Air compression device for explosion-proof diesel engine, control method, explosion-proof diesel engine and maintenance method

Abstract

The invention belongs to the technical field of gas compression of explosion-proof diesel engines, and particularly relates to a gas compression device for an explosion-proof diesel engine, a control method, the explosion-proof diesel engine and a maintenance method. The invention solves the problem of low reliability and high failure rate of a gas compressor in an underground coal mine, and comprises a gas path control module which comprises a gas inlet one-way solenoid valve and an exhaust port one-way solenoid valve and is used for independently controlling the on-off of a gas inlet and an exhaust port; the dynamic sensing module is integrated with a cylinder cover gas pressure sensor, a compressed gas pressure sensor and a crankshaft position sensor; and the intelligent execution module is connected with the modules through an ECU to realize opening and closing of the valve based on crankshaft phase synchronization, dynamic adjustment of an air inlet valve based on cylinder cover pressure and activation of a no-load protection mode based on air pocket pressure. According to the invention, the failure rate is greatly reduced, and meanwhile, the convenience of equipment maintenance is improved.

Description

Technical Field

[0001] This invention belongs to the field of compressed gas technology for explosion-proof diesel engines, specifically an explosion-proof diesel engine compressor, control method, explosion-proof diesel engine, and maintenance method. Background Technology

[0002] The explosion-proof diesel engine vehicles used in the underground auxiliary transportation system of coal mines operate in extremely harsh environments. The compressors often fail to pump air due to poor reliability of the diaphragm at the cavity, resulting in incomplete sealing and affecting the safe operation of the explosion-proof vehicles.

[0003] The diaphragm at the compressor compartment often fails to seal the gas properly, causing the air pump to stop pumping air. When this happens, the compressor needs to be removed and replaced with a new one. However, the working conditions in coal mines are dark, and the space in explosion-proof vehicles is cramped. The compressor is located below the diesel engine, making operation extremely difficult. Therefore, it is necessary to design a highly reliable electronically controlled and adjustable compressor to avoid malfunctions or accidents caused by diaphragm-type air compressors due to poor diaphragm sealing, while also increasing the convenience of equipment maintenance. Summary of the Invention

[0004] To address the problem of low reliability and high failure rate of compressors in underground coal mines, this invention provides a compressor device, control method, explosion-proof diesel engine, and maintenance method for explosion-proof diesel engines.

[0005] The present invention adopts the following technical solution: a compressor device for an explosion-proof diesel engine, comprising: The air circuit control module includes an inlet one-way solenoid valve and an exhaust one-way solenoid valve, which are used to independently control the opening and closing of the inlet and exhaust ports. The dynamic sensing module integrates a cylinder head gas pressure sensor, a compressed gas pressure sensor, and a crankshaft position sensor. The intelligent execution module, connected to the above modules via the ECU, enables the opening and closing of valves based on crankshaft phase synchronization, dynamic adjustment of intake valves based on cylinder head pressure, and activation of no-load protection mode based on air bag pressure.

[0006] In some embodiments, the no-load protection mode is that when the compressed gas pressure sensor detects that the gas tank pressure exceeds the limit, the ECU controls the exhaust port one-way solenoid valve to remain normally closed and the intake port one-way solenoid valve to remain normally open.

[0007] In some embodiments, the intelligent execution module performs: The intake port check valve is closed at the bottom dead center of the piston. The exhaust port check valve is opened after the piston passes bottom dead center. When the cylinder head gas pressure sensor detects an excessive value, the default timing is interrupted and the intake port one-way solenoid valve is closed prematurely.

[0008] In some embodiments, it also includes: Active cooling module: It consists of cylinder head water inlet, cylinder head body water cavity and cylinder head water outlet, forming a forced convection cooling path to meet the surface temperature ≤150℃.

[0009] In some embodiments, the dynamic sensing module further includes a data fusion unit, which performs real-time cross-analysis of data from the cylinder head gas pressure sensor, compressed gas pressure sensor, and crankshaft position sensor to generate a pressure-phase coordination coefficient. The ECU dynamically optimizes the intake valve closing timing and exhaust valve opening duration based on this coefficient.

[0010] In some embodiments, the active cooling module dynamically adjusts the inlet flow rate by monitoring the cylinder head surface temperature, specifically including: Increase the flow rate when the temperature is >130℃; Reduce flow rate when the temperature is below 100℃.

[0011] A method for controlling a compressor device, applicable to compressor devices for explosion-proof diesel engines, comprising: Piston stroke is analyzed using a crankshaft position sensor; The intake port one-way solenoid valve opens during the piston's downward movement and closes 0.5-2ms before the bottom dead center. During the compression period, the one-way solenoid valve at the exhaust port is opened, and the opening duration is dynamically adjusted according to the pressure in the air tank. Respond to stress overload events, overriding the default timing.

[0012] An explosion-proof diesel engine integrates an explosion-proof diesel engine compressor, and the explosion-proof diesel engine compressor maintains a surface temperature of ≤150℃ through a cooling module.

[0013] A method for maintaining a compressor unit, specifically for a compressor unit used in an explosion-proof diesel engine, includes: When disassembling a faulty solenoid valve, keep the cylinder head and crankcase intact. Faults can be located by reading historical data from the cylinder head gas pressure sensor and compressed gas pressure sensor through the ECU diagnostic interface.

[0014] In some embodiments, it also includes: Based on historical data from the cylinder head gas pressure sensor and compressed gas pressure sensor, the ECU calculates the valve wear coefficient in real time and dynamically adjusts the control parameters of the intake port one-way solenoid valve and the exhaust port one-way solenoid valve accordingly. When the wear coefficient exceeds the preset threshold, the ECU automatically generates a maintenance alarm and optimizes the valve opening and closing sequence to compensate for wear.

[0015] Compared with the prior art, the present invention has the following beneficial effects: This invention is mainly used to solve the problem of low reliability and high failure rate of air compressors in underground coal mines. The piston of this air compressor device only performs intake and compression work. Even if a failure occurs, the intake and exhaust channels are controlled by the ECU to open and close the solenoid valve, which greatly reduces the failure rate and increases the convenience of maintenance. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the present invention; In the diagram: 1-Intake port one-way solenoid valve, 2-Intake port, 3-Cylinder head outlet, 4-Cylinder head gas pressure sensor, 5-Cylinder head inlet, 6-Exhaust port, 7-Exhaust port one-way solenoid valve, 8-Compressed gas pressure sensor, 9-Crankshaft position sensor. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] This invention relates to a highly reliable air compressor device for explosion-proof diesel engines with electronically adjustable control. The technical solution is described in detail below with reference to the accompanying drawings. The core of this device consists of an air circuit control module, a dynamic sensing module, an intelligent execution module, and an active cooling module, solving problems such as high failure rate and difficult maintenance of diaphragm compressors in underground coal mines.

[0019] like Figure 1 As shown, the air compressor is connected to the crankcase of the explosion-proof diesel engine via a flange. It includes an air compressor, within which a crankshaft and piston are housed. An air chamber is located within the air compressor, and a cylinder head is mounted on top of the air chamber. The air chamber has an intake port 2 and an exhaust port 6, with the exhaust port 6 connected to an air manifold. It also includes: The air circuit control module includes an inlet one-way solenoid valve 1 and an exhaust one-way solenoid valve 7, which are used to independently control the opening and closing of the inlet 2 and the exhaust 6. The dynamic sensing module includes a cylinder head gas pressure sensor 4 mounted on the cylinder head, a compressed gas pressure sensor 8 mounted on the exhaust port 6, and a crankshaft position sensor 9 for detecting the crankshaft position. The intelligent execution module, connected to the above modules via the ECU, enables the opening and closing of valves based on crankshaft phase synchronization, dynamic adjustment of intake valves based on cylinder head pressure, and activation of no-load protection mode based on air bag pressure.

[0020] The active cooling module includes a cylinder head inlet 5, a water chamber inside the cylinder head, and a cylinder head outlet 3, forming a forced convection cooling path to meet the surface temperature ≤150℃. A spiral gradually expanding flow channel is designed between the cylinder head inlet 5 and the outlet 3 to form a forced convection cooling path.

[0021] The crankshaft of the compressor unit is driven by an explosion-proof diesel engine to rotate, which in turn drives the connecting rod and piston to reciprocate, continuously performing a cycle of intake and compression. When the piston moves downward, fresh air enters the compressor unit's air chamber through the open intake port one-way solenoid valve 1 and intake port 2. When the piston reaches the bottom dead center, the intake port one-way solenoid valve 1 closes to prevent air from flowing back. After the piston passes the bottom dead center, the ECU receives a signal from the crankshaft position sensor 9 and controls the electronically controlled exhaust port solenoid valve 7 to open the channel, allowing compressed air to enter the exhaust port 6 and flow through the exhaust port one-way electronically controlled valve 7 into the air reservoir for storage. The cylinder head gas pressure sensor 4 and the compressed gas pressure sensor 8 detect the pressure of the compressed gas in the compressor unit and the pressure signal of the pipeline entering the air reservoir, respectively. The signals are transmitted to the ECU to control the opening and closing of the intake port one-way solenoid valve 1 to prevent excessive gas pressure from causing malfunctions in the pipeline and air reservoir.

[0022] The active cooling module dynamically adjusts the inlet flow rate by monitoring the cylinder head surface temperature, specifically including: T > 130℃: Increase cooling water flow rate to 120%; T < 100℃: Switch to energy-saving mode (flow rate reduced to 60%).

[0023] Specifically, in the no-load protection mode, when the compressed gas pressure sensor 8 detects that the air tank pressure exceeds the limit, the ECU controls the exhaust port one-way solenoid valve 7 to remain normally closed and the intake port one-way solenoid valve 1 to remain normally open.

[0024] The intelligent execution module executes: Close the one-way solenoid valve 1 at the bottom dead center of the piston; After the piston passes the bottom dead center, the exhaust port one-way solenoid valve 7 is opened; When the cylinder head gas pressure sensor 4 detects an excessive value, the default timing is interrupted and the intake port one-way solenoid valve 1 is closed prematurely.

[0025] In a specific embodiment, when the crankshaft is driven to rotate by the diesel engine: Intake phase: During the piston's downward movement, the ECU controls the intake port one-way solenoid valve 1 to open, and fresh air enters the air chamber through the intake port 2.

[0026] Compression phase: When the piston reaches the bottom dead center, the ECU closes the intake valve 1 based on the signal from the crankshaft position sensor 9; after the piston passes the bottom dead center, the exhaust port one-way solenoid valve 7 is opened, and compressed air enters the air bag through the exhaust port 6.

[0027] When the compressed gas pressure sensor 8 detects that the air tank pressure is greater than 0.75 MPa, the ECU locks the exhaust valve 7 normally closed and the intake valve 1 normally open, and illuminates the cab warning light.

[0028] When the cylinder head gas pressure sensor 4 detects a value > 0.8 MPa, the ECU immediately closes the intake valve 1 until the pressure drops below 0.75 MPa and is maintained for 10 ms.

[0029] The dynamic sensing module also includes a data fusion unit, which performs real-time cross-analysis of data from the cylinder head gas pressure sensor 4, compressed gas pressure sensor 8, and crankshaft position sensor 9 to generate a pressure-phase coordination coefficient. Based on this coefficient, the ECU dynamically optimizes the intake valve closing timing and exhaust valve opening duration.

[0030] The ECU calculates the pressure-phase coordination coefficient in real time through the data fusion unit. in, for Changes in cylinder head gas pressure over time for For the change in crankshaft angle over time, K > 0.8: the intake valve closes 0.1ms earlier; K < 0.5: the exhaust valve opening time increases by 1ms.

[0031] A method for controlling a compressor device, applicable to compressor devices for explosion-proof diesel engines, comprising: Piston stroke is analyzed using crankshaft position sensor 9; During the piston's downward movement, the intake port one-way solenoid valve 1 is opened and closed within 0.5-2ms before the bottom dead center; During the compression period, the exhaust port one-way solenoid valve 7 is opened, and the opening duration is dynamically adjusted according to the air tank pressure. Respond to stress overload events, overriding the default timing.

[0032] An explosion-proof diesel engine integrates an explosion-proof diesel engine compressor, and the explosion-proof diesel engine compressor maintains a surface temperature of ≤150℃ through a cooling module.

[0033] A method for maintaining a compressor unit, specifically for a compressor unit used in an explosion-proof diesel engine, includes: When disassembling a faulty solenoid valve, keep the cylinder head and crankcase intact. Faults can be located by reading historical data from cylinder head gas pressure sensor 4 and compressed gas pressure sensor 8 through the ECU diagnostic interface.

[0034] Based on historical data from cylinder head gas pressure sensor 4 and compressed gas pressure sensor 8, the ECU calculates the valve wear coefficient in real time and dynamically adjusts the control parameters of intake port one-way solenoid valve 1 and exhaust port one-way solenoid valve 7 accordingly. When the wear coefficient exceeds the preset threshold, the ECU automatically generates a maintenance alarm and optimizes the valve opening and closing sequence to compensate for wear.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A compressor device for an explosion-proof diesel engine, comprising a compressor, a crankshaft and a piston disposed within the compressor, an air chamber disposed within the compressor, a cylinder head disposed above the air chamber, an air inlet (2) and an exhaust port (6) disposed within the air chamber, the exhaust port (6) being connected to an air manifold, characterized in that, Also includes: The air circuit control module includes an inlet one-way solenoid valve (1) and an outlet one-way solenoid valve (7) for independently controlling the opening and closing of the inlet (2) and outlet (6); The dynamic sensing module includes a cylinder head gas pressure sensor (4) mounted on the cylinder head, a compressed gas pressure sensor (8) mounted on the exhaust port (6), and a crankshaft position sensor (9) for detecting the crankshaft position. The intelligent execution module, connected to the above modules via the ECU, enables the opening and closing of valves based on crankshaft phase synchronization, dynamic adjustment of intake valves based on cylinder head pressure, and activation of no-load protection mode based on air bag pressure.

2. The air compressor for an explosion-proof diesel engine according to claim 1, characterized in that: The no-load protection mode is that when the compressed gas pressure sensor (8) detects that the air bag pressure exceeds the limit, the ECU controls the exhaust port one-way solenoid valve (7) to remain normally closed and the intake port one-way solenoid valve (1) to remain normally open.

3. The air compressor for an explosion-proof diesel engine according to claim 1, characterized in that: The intelligent execution module performs the following: Close the one-way solenoid valve at the bottom dead center of the piston (1); After the piston passes the bottom dead center, the exhaust port one-way solenoid valve (7) is opened. When the cylinder head gas pressure sensor (4) detects an excessive value, the default timing is interrupted and the intake port one-way solenoid valve (1) is closed in advance.

4. The air compressor for an explosion-proof diesel engine according to any one of claims 1-3, characterized in that: Also includes: The active cooling module includes a cylinder head inlet (5), a cylinder head body water chamber, and a cylinder head outlet (3) provided on the cylinder head, forming a forced convection cooling path to meet the surface temperature ≤150℃.

5. The air compressor for an explosion-proof diesel engine according to claim 1, characterized in that: The dynamic sensing module also includes a data fusion unit, which performs real-time cross-analysis of the data from the cylinder head gas pressure sensor (4), the compressed gas pressure sensor (8), and the crankshaft position sensor (9) to generate a pressure-phase coordination coefficient. Based on this coefficient, the ECU dynamically optimizes the timing of intake valve closure and exhaust valve opening duration.

6. The air compressor for an explosion-proof diesel engine according to claim 4, characterized in that: The active cooling module dynamically adjusts the inlet (5) flow rate by monitoring the cylinder head surface temperature, specifically including: Increase the flow rate when the temperature is >130℃; Reduce flow rate when the temperature is below 100℃.

7. A method for controlling a compressor device, applicable to the compressor device for an explosion-proof diesel engine as described in claims 1-6, characterized in that, include: The piston stroke is analyzed by the crankshaft position sensor (9); The intake port one-way solenoid valve (1) is opened during the piston's downward movement and closed within 0.5-2ms before the bottom dead center; During the compression period, the one-way solenoid valve (7) at the exhaust port is opened, and the opening time is dynamically adjusted according to the pressure of the air tank. Respond to stress overload events, overriding the default timing.

8. An explosion-proof diesel engine, characterized in that... The explosion-proof diesel engine compressor device according to any one of claims 1-6 is integrated, and the explosion-proof diesel engine compressor device maintains a surface temperature of ≤150°C through a cooling module.

9. A method for maintaining a compressor device, specifically for the compressor device for an explosion-proof diesel engine as described in claim 1, characterized in that... include: When disassembling a faulty solenoid valve, keep the cylinder head and crankcase intact. Faults can be located by reading historical data from the cylinder head gas pressure sensor (4) and compressed gas pressure sensor (8) through the ECU diagnostic interface.

10. The method for maintaining a compressed air device according to claim 9, characterized in that, Also includes: Based on historical data from the cylinder head gas pressure sensor (4) and compressed gas pressure sensor (8), the ECU calculates the valve wear coefficient in real time and dynamically adjusts the control parameters of the intake port one-way solenoid valve (1) and the exhaust port one-way solenoid valve (7) accordingly. When the wear coefficient exceeds the preset threshold, the ECU automatically generates a maintenance alarm and optimizes the valve opening and closing sequence to compensate for wear.

Images