and achieves electrical connection and coordinated scheduling with each unit through the power hardware control unit 14.

[0122] It receives the target pressure command from the intelligent pressure control unit and synchronously controls the operation of the compressor and valves.

[0123] Coordinate the data acquisition sequence between the remote online monitoring unit and the intelligent leak detection unit (e.g., during the pressure holding stage, prioritize the acquisition of pressure data while simultaneously performing leak detection);

[0124] Integrate anomaly information from the predictive maintenance unit and simultaneously output early warnings on the UI interface and IoT platform;

[0125] Ensure the compatibility of each unit under different operating modes (high purity and low pressure, low purity and high pressure) to ensure stable system operation.

[0126] The principle of high-purity low-pressure nitrogen production: After the primary gas compressor 9 draws in air, it outputs compressed air. The compressed air passes through the air-cooling module 10, where the gas is cooled to produce liquid water, separating the moisture from the gas. The compressed air then passes through the liquid-cooling module 11, where the gas is further cooled, producing more liquid water, further separating the moisture. The cooled compressed air enters the dehydration module 12, where the separated moisture is discharged through the pipeline, and dry air is output. The dry air enters the nitrogen separation membrane 13, and high-concentration nitrogen is output from the nitrogen outlet 131. Separated oxygen is output from oxygen outlet 132, and high-concentration nitrogen enters inlet pipe 310. By opening the corresponding low-pressure solenoid valve 34, the gas enters high-purity low-pressure pipe 317. The flow rate is adjusted by flow regulating valve 35 to improve purity. The output high-purity nitrogen enters conversion pipe 311 through connecting pipe 37. By opening the corresponding first high-pressure solenoid valve 39 and second high-pressure solenoid valve 312, it can be discharged through output pipe 33 and finally discharged through nitrogen outlet 31. The nitrogen purity is ≥99.5%, which is suitable for welding protection operations.

[0127] The principle of low-purity high-pressure nitrogen production: After the first-stage gas compressor 9 draws in air, it outputs compressed air. The compressed air passes through the air-cooling module 10, where the gas is cooled and liquid water is produced, separating the moisture from the gas. The compressed air then passes through the liquid-cooling module 11, where the gas is further cooled and more liquid water is produced, ensuring complete separation of the moisture from the gas. The cooled compressed air enters the dehydration module 12, which discharges the separated moisture through the pipeline and outputs dry air. The dry air enters the nitrogen separation membrane 13, from which high-concentration nitrogen is output from the nitrogen outlet 131. The nitrogen produced by the nitrogen separation membrane 13 enters the low-purity high-pressure pipeline 32. The mesh-type gas storage pipeline can store nitrogen, ensuring sufficient gas volume entering the compressor. It then enters the second-stage gas compressor 16 through the exhaust pipe 36. After outputting high-pressure nitrogen, it passes through the one-way valve 38 and enters the conversion pipeline 311, which then passes through the output pipeline 33 and finally exits through the nitrogen outlet 31. The nitrogen purity is ≥85%, and the nitrogen pressure is ≥4.5MPa, allowing for nitrogen filling and pressure holding operations.

[0128] To detect the purity and humidity of the output nitrogen, simply open the corresponding second high-pressure solenoid valve 312 to allow some gas to enter the detection pipeline 314, where the purity and humidity are detected by the humidity sensor 315 and the nitrogen purity sensor 316, respectively.

[0129] This equipment also has significant advantages in energy saving and consumption reduction:

[0130] 1. Reduced carbon emissions from transportation

[0131] Case data: When using an average of 50 bottles of nitrogen per month, the original transportation required 500L of diesel (equivalent to 1.34 tons of CO2). The mobile nitrogen generator produces nitrogen locally, which is only 1 / 3 of the traditional energy consumption, saving more than 1 ton of carbon per month.

[0132] 2. Improved gas utilization rate

[0133] Traditional bottled nitrogen leaves 10%-15% residue, resulting in gas waste and posing a risk of leakage during transportation; mobile nitrogen generators produce and use nitrogen immediately, with a gas utilization rate of over 98%.

[0134] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A mobile multifunctional nitrogen generator, comprising a housing (1), characterized in that, The equipment housing (1) is provided with lifting components on both sides and a moving component at the bottom. Inside, a primary gas compressor (9), an air-cooled module (10), a liquid-cooled module (11), a water removal module (12), a nitrogen separation membrane (13), a pipeline valve integration module (3), and a secondary gas compressor (16) are installed in series. The air passes through a primary gas compressor (9), an air-cooled module (10), a liquid-cooled module (11), a water removal module (12), a nitrogen separation membrane (13), and a pipeline valve integration module (3) in sequence before outputting high-purity low-pressure nitrogen. Air passes through a primary gas compressor (9), an air-cooled module (10), a liquid-cooled module (11), a water removal module (12), a nitrogen separation membrane (13), a pipeline valve integration module (3), and a secondary gas compressor (16) in sequence before outputting high-pressure, low-purity nitrogen. It also includes a control system, which includes a power hardware control unit (14), a nitrogen generator software control unit (15), an intelligent pressure control unit, a remote online monitoring unit, and an intelligent leak detection unit; The intelligent pressure control unit includes a parameter input module, a sensor group one, an algorithm processing module one, and a pressure regulation execution module. The parameter input module includes a mobile APP mini-program interaction module and a UI interface and button interaction module, used to receive air conditioning system parameters input by the user or manually set pressure values. The sensor group one includes a flow sensor, a pressure sensor, and a temperature sensor, used to collect gas temperature, ambient temperature, and pipeline flow parameters. The algorithm processing module one is used to calculate the pipeline capacity and determine the target pressure holding value based on the parameters received by the parameter input module or the parameters collected by the sensor group one. The pressure regulation execution module is used to control the pressurization action of the nitrogen generator according to the target pressure holding value, and automatically stops pressurization when the pressure reaches the target pressure holding value. The remote online monitoring unit includes a 4G positioning module, a data acquisition module, a smart pressure gauge communication module, and an IoT platform interaction module. The 4G positioning module is used to acquire the location information of the nitrogen generator. The data acquisition module is used to collect the working time, nitrogen purity, humidity and dew point parameters during pipeline welding and nitrogen pressure holding operations. The smart pressure gauge communication module is used to establish a communication connection with a smart pressure gauge with 4G positioning function. The IoT platform interaction module is used to upload the collected location information, operation parameters, and pipeline pressure data fed back by the smart pressure gauge to the IoT platform to realize remote real-time monitoring and pressure anomaly early warning. The intelligent leak detection unit includes a negative pressure detection module, a second sensor group, and a second algorithm processing module. The negative pressure detection module is used to detect negative pressure leaks in the pipeline after vacuuming. The second sensor group includes a pressure sensor and a temperature sensor, which are used to collect pipeline pressure and ambient temperature data after nitrogen purging and pressurization. The second algorithm processing module is used to calculate and analyze the data collected by the second sensor group to determine whether there is a leak in the pipeline. The control system also includes a predictive maintenance unit, which comprises a life calibration module, a sensor group three, an anomaly analysis module, and an early warning module. The life calibration module is used to calibrate the life parameters of key components and vulnerable parts of the nitrogen generator. The sensor group three includes a pressure sensor, a temperature sensor, a flow sensor, a purity sensor, and a humidity sensor, used to monitor the working status parameters of each component in real time. The anomaly analysis module is used to analyze and determine abnormal modules and components based on the parameters collected by the sensor group three and the life calibration data. The early warning module includes a UI interface prompt module and an IoT platform early warning module, used to display abnormal codes through the UI interface and send abnormal early warning information to the IoT platform.

2. The mobile multifunctional nitrogen generator according to claim 1, characterized in that, The lifting assembly includes handles (4) fixedly installed on the top of the front and rear sides of the equipment housing (1). A pull rod (5) is also rotatably connected to the front end of the equipment housing (1). The moving assembly includes two pairs of moving wheels (6) installed at the bottom of the equipment housing (1). The front pair of moving wheels (6) are universal wheels, and the rear pair of moving wheels (6) are directional wheels.

3. The mobile multifunctional nitrogen generator according to claim 1, characterized in that, A pair of suction fans (7) are installed on the rear side of the equipment housing (1), and cooling fans (8) are provided on the front side of the equipment housing (1), both sides of the equipment housing (1), and the primary gas compressor (9).

4. The mobile multifunctional nitrogen generator according to claim 1, characterized in that, The compressor filter element (91) of the first-stage gas compressor (9) is exposed on the outside of the equipment housing (1). The cylinder heads of the second-stage gas compressor (16) at the inlet and outlet are covered with air guide shrouds (162), and a cooling fan (161) is installed at the opening of the air guide shroud (162).

5. A mobile multifunctional nitrogen generator according to claim 1, characterized in that, The air-cooled module (10) consists of a spiral heat dissipation pipe and an air-cooled fan. The air outlet end of the spiral heat dissipation pipe is also equipped with an air-cooled module temperature sensor (101), and the air outlet end of the liquid-cooled module (11) is equipped with a liquid-cooled module temperature sensor (111).

6. A mobile multifunctional nitrogen generator according to claim 1, characterized in that, The dehydration module (12) includes an air source dryer (121), a first-stage micron-sized sieve (122), and a second-stage nano-sized sieve (123) connected in series. The cooled compressed air passes through the air source dryer (121), the first-stage micron-sized sieve (122), and the second-stage nano-sized sieve (123) in sequence before being output as dry air. A low-pressure sensor (124) is installed at the outlet of the dehydration module (12).

7. A mobile multifunctional nitrogen generator according to claim 1, characterized in that, The nitrogen separation membrane (13) is provided with an oxygen outlet (132) and a nitrogen outlet (131) at one end, and the oxygen outlet (132) is connected to an oxygen storage tank.

8. A mobile multifunctional nitrogen generator according to claim 1, characterized in that, The pipeline valve integration module (3) includes an intake pipeline (310), a high-purity low-pressure pipeline (317), a low-purity high-pressure pipeline (32), a switching pipeline (311), an output pipeline (33), and a detection pipeline (314). A low-pressure solenoid valve (34) is installed at the connection points between the high-purity low-pressure pipeline (317), the low-purity high-pressure pipeline (32), and the intake pipeline (310). A flow regulating valve (35) is connected in series on the high-purity low-pressure pipeline (317). The high-purity low-pressure pipeline (317) and the switching pipeline (311) are connected via a connecting pipe (37). The low-purity high-pressure pipeline (32) is provided with a mesh gas storage pipeline. The outlet end of the mesh gas storage pipeline is connected to the secondary gas compressor (16) through an exhaust pipe (36). The high-pressure low-purity nitrogen output by the secondary gas compressor (16) enters the conversion pipeline (311) through a one-way valve (38). A pair of first high-pressure solenoid valves (39) are installed on the conversion pipeline (311). A second high-pressure solenoid valve (312) is installed on both the output pipeline (33) and the detection pipeline (314). A nitrogen outlet (31) is provided at the end of the output pipeline (33).

9. A mobile multifunctional nitrogen generator according to claim 8, characterized in that, The output pipeline (33) is equipped with a pressure relief valve (313) and a high pressure sensor, and the detection pipeline (314) is connected in series with a humidity sensor (315) and a nitrogen purity sensor (316).

10. An intelligent control system for a mobile multifunctional nitrogen generator, applied to the mobile multifunctional nitrogen generator according to any one of claims 1-9, characterized in that, It includes an intelligent pressure control unit, a remote online monitoring unit, an intelligent leak detection unit, a predictive maintenance unit, and a main control module for coordinating the collaborative work of all units. Each unit is electrically connected to the main control module.

Images