Electromagnetic driving and mechanical self-locking coupled clearance adjusting system and method

Abstract

The invention relates to an electromagnetic driving and mechanical self-locking coupled clearance adjusting system and method, and belongs to the field of natural gas compressors. The system comprises a clearance volume adjusting device, a self-adaptive multivariable monitoring unit and a control system, a clearance piston is driven through electromagnetism, and mechanical locking is achieved in combination with a ball head self-locking mechanism. The self-adaptive multivariable monitoring unit collects pressure, temperature and position signals in real time through multiple sensors, the control system optimizes data through a Kalman filtering algorithm, and then a control instruction is generated through a fuzzy PID algorithm. According to the system, traditional mechanical or hydraulic drive is replaced with electromagnetic drive, the problems of low drive precision, slow response and high maintenance cost are solved, high-precision dynamic self-adaptive adjustment of clearance volume is achieved, and energy efficiency and operation stability are remarkably improved. Meanwhile, a locking time sequence and a dual verification mechanism are optimized through a fuzzy PID algorithm, so that the locking reliability is ensured, and the requirements of complex working conditions are met.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of natural gas reciprocating compressor, and particularly relates to a clearance adjustment system and method coupled with electromagnetic drive and mechanical self-locking. BACKGROUND

[0002] As a kind of gas compression and delivery equipment widely used in industrial field, reciprocating compressor is used as a key power machine in petroleum, chemical industry and other industries. Since the rated discharge capacity of reciprocating compressor is determined at the design time, however, due to the change of process flow in the process of natural gas exploitation and oil-gas gathering and transportation, the compressor is not always operated at full load, so in the actual use process, the reciprocating compressor is often operated below the design discharge capacity, which leads to high energy consumption. At this time, the discharge capacity needs to be adjusted by additional device to meet the actual process requirement of discharge capacity.

[0003] In the gas volume adjustment strategy of reciprocating compressor, the adjustment of clearance volume has important influence on equipment efficiency, energy consumption and operation stability. The traditional clearance adjustment methods mainly include fixed clearance, manual mechanical adjustment and hydraulic adjustment, but all have significant limitations: the fixed clearance mechanism cannot adapt to the variable working condition requirement, which leads to a large decrease in compression efficiency and an increase in energy consumption under partial load; manual mechanical adjustment needs to be operated with shutdown, has poor adjustment accuracy and cannot realize dynamic response, which is difficult to meet the intelligent demand of modern industry; the hydraulic adjustment system drives the clearance piston through oil pressure, which can realize a certain degree of dynamic adjustment, but has problems such as risk of hydraulic oil leakage and high maintenance cost. In addition, the hydraulic system is prone to adjustment failure due to change of oil viscosity under low temperature environment. Therefore, a clearance adjustment scheme with high response, low loss and low maintenance cost is urgently needed, which can realize real-time regulation and control of clearance volume during the operation of compressor and adapt to severe natural gas production conditions. SUMMARY

[0004] The purpose of the present application is to overcome the deficiencies of the prior art, and provide a clearance adjustment system and method coupled with electromagnetic drive and mechanical self-locking. The present application proposes an electromagnetic-mechanical hybrid drive system, which solves the above bottleneck through the innovative design of electromagnetic direct drive and ball head self-locking.

[0005] In order to achieve the above object, the technical scheme adopted by the present application is: the present application is a kind of electromagnetic drive and mechanical locking reciprocating compressor clearance adjusting device and method, including installation in the clearance volume adjusting device of compressor cover side, adaptive multivariate monitoring unit, control system, the clearance volume adjusting device is by clearance piston, clearance piston cylinder, clearance piston rod, electromagnetic power unit, ball head self-locking mechanism, wherein the electromagnetic power unit is directly acted on clearance piston rod by electromagnetic drive mode, make clearance piston reciprocating motion in clearance piston cylinder, the adaptive multivariate monitoring unit, it includes integrated pressure-temperature sensor of inlet pipeline, integrated pressure-temperature sensor of exhaust pipeline and the key phase sensor of compressor crankshaft and the position sensor in clearance volume adjusting device, the control system is based on multi-parameter data fusion technology, adopts Kalman filter algorithm to carry out real-time processing to sensor data, obtains accurate position of piston through dynamic calculation, while combining with pressure, temperature and other multidimensional working condition parameters, control system outputs accurate control instruction to electromagnetic power unit and ball head self-locking mechanism, realizes clearance volume regulation and clearance piston self-locking.

[0006] Preferably, the ball head self-locking mechanism is composed of an electromagnetic actuator, a position feedback module, a steel ball, a return spring and a guide sleeve, the ball head self-locking mechanism is fixedly installed in the circumferential threaded hole of the clearance piston by threaded connection, the electromagnetic actuator includes an electromagnet and its driving circuit, the electromagnet is fixedly installed inside the guide sleeve, the position feedback module adopts a micro switch and is installed at the bottom of the guide sleeve, the steel ball is retracted to press the switch contact, for real-time monitoring of the locking state of the steel ball and feeding back signals to the control system, the circumferential of the clearance piston is uniformly arranged with a plurality of ball head self-locking mechanisms, the inner wall of the clearance piston cylinder is uniformly arranged with a plurality of groove arrays matched with the steel balls, the electromagnetic actuator drives the return spring and the steel ball to complete the extension and retraction movement by controlling the on-off of the control circuit: when powered on, the electromagnet generates magnetic force to attract the steel ball and compress the return spring, so that it is retracted into the guide sleeve; when powered off, the return spring releases the elastic force to push the steel ball out and engage with the groove to lock, the control system adjusts the on-off time sequence of the electromagnet by using fuzzy PID control algorithm, to ensure the rapidity and reliability of the locking action.

[0007] Preferably, the system initialization phase establishes the mapping relationship between the crank angle signal and the piston position and sets the sampling frequency and control period of each sensor, the crank angle signal is collected in real time through the key phase sensor, the real-time position of the piston is determined through the position calculation model, the monitoring data of the pressure and temperature sensors are read at the same time for multi-parameter fusion processing, the working condition parameters are converted into the load signal required for clearance volume adjustment based on the clearance volume-load characteristic curve, if adjustment is needed, the solenoid is energized through the electromagnetic actuator to make the steel ball retract, and then the control command is output to drive the clearance piston to move to the target position, the steel ball is ejected to lock after the clearance piston reaches the target position, finally, the locking state is verified by the position feedback module and the position sensor in the clearance volume adjustment device, if the locking fails, the locking control process is executed again, after the adjustment is completed, the system state parameters are updated and the next control cycle is entered for monitoring and adjustment.

[0008] Preferably, the compressor-related parameters are obtained: crank radius r, connecting rod length L, piston area A p , thermal compression coefficient k, gas valve flow coefficient a v , number of intake / exhaust valves N, valve lift h, valve average diameter d cp , gas constant R, intake pressure P s , intake temperature T s , exhaust pressure P d , exhaust temperature T d , and the crank angle θ signal of the compressor crank is monitored in real time by the key phase sensor, it is specified that when the crank angle θ=0°, it is at the expansion starting point of the reciprocating compressor, that is, the crank is at the outer dead center, and the mapping relationship between the crank angle signal and the piston position x is established. The control system uses multi-parameter data fusion technology to accurately determine the current gas compression stage of the compressor by monitoring the crank angle θ in real time, and to provide real-time working condition basis for accurate adjustment of the clearance volume according to the gas characteristics of different compression stages and combined with the thermodynamic model calculation of the in-cylinder gas pressure P.

[0009] Preferably, the control system solves the load signal under different gas compression stages: if the compressor is in the suction stage at this time, the in-cylinder gas pressure P in the suction stage is solved according to the suction valve flow differential equation: If the compressor is in the exhaust stage at this time, the in-cylinder gas pressure P in the exhaust stage is solved according to the exhaust valve flow differential equation: If the compressor is in the expansion or compression stage at this time, the in-cylinder gas pressure P in the expansion or compression stage is solved according to the polytropic equation model: PV m = constant, the clearance piston needs to overcome the in-cylinder gas force F g to realize movement, the electromagnetic force Fe With the gas force F g Satisfies: F e ≥F g =P·A p , the number of turns of the coil Z, the vacuum permeability μ0, the magnetic pole cross-sectional area A gap , the air gap length g, according to the electromagnetic force Formula, the current At different crank angles θ can be solved The control system adopts a fuzzy PID control algorithm to dynamically optimize the current parameters, and ensures the balance of the electromagnetic force F e With the gas force F g .

[0010] The present application has the following beneficial effects: 1. The present application adopts a technical scheme combining electromagnetic drive and mechanical locking, realizes high-precision dynamic adjustment of the clearance volume, adjusts the on-off timing of electricity by a fuzzy PID control algorithm, and sets a double verification mechanism to ensure the locking state, thereby significantly improving the energy efficiency and operation stability of the compressor 2. The electromagnetic drive of the present application replaces the traditional mechanical transmission mechanism and hydraulic control system, significantly reducing mechanical wear and system complexity, and the modular design of the ball head self-locking mechanism makes installation and maintenance more convenient. 3. The present application realizes adaptive control of clearance adjustment by real-time processing of pressure, temperature and position signals through multi-parameter data fusion technology and Kalman filtering algorithm, dynamically adjusting the electromagnetic force in combination with a thermodynamic model and a fuzzy PID control algorithm, so that the system can adapt to complex working condition changes. BRIEF DESCRIPTION OF DRAWINGS

[0011] Figure 1 is a system configuration diagram of the present application;

[0012] Figure 2 is a structure diagram of a single-sided cylinder when the clearance adjustment device of the present application is not started;

[0013] Figure 3 is a structure diagram of a single-sided cylinder before locking when the clearance adjustment of the present application is executed;

[0014] Figure 4 is Figure 3 a partial enlarged view;

[0015] Figure 5 is a structure diagram of a single-sided cylinder after locking when the clearance adjustment of the present application is executed;

[0016] Figure 6 is Figure 5 a partial enlarged view;

[0017] Figure 7 is a control flow chart of the system of the present application;

[0018] Figure 8Electromagnetic power control signal flow chart of the present application.

[0019] In the figure, 1. clearance volume adjusting device, 101. clearance piston, 102. clearance piston cylinder, 103. clearance piston rod, 104. position sensor, 105. electromagnetic power unit, 106. ball head self-locking mechanism, 107. guide sleeve, 108. position feedback module, 109. electromagnetic actuator, 110. reset spring, 111. steel ball, 2. integrated pressure-temperature sensor of intake pipeline, 3. compressor, 301. key phase sensor, 302. piston, 4. integrated pressure-temperature sensor of exhaust pipeline, 5. control system. DETAILED DESCRIPTION

[0020] Figure 1 System control principle diagram of the present application, which is composed of 1. clearance volume adjusting device, 101. clearance piston, 102. clearance piston cylinder, 103. clearance piston rod, 104. position sensor, 105. electromagnetic power unit, 106. ball head self-locking mechanism, 107. guide sleeve, 108. position feedback module, 109. electromagnetic actuator, 110. reset spring, 111. steel ball, 2. integrated pressure-temperature sensor of intake pipeline, 3. compressor, 301. key phase sensor, 302. piston, 4. integrated pressure-temperature sensor of exhaust pipeline, 5. control system. According to different working conditions, through electromagnetic direct drive and ball head self-locking mode, real-time clearance adjustment is carried out to realize stable gas volume regulation in a wide working condition range.

[0021] Figure 2 Unilateral cylinder structure diagram of the present application when the clearance adjusting device is not started, as shown in Figure 2 When the compressor 3 is in full load operation and no clearance adjustment is required, the clearance volume adjusting device 1 remains in a non-working state, the clearance piston 101 is located at the initial position, at this time the electromagnetic control unit 105 is in the closed state, the steel ball in the ball head self-locking mechanism 106 is ejected and engaged with the clearance piston cylinder 102 groove to realize mechanical locking and ensure stable operation of the system.

[0022] Figure 3 Unilateral cylinder structure diagram of the present application when the clearance adjusting device is not started, as shown in Figure 4 Figure 3 ​A partially enlarged view is shown. As illustrated, when clearance adjustment is required during compressor 3 operation, clearance volume adjustment device 1 is activated. At this time, the electromagnetic actuator 109 in the ball-head self-locking mechanism 106 is energized, generating magnetic force to attract the steel ball 111 back into the guide sleeve 107, thereby disengaging it from the groove of the clearance piston cylinder 102 and releasing the free movement capability of the clearance piston 101. Subsequently, the electromagnetic power unit 105 acts directly on the clearance piston rod 103 via electromagnetic drive, causing the clearance piston 101 to move to the target position within the clearance piston cylinder 102. This achieves precise adjustment of the clearance volume.

[0023] Figure 5 This is a schematic diagram of the single-sided cylinder structure after locking during clearance adjustment according to the present invention. Figure 6 for Figure 5 A partially enlarged view is shown. As illustrated, when the clearance piston 101 moves to the target position under the drive of the electromagnetic power unit 105, the ball head self-locking mechanism 106 begins to perform the locking action: the electromagnetic actuator 109 is de-energized, the magnetic force disappears, and the steel ball 111, under the action of the return spring 110, pops out from the guide sleeve 107 and re-engages with the groove of the clearance piston cylinder 102, achieving mechanical locking. At this time, the clearance piston 101 is firmly fixed, and the electromagnetic power unit 105 immediately stops working, ensuring optimal system energy consumption. The adjusted clearance volume remains stable, the electromagnetic power unit 105 remains in the off state, and the system enters a new stable working mode, providing stable operating conditions for the compressor 3.

[0024] Figure 7 The control flowchart of the system of this invention is shown in the figure. After the system starts, it first enters the initialization stage, establishing the mapping relationship between the crankshaft angle signal and the piston 302 position, and setting the sampling frequency and control cycle of each sensor. During operation, the key phase sensor 301 collects the crankshaft angle signal in real time, combined with the position calculation model. The real-time position of the piston 302 is accurately calculated, and the monitoring data of the integrated pressure and temperature sensors are processed through multi-parameter fusion. Based on the preset clearance volume-load characteristic curve, the system converts the working condition parameters into accurate load adjustment signals. When it is determined that adjustment is needed, the electromagnetic actuator 109 is first controlled to energize the electromagnet, causing the steel ball 111 to retract and unlock; then the control command is output to drive the clearance piston 101 to move to the target position, and after reaching the position, the electromagnet is de-energized to make the steel ball 111 pop out to complete mechanical locking. To ensure reliability, the system performs double-state verification through the position feedback module 108 and the position sensor 104 in the clearance volume adjustment device 1, and if locking fails, the locking process is automatically restarted. After the adjustment is completed, the system updates the state parameters and enters the real-time monitoring and adjustment cycle of the next control period, realizing continuous optimization of the compressor working condition. The entire process includes an abnormality judgment mechanism, which immediately executes de-energization locking protection when position abnormalities are detected, and real-time feedback of system status through the display to ensure safe and reliable operation.

[0025] Figure 8 The load signal conversion flowchart of the present application is shown in the figure. The control system 5 accurately solves the in-cylinder gas pressure P by real-time judgment of the working stage of the compressor 3 using the corresponding mathematical model: in the suction stage, based on the suction valve flow differential equation: solving; in the exhaust stage, the exhaust valve flow differential equation is used for calculation: ; and in the expansion or compression stage, the multi-variable equation PV m = constant is used for solving. To drive the clearance piston 101 to overcome the in-cylinder gas force and realize accurate movement, the control system 5 accurately controls through the electromagnetic force F e and the gas force F g balance principle. According to the electromagnetic force calculation formula combined with the known coil turns Z, vacuum permeability μ0, magnetic pole cross-sectional area A gap , and air gap length g parameters, the system can calculate the current at different crank angles θ. In particular, the control system 5 uses an advanced fuzzy PID control algorithm to dynamically adjust the electromagnetic force and optimize the current parameters, and real-time adjusts the output of the electromagnetic power unit 105, to ensure that the electromagnetic force F e and the gas force F g always remain in balance. Through real-time curve conversion and numerical calculation, the system ensures stable performance under various working conditions.

[0026] The above description is not intended to limit the present application in any form, although the present application has been disclosed by the above examples, however, not intended to limit the present application, any skilled person in the art, without departing from the technical solution of the present application, can utilize the disclosed technical content to make some changes or modifications as the changed examples, but as long as it does not deviate from the technical solution of the present application, according to the technical essence of the present application, any simple modification, change and modification of the above examples, still belongs to the scope of the technical solution of the present application.

Claims

1. A clearance adjustment system and method for electromagnetic drive and mechanical self-locking coupling, characterized in that: The compressor 3 is equipped with a clearance volume adjustment device 1, an adaptive multivariable monitoring unit, and a control system 5. The clearance volume adjustment device 1 consists of a clearance piston 101, a clearance piston cylinder 102, a clearance piston rod 103, an electromagnetic power unit 105, and a ball-head self-locking mechanism 106. The electromagnetic power unit 105 directly acts on the clearance piston rod 103 via electromagnetic drive, causing the clearance piston 101 to reciprocate within the clearance piston cylinder 102. The adaptive multivariable monitoring unit includes an integrated pressure-temperature sensor 2 for the intake pipe, an integrated pressure-temperature sensor 4 for the exhaust pipe, a key phase sensor 301 for the compressor crankshaft, and a position sensor 104 within the clearance volume adjustment device 1. The control system 5 uses multi-parameter data fusion technology and a Kalman filter algorithm to process the sensor data in real time. It obtains the precise position of the piston through dynamic calculation and outputs precise control commands to the electromagnetic power unit 105 and the ball-head self-locking mechanism 106 to achieve clearance volume adjustment and clearance piston 101 self-locking.

2. The clearance adjustment system and method of electromagnetic drive and mechanical self-locking coupling according to claim 1, characterized in that: The ball-head self-locking mechanism 106 consists of an electromagnetic actuator 109, a position feedback module 108, a steel ball 111, a return spring 110, and a guide sleeve 107. The ball-head self-locking mechanism 106 is fixedly installed in the circumferential threaded hole of the clearance piston 101 via a threaded connection. The electromagnetic actuator 109 includes an electromagnet and its driving circuit. The electromagnet is fixedly installed inside the guide sleeve 107. The position feedback module 108 is a micro switch installed at the bottom of the guide sleeve 107. When the steel ball 111 retracts, it presses the switch contacts, used to monitor the locking status of the steel ball in real time and feed the signal back to the control system 5. The circumferential thread of the clearance piston 101... Multiple ball-head self-locking mechanisms 106 are evenly arranged. The inner wall of the clearance piston cylinder 102 is evenly distributed with multiple groove arrays that cooperate with the steel ball 111 along the circumferential direction. The electromagnetic actuator 109 drives the return spring 110 and the steel ball 111 to complete the extension and retraction movement by controlling the power on and off of the control circuit: when energized, the electromagnet generates magnetic force to attract the steel ball 111 and compress the return spring 110, causing it to retract into the guide sleeve 107; when de-energized, the return spring 110 releases its elastic force to push the steel ball 111 out and engage with the groove to lock. The control system 5 uses a fuzzy PID control algorithm to adjust the power on and off timing of the electromagnet to ensure the speed and reliability of the locking action.

3. The clearance adjustment system and method of electromagnetic drive and mechanical self-locking coupling according to claim 1, characterized in that: During the system initialization phase, a mapping relationship between the crankshaft angle signal and the piston 302 position is established, and the sampling frequency and control cycle of each sensor are set. The crankshaft angle signal is collected in real time through the key phase sensor 301, and the real-time position of the piston 302 is determined through the position calculation model. At the same time, the monitoring data of the pressure and temperature sensors are read and multi-parameter fusion processing is performed. Based on the clearance volume-load characteristic curve, the operating parameters are converted into the load signal required for clearance adjustment. If adjustment is required, the electromagnet is energized through the electromagnetic actuator 109 to retract the steel ball 111. Then, the control command is output to drive the clearance piston 101 to move to the target position. After the clearance piston 101 reaches the target position, the power is cut off to make the steel ball 111 pop out and lock. Finally, the locking status is verified by the position feedback module 108 and the position sensor 104 in the clearance volume adjustment device 1. If the locking fails, the locking control process is re-executed. After the adjustment is completed, the system status parameters are updated and the monitoring and adjustment of the next control cycle begins.

4. The clearance adjustment system and method of electromagnetic drive and mechanical self-locking coupling according to claim 3, characterized in that: Obtain the relevant parameters of compressor 3: crankshaft radius r, connecting rod length L, piston area A p Thermal compressibility coefficient k, valve flow coefficient a v Number of intake / exhaust valves N, valve lift h, average valve diameter d cp The gas constant R is monitored in real time by an integrated pressure-temperature sensor 2 installed in the intake pipe, which monitors the intake pressure P. s Intake air temperature T s The integrated pressure-temperature sensor 4 in the exhaust pipe monitors the exhaust pressure P in real time. d Exhaust temperature T d The key phase sensor 301 of the compressor crankshaft monitors the crankshaft angle θ signal in real time. It is defined that when the crankshaft angle θ = 0°, it is at the expansion starting point of the reciprocating compressor, that is, the crank is at the outer dead center. A mapping relationship between the crankshaft angle signal and the piston position x of 302 is established: The control system employs multi-parameter data fusion technology. By monitoring the crankshaft angle θ in real time, it accurately determines the current gas compression stage of the compressor. Based on the gas characteristics of different compression stages, it calculates the in-cylinder gas pressure P using a thermodynamic model, providing real-time operating condition data for precise adjustment of clearance volume.

5. The clearance adjustment system and method of electromagnetic drive and mechanical self-locking coupling according to claim 4, characterized in that: Solving for the load signal of control system 5 under different gas compression stages: If compressor 3 is in the suction stage at this time, according to the flow differential equation of the suction valve: Solve for the cylinder gas pressure P during the intake phase; if compressor 3 is in the exhaust phase at this time, according to the flow differential equation of the exhaust valve: Solve for the in-cylinder gas pressure P during the exhaust phase; if the compressor is in the expansion or compression phase at this time, according to the multivariate equation model: PV m = constant, solve for the cylinder gas pressure P during the expansion or compression stage, and the clearance piston 101 needs to overcome the cylinder gas force F. g To achieve motion, electromagnetic force F e With gas force F g Satisfy: F e ≥F g =P·A p Given the number of turns Z of the coil, the permeability of free space μ0, and the cross-sectional area of ​​the magnetic poles A. gap The air gap length g is determined by electromagnetic force. The formula can be used to solve for the current at different crankshaft rotation angles θ. The control system 5 uses a fuzzy PID control algorithm to dynamically adjust the current parameters to ensure the balance between electromagnetic force and gas force.

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