Energy-efficient gas compressor

Abstract

This invention relates to the field of gas compression equipment technology, specifically a high-efficiency and energy-saving gas compressor. The invention filters the incoming air to the gas compressor. Once the filtered air meets the cleanliness standards, a target exhaust pressure is determined based on the minimum required pressure for normal operation of the gas-using equipment and pipeline loss pressure. The control parameters required for the gas compressor's operation are analyzed based on the target exhaust pressure. After adjustment, the actual exhaust pressure is collected, and the actual exhaust pressure is compared with the target exhaust pressure to determine if it meets the exhaust requirements. If it does not meet the requirements, the control parameters of the gas compressor are adjusted to avoid ineffective work or insufficient gas supply, thereby improving compression efficiency and achieving energy-saving operation of the compressor. Simultaneously, the response timeliness is analyzed based on the control time interval during the adjustment process, enabling timely detection and optimization of control mechanism deficiencies, thus improving the stability and reliability of compressor operation.

Description

Technical Field

[0001] This invention relates to the field of gas compression equipment technology, and specifically to a high-efficiency and energy-saving gas compressor. Background Technology

[0002] As a core power device in industrial systems, the main function of gas compressors is to compress low-pressure gas into high-pressure gas, providing a gas source that meets the pressure and flow requirements of subsequent gas-consuming equipment. With the increasing demands for energy consumption control and operational stability in industrial production, existing gas compressors struggle to balance the dual needs of efficient gas supply and energy-saving operation.

[0003] However, the existing technology has the following problems: 1. The existing technology usually sets the compressor discharge pressure based on the rated pressure of the gas-using equipment or human experience, without adjusting the operation strategy according to the dynamic needs and changes in the operating conditions of the gas-using equipment. If the discharge pressure is set too high, it will cause the compressor to do extra work, resulting in energy waste; if it is set too low, it will not be able to meet the normal working needs of some gas-using equipment, affecting the continuity of production.

[0004] 2. The control parameters of the compressor directly determine the compression efficiency and energy consumption. However, existing technologies mostly rely on fixed parameter operation and adjustment, without combining the compressor's characteristic curve and the actual flow demand of the gas-using equipment for accurate calculation. This can easily lead to a mismatch between the control parameters and the target exhaust pressure, resulting in problems such as over-engineering or insufficient gas supply, thus reducing operating efficiency. Summary of the Invention

[0005] To address the problems existing in current gas compressors, this invention provides a high-efficiency and energy-saving gas compressor. Through modular design, it achieves precise control of the entire process, including intake filtration, pressure determination, parameter regulation, and response evaluation, ultimately achieving the goals of reducing energy consumption, improving operational stability, and extending equipment life.

[0006] The technical solution adopted by the present invention to solve its technical problem is: a high-efficiency and energy-saving gas compressor, including an intake air filtration analysis module, an exhaust pressure determination module, a control parameter analysis module, an exhaust pressure compliance analysis module, and a control response evaluation module.

[0007] The connections between the modules are as follows: the intake air filtration analysis module is communicatively connected to the exhaust pressure determination module; the control parameter analysis module is communicatively connected to both the exhaust pressure determination module and the exhaust pressure conformity analysis module; and the control response evaluation module is communicatively connected to the exhaust pressure conformity analysis module.

[0008] The intake air filtration and analysis module filters the intake air entering the gas compressor, detects the cleanliness characteristics of the filtered intake air, and determines whether the intake air meets the intake air cleanliness standards.

[0009] The exhaust pressure determination module determines the minimum required pressure for normal operation of each gas-consuming device based on its operating parameters, and obtains the target exhaust pressure by combining the pipeline loss pressure from the gas compressor exhaust port to each gas-consuming device.

[0010] The control parameter analysis module analyzes the control parameters required for the operation of the gas compressor based on the target exhaust pressure. The control parameters include the speed control and the intake valve opening. The control parameters are then transmitted to the control center.

[0011] The exhaust pressure compliance analysis module collects the actual exhaust pressure of the gas compressor and compares it with the target exhaust pressure to determine whether the actual exhaust pressure meets the exhaust requirements.

[0012] The control response evaluation module adjusts the control parameters of the gas compressor when the exhaust requirements are not met. It analyzes the timeliness of the control response to the exhaust pressure based on the control time interval during the adjustment process, calculates the timeliness rate of the gas compressor's response during operation, and provides feedback.

[0013] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention filters the air entering the gas compressor, detects the cleanliness characteristic parameters of the filtered air, and determines whether the air meets the air cleanliness standard, effectively avoiding the wear of impurities on the internal components of the compressor, extending the service life of the compressor, and avoiding impurities affecting the compression efficiency, so that the compressor can maintain a high-efficiency compression state for a long time.

[0014] (2) Based on the working parameters of each gas-using device, the present invention determines the minimum required pressure for normal operation of the gas-using device, and combines the pipeline loss pressure from the gas compressor exhaust port to each gas-using device to obtain the target exhaust pressure, so that the target exhaust pressure accurately matches the dynamic demand of the gas-using device, avoids energy waste caused by excessive pressure, and prevents the gas-using device from shutting down due to excessively low pressure, thus ensuring production continuity.

[0015] (3) Based on the target exhaust pressure, this invention analyzes the control parameters required for the operation of the gas compressor by combining the standard characteristic curve of the gas compressor, and transmits the control parameters to the control center so that the speed regulation and intake valve opening are accurately matched to the target exhaust pressure and flow requirements, avoiding the problem of ineffective work or insufficient gas supply, while improving compression efficiency, reducing energy consumption, and realizing energy-saving operation of the compressor.

[0016] (4) The present invention adjusts the control parameters of the gas compressor, analyzes the control response timeliness of the exhaust pressure based on the control time interval of the adjustment process, statistically analyzes the response timeliness rate of the gas compressor during operation, and provides feedback, thereby ensuring timely control response of the exhaust pressure, timely detection and optimization of the control mechanism, improving the stability and reliability of the compressor operation, and ensuring that the gas source meets the requirements for the gas-using equipment for a long time. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the system module connections of the present invention.

[0019] Figure 2 This is a schematic diagram of the unit frame connection in the air intake filtration analysis module of the present invention.

[0020] Figure 3 This is a schematic diagram of the steps for obtaining the target exhaust pressure in this invention.

[0021] Figure 4 This is a schematic diagram illustrating the specific steps of the exhaust pressure compliance analysis module in this invention. Detailed Implementation

[0022] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. Furthermore, it should be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale.

[0023] The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the invention or its application or use. Techniques, methods, and apparatus known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and apparatus should be considered part of the specification.

[0024] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0025] Please see Figure 1 As shown, the present invention provides a high-efficiency and energy-saving gas compressor, including an intake air filtration analysis module, an exhaust pressure determination module, a control parameter analysis module, an exhaust pressure compliance analysis module, and a control response evaluation module.

[0026] The connections between the modules are as follows: the intake air filtration analysis module is communicatively connected to the exhaust pressure determination module; the control parameter analysis module is communicatively connected to both the exhaust pressure determination module and the exhaust pressure conformity analysis module; and the control response evaluation module is communicatively connected to the exhaust pressure conformity analysis module.

[0027] The intake air filtration and analysis module filters the intake air entering the gas compressor, detects the cleanliness characteristics of the filtered intake air, and determines whether the intake air meets the intake air cleanliness standards.

[0028] like Figure 2 As shown, the intake air filtration analysis module includes a primary filtration unit, a secondary filtration unit, and an intake air detection unit.

[0029] The primary filtration unit is used to intercept and filter solid impurities in the intake air. By using a metal filter screen to physically intercept solid impurities in the intake air, including dust, pipe rust debris, and externally drawn-in particles, the coarse filtration prioritizes blocking large solid impurities, preventing them from directly damaging the compressor cylinder or piston components.

[0030] The secondary filtration unit is used to adsorb and filter gaseous impurities in the intake air after solid impurities have been filtered. An activated carbon adsorption layer is used to adsorb residual gaseous impurities after coarse filtration, primarily adsorbing acidic or harmful gases such as hydrogen sulfide and carbon dioxide. Fine filtration addresses the corrosion problem of gaseous impurities on the internal metal components of the compressor.

[0031] The intake detection unit is used to detect the cleanliness characteristic parameters of the filtered intake air, including the content of solid impurities and the concentration of gaseous impurities, and compares them with the preset intake cleanliness standard of the gas compressor.

[0032] If the content of solid impurities or the concentration of gaseous impurities exceeds the corresponding standard threshold in the intake air cleanliness standard, the intake air does not meet the intake air cleanliness standard, and the filtered intake air is prohibited from entering the compressor. A filter component maintenance reminder signal is sent to prompt the filter component to be cleaned or replaced. Otherwise, the intake air meets the intake air cleanliness standard.

[0033] In one specific embodiment, a laser particle counter and a dedicated gas sensor are used to detect the content of solid impurities and the concentration of gaseous impurities in the filtered intake air, respectively.

[0034] This invention filters the intake air entering the gas compressor, detects the cleanliness characteristics of the filtered intake air, and determines whether the intake air meets the intake air cleanliness standard. This effectively avoids impurities from causing wear on the internal components of the compressor, extends the service life of the compressor, and prevents impurities from affecting the compression efficiency, allowing the compressor to maintain a high-efficiency compression state for a long time.

[0035] The exhaust pressure determination module determines the minimum required pressure for normal operation of each gas-consuming device based on its operating parameters, and obtains the target exhaust pressure by combining the pipeline loss pressure from the gas compressor exhaust port to each gas-consuming device.

[0036] The operating parameters of each gas-using device can be obtained from the device's technical manual, which contains safety thresholds specified by the device manufacturer.

[0037] It should be noted that the determination of the minimum required pressure for the normal operation of the gas-consuming equipment is as follows: First, extract the start-up and shutdown times of all gas-consuming equipment connected to the gas compressor in each production cycle from the compressor's operating history, and select the equipment combination with the largest number of simultaneously operating devices. This ensures that the pressure setting can cope with the scenario of the strongest gas demand, avoiding the risk of some equipment failing to work properly due to insufficient pressure, and mitigating the risk of missing extreme operating conditions from the source.

[0038] The second step is to extract the minimum allowable pressure requirement from the operating parameters of each gas-consuming device in the maximum device combination, and then take the maximum value of the minimum allowable pressure requirement in descending order as the peak value of the simultaneous operating pressure requirement. This peak value ensures that the minimum pressure requirements of all devices in the maximum device combination are covered.

[0039] The third step is to correct the peak pressure demand of each gas-consuming device in each production cycle based on the maximum pressure fluctuation value of each gas-consuming device in the combination of the most equipment to obtain the minimum required pressure for normal operation of the gas-consuming device.

[0040] Specifically, for each gas-consuming device in the combination of the most equipment, the highest and lowest pressure values ​​within each production cycle are extracted. The difference between these values ​​is taken as the maximum pressure fluctuation value. The maximum value among the maximum pressure fluctuation values ​​of each gas-consuming device in each production cycle is then taken as the overall maximum pressure fluctuation value. The sum of this overall maximum pressure fluctuation value and the peak pressure required for simultaneous operation is taken as the minimum required pressure for the gas-consuming device to operate normally. This ensures that all gas-consuming devices receive pressure no less than their minimum required pressure under any normal production scenario, preventing downtime due to insufficient pressure, guaranteeing the continuity of the production process, and reducing downtime losses.

[0041] In one specific embodiment, the method for selecting the equipment combination with the largest number of simultaneously operating devices is as follows: based on the start and stop times of all gas-consuming devices connected to the gas compressor in each production cycle, the combination of devices operating simultaneously in each production cycle is counted.

[0042] Based on the number of equipment combinations that operate simultaneously in each production cycle, the combination with the largest number of equipment is selected.

[0043] like Figure 3As shown, the target exhaust pressure is obtained by: firstly, extracting the output exhaust pressure from the gas compressor exhaust port to each gas-consuming device and the input exhaust pressure of each gas-consuming device from the compressor operation history.

[0044] Next, the output exhaust pressure from the gas compressor's exhaust port to each gas-consuming device is analyzed against the corresponding input exhaust pressure to obtain the exhaust pressure deviation value for each gas-consuming device. By analyzing the exhaust pressure deviation value, the losses in each pipeline section are accurately quantified, ensuring that the target exhaust pressure setting no longer ignores pipeline loss pressure, and guaranteeing that the inlet pressure of the gas-consuming device meets the standard.

[0045] Next, the exhaust pressure deviation values ​​of each gas-consuming device in each production cycle are statistically analyzed, and their average value is used as the pipeline loss pressure from the gas compressor exhaust port to each gas-consuming device. By statistically analyzing the average values ​​over multiple production cycles, instantaneous fluctuations can be smoothed out, allowing the pipeline loss pressure to closely approximate the long-term true level and ensuring the stability of the target exhaust pressure.

[0046] Finally, the maximum pipeline loss pressure is selected from the pipeline loss pressure from the gas compressor exhaust port to each gas-consuming device, and the sum of this pressure and the minimum required pressure for normal operation of the gas-consuming device is taken as the target exhaust pressure.

[0047] This invention determines the minimum required pressure for normal operation of each gas-consuming device based on its operating parameters. Combined with the pipeline loss pressure from the gas compressor exhaust port to each gas-consuming device, the target exhaust pressure is obtained. This ensures that the target exhaust pressure accurately matches the dynamic needs of the gas-consuming device, avoiding energy waste caused by excessive pressure and preventing the gas-consuming device from shutting down due to excessively low pressure, thus ensuring production continuity.

[0048] The control parameter analysis module analyzes the control parameters required for the operation of the gas compressor based on the target exhaust pressure. The control parameters include the speed control and the intake valve opening. The control parameters are then transmitted to the control center.

[0049] It should be noted that the control parameter analysis module specifically includes: determining the speed corresponding to the target exhaust pressure based on the standard characteristic curve of the pressure and speed of the gas compressor, taking it as the maximum value of the adaptive speed range for the target exhaust pressure, and taking the rated minimum stable speed of the gas compressor as the minimum value of the adaptive speed range.

[0050] The rated minimum stable speed of a gas compressor is specified by the manufacturer and refers to the lowest operating speed at which the compressor will not experience surge or excessive vibration. If the speed is lower than the minimum operating speed, the airflow inside the compressor will become turbulent or surge, leading to increased wear on components and even shutdown.

[0051] Extract the rated operating flow rate from the operating parameters of each gas-consuming device in the combination of the most devices, sum them up to obtain the maximum simultaneous operating flow rate, and calculate the required speed based on the theoretical displacement formula of the gas compressor.

[0052] If the required speed is within the suitable speed range, and the exhaust pressure on the pressure-speed standard characteristic curve is greater than or equal to the target exhaust pressure, then the required speed is taken as the control speed required for the operation of the gas compressor body. Otherwise, the required speed is recalculated until the control speed required for the operation of the gas compressor body is determined.

[0053] The process of recalculating the required speed requires rechecking the maximum simultaneous working flow rate or adjusting the displacement formula parameters, such as confirming whether the cylinder diameter or piston stroke is the latest measured value.

[0054] If the compressor operates at the rated maximum speed, the exhaust pressure will exceed the target exhaust pressure due to the excessive speed, requiring the compressor to perform additional work to relieve the pressure, resulting in energy waste. If it operates at the rated minimum speed, the maximum simultaneous working flow cannot be met, leading to a drop in the pressure of the gas-using equipment. This invention ensures that the speed can cover the maximum gas demand by matching the required speed based on the maximum simultaneous working flow, thus meeting the flow and pressure requirements and reducing ineffective work.

[0055] The control parameter analysis module further includes substituting the required operating speed of the gas compressor body into the theoretical displacement formula of the gas compressor to obtain the theoretical displacement corresponding to the operating speed. The theoretical displacement formula of the gas compressor is existing technology and will not be described in detail in this invention.

[0056] Retrieve the three-dimensional standard characteristic curves of pressure, displacement, and opening degree of the gas compressor. Locate the coordinate point corresponding to the theoretical displacement and the target exhaust pressure in the curve, and read the opening degree corresponding to the coordinate point, which is recorded as the initial opening degree.

[0057] If the initial opening is greater than the rated minimum stable opening of the gas compressor, the initial opening is used as the exhaust valve opening; otherwise, the rated minimum stable opening is used as the exhaust valve opening.

[0058] In the above-mentioned case, if the opening is too large, the intake air volume will exceed the demand, and the compressor will need to release the excess gas through the pressure relief valve, which wastes energy; if the opening is too small, the intake air will be insufficient, the displacement will decrease, and the flow rate demand will not be met. This module determines the opening of the exhaust valve through the three-dimensional standard characteristic curve of the gas compressor corresponding to the pressure, displacement and opening degree, so as to ensure that the opening degree is just matched with the displacement and pressure, thereby improving the compression efficiency.

[0059] In one specific embodiment, the standard characteristic curve of the gas compressor is the exhaust pressure-speed relationship measured by experiments before the compressor leaves the factory. It reflects the maximum exhaust capacity of the same compressor at different speeds. The higher the speed, the greater the exhaust pressure.

[0060] The three-dimensional standard characteristic curves of pressure, displacement and opening degree of the gas compressor are the three-dimensional relationship between the actual measured discharge pressure, theoretical displacement and discharge valve opening degree of the compressor at the factory. They reflect the optimal intake opening degree under different displacement and pressure. The larger the discharge valve opening degree, the more intake air and the larger the displacement.

[0061] This invention analyzes the control parameters required for the operation of a gas compressor based on the target exhaust pressure and the corresponding standard characteristic curve of the gas compressor. The control parameters are then transmitted to the control center to ensure that the speed regulation and intake valve opening are precisely matched to the target exhaust pressure and flow requirements. This avoids problems such as ineffective work or insufficient gas supply, while improving compression efficiency, reducing energy consumption, and achieving energy-saving operation of the compressor.

[0062] The exhaust pressure compliance analysis module collects the actual exhaust pressure of the gas compressor and compares it with the target exhaust pressure to determine whether the actual exhaust pressure meets the exhaust requirements.

[0063] like Figure 4 As shown, the specific content of the exhaust pressure compliance analysis module is as follows: the actual exhaust pressure is compared with the target exhaust pressure. If the real-time exhaust pressure is within the preset fluctuation range of the target exhaust pressure, it is determined that the actual exhaust pressure meets the exhaust requirements, a pressure control trigger signal is generated, and it is transmitted to the control center.

[0064] If the real-time exhaust pressure exceeds the preset fluctuation range of the target exhaust pressure, it is determined that the actual exhaust pressure does not meet the exhaust requirements.

[0065] The preset fluctuation range is the allowable deviation range of the target exhaust pressure, which is usually set as the target exhaust pressure ± a fixed percentage. For example, if the target exhaust pressure is 1.01 MPa, and the conventional control accuracy of the reference gas compressor is ±2% pressure fluctuation, then the preset fluctuation range can be set to 1.01 MPa ± 0.02 MPa.

[0066] This invention compares the actual exhaust pressure of the gas compressor with the target exhaust pressure to determine whether the actual exhaust pressure meets the exhaust requirements, thereby ensuring that the actual exhaust pressure of the compressor is consistent with the target exhaust pressure, and providing a precise triggering basis for subsequent control adjustments.

[0067] The control response evaluation module adjusts the control parameters of the gas compressor when the exhaust requirements are not met. It analyzes the timeliness of the control response to the exhaust pressure based on the control time interval during the adjustment process, calculates the timeliness rate of the gas compressor's response during operation, and provides feedback.

[0068] It should be noted that the process of adjusting the control parameters of the gas compressor is as follows: First, compare the deviation between the real-time exhaust pressure and the preset fluctuation range of the target exhaust pressure to obtain the deviation value and type of the real-time exhaust pressure and the target exhaust pressure.

[0069] The second step is to determine the adjustment speed and the adjustment valve opening based on the deviation value and deviation type from the standard characteristic curves of pressure and speed and the three-dimensional standard characteristic curves of pressure, displacement and opening degree corresponding to the gas compressor.

[0070] The deviation types include positive deviation and negative deviation. When the deviation type is positive, the adjustment speed corresponding to the real-time exhaust pressure dropping to the deviation value needs to be found from the pressure-speed standard characteristic curve; when the deviation type is negative, the adjustment speed corresponding to the real-time exhaust pressure reaching the deviation value needs to be found from the pressure-speed standard characteristic curve.

[0071] Calculate the theoretical displacement corresponding to the regulating speed based on the theoretical displacement formula of the gas compressor. Referring to the above method for finding the regulating speed, similarly, based on the calculated theoretical displacement and the deviation value and type, find the corresponding regulating exhaust valve opening from the three-dimensional standard characteristic curve of pressure, displacement and opening degree.

[0072] The third step is to adjust the control parameters of the gas compressor according to the speed adjustment and the opening of the exhaust valve, and to collect the exhaust pressure of the gas compressor in real time until the exhaust pressure meets the exhaust requirements.

[0073] The above method compares the real-time exhaust pressure with the target exhaust pressure within a preset fluctuation range to accurately obtain the deviation value and type. Adjustments are then made based on the determined adjustment speed and exhaust valve opening. This reduces energy consumption caused by blind adjustments, ensures stable exhaust pressure that meets requirements, effectively reduces the risk of gas-using equipment shutting down due to insufficient pressure, and ultimately achieves the goals of high efficiency, energy saving, stable gas supply, and ensuring production continuity.

[0074] The analysis of the timeliness of the control response of the exhaust pressure is as follows: taking the adjustment time of the control parameters of the gas compressor as the starting time point and the time when the exhaust pressure of the gas compressor meets the exhaust requirements as the ending time point, the control time interval between the starting time point and the ending time point is calculated.

[0075] If the control time interval is less than the response reference time, the control response of the exhaust pressure is considered timely; otherwise, the control response of the exhaust pressure is considered untimely.

[0076] The response reference time can be set according to industry standards in this field. For example, in one embodiment, the response reference time for the gas compressor is set to 60 seconds by default.

[0077] The statistical analysis of the response timeliness during the operation of the gas compressor specifically includes: obtaining the control response timeliness of each control parameter adjustment during the operation of the gas compressor, and filtering the number of control parameter adjustments with timely control responses.

[0078] The response time rate is the ratio of the number of times the control parameters are adjusted in a timely manner to the total number of times the control parameters are adjusted during the operation of the gas compressor.

[0079] If the response time rate is less than the set response time rate threshold, an early warning feedback will be issued through the control center.

[0080] This invention adjusts the control parameters of a gas compressor, analyzes the control response timeliness of the exhaust pressure based on the control time interval during the adjustment process, statistically analyzes the response timeliness rate of the gas compressor during operation, and provides feedback to ensure timely control response of the exhaust pressure. It also promptly identifies and optimizes deficiencies in the control mechanism, improves the stability and reliability of the compressor operation, and ensures a long-term supply of gas that meets the requirements for gas-using equipment.

[0081] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, in the form of a computer program product.

[0082] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0083] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0084] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0085] Finally, 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 high-efficiency and energy-saving gas compressor, characterized in that, include: The intake air filtration and analysis module filters the intake air of the gas compressor, detects the cleanliness characteristic parameters of the filtered intake air, and determines whether the intake air meets the intake air cleanliness standards. The exhaust pressure determination module determines the minimum required pressure for normal operation of each gas-consuming device based on the operating parameters of each device, and obtains the target exhaust pressure by combining the pipeline loss pressure from the gas compressor exhaust port to each device. The control parameter analysis module analyzes the control parameters required for the operation of the gas compressor based on the target exhaust pressure. The control parameters include the speed control and the intake valve opening. The control parameters are then transmitted to the control center. The exhaust pressure compliance analysis module collects the actual exhaust pressure of the gas compressor and compares it with the target exhaust pressure to determine whether the actual exhaust pressure meets the exhaust requirements. The control response evaluation module adjusts the control parameters of the gas compressor when the exhaust requirements are not met. It analyzes the timeliness of the control response to the exhaust pressure based on the control time interval during the adjustment process, calculates the timeliness rate of the gas compressor's response during operation, and provides feedback. The process of adjusting the control parameters of the gas compressor is as follows: the deviation between the real-time exhaust pressure and the target exhaust pressure is compared with the preset fluctuation range to obtain the deviation value and type of the real-time exhaust pressure and the target exhaust pressure. Based on the deviation value and deviation type, the adjustment speed and the adjustment valve opening are determined from the standard characteristic curves of pressure and speed and the three-dimensional standard characteristic curves of pressure, displacement and opening degree of the gas compressor. The control parameters of the gas compressor are adjusted by regulating the rotation speed and the opening of the exhaust valve, and the exhaust pressure of the gas compressor is collected in real time until the exhaust pressure meets the exhaust requirements. The statistical analysis of the response timeliness during the operation of the gas compressor specifically includes: obtaining the control response timeliness of the gas compressor during each adjustment of control parameters during operation, and filtering the number of control parameter adjustments with timely control response. The response time rate is the ratio of the number of times the control parameters are adjusted in a timely manner to the total number of times the control parameters are adjusted during the operation of the gas compressor. If the response time rate is less than the set response time rate threshold, an early warning feedback will be issued through the control center.

2. The high-efficiency energy-saving gas compressor according to claim 1, characterized in that: The intake air filtration analysis module includes a primary filtration unit, a secondary filtration unit, and an intake air detection unit. The primary filtration unit is used to intercept and filter solid impurities in the intake air. The secondary filtration unit is used to adsorb and filter gaseous impurities in the intake air after solid impurities have been filtered. The intake detection unit is used to detect the cleanliness characteristic parameters of the filtered intake air, including the solid impurity content and gaseous impurity concentration, and compares them with the preset intake air cleanliness standard of the gas compressor. If the content of solid impurities or the concentration of gaseous impurities is greater than the corresponding standard threshold in the intake air cleanliness standard, the intake air does not meet the intake air cleanliness standard; otherwise, the intake air meets the intake air cleanliness standard.

3. The high-efficiency energy-saving gas compressor according to claim 1, characterized in that: The minimum required pressure for the normal operation of the gas-using equipment is determined as follows: Extract the start and stop times of all gas-consuming equipment connected to the gas compressor in each production cycle from the compressor operation history, and filter the equipment combination with the largest number of simultaneously operating equipment; Extract the minimum allowable pressure requirement from the operating parameters of each gas-consuming device in the combination of the most devices, and take the maximum value of the minimum allowable pressure requirement in descending order as the peak value of the simultaneous operating pressure requirement. Based on the maximum pressure fluctuation value of each gas-consuming equipment in each production cycle in the most equipment combination, the peak pressure demand for simultaneous operation is corrected to obtain the minimum required pressure for normal operation of the gas-consuming equipment.

4. The high-efficiency energy-saving gas compressor according to claim 3, characterized in that: The target exhaust pressure is obtained as follows: Extract the output exhaust pressure from the gas compressor exhaust port to each gas-consuming device and the input exhaust pressure of each gas-consuming device from the compressor operation history record for each production cycle; By analyzing the deviation between the output exhaust pressure from the gas compressor exhaust port to each gas-consuming device and the corresponding input exhaust pressure, the exhaust pressure deviation value of each gas-consuming device is obtained. The exhaust pressure deviation of each gas-consuming equipment in each production cycle is statistically analyzed, and the average value is used as the pipeline loss pressure from the gas compressor exhaust port to each gas-consuming equipment. The maximum pipeline loss pressure is selected from the pipeline loss pressure from the gas compressor exhaust port to each gas-consuming device, and the sum of this pressure and the minimum required pressure for normal operation of the gas-consuming device is taken as the target exhaust pressure.

5. A high-efficiency energy-saving gas compressor according to claim 4, characterized in that: The control parameter analysis module specifically includes: Based on the standard characteristic curve of pressure and speed of the gas compressor, determine the speed corresponding to the target exhaust pressure, and take it as the maximum value of the suitable speed range for the target exhaust pressure, and take the rated minimum stable speed of the gas compressor as the minimum value of the suitable speed range. Extract the rated working flow rate from the working parameters of each gas-consuming device in the maximum equipment combination, sum them up to obtain the maximum simultaneous working flow rate, and calculate the required speed according to the theoretical displacement formula of the gas compressor. If the required speed is within the suitable speed range, and the exhaust pressure on the pressure-speed standard characteristic curve is greater than or equal to the target exhaust pressure, then the required speed is taken as the control speed required for the operation of the gas compressor body. Otherwise, the required speed is recalculated until the control speed required for the operation of the gas compressor body is determined.

6. A high-efficiency energy-saving gas compressor according to claim 5, characterized in that: The control parameter analysis module further includes: Substitute the required operating speed of the gas compressor body into the theoretical displacement formula of the gas compressor to obtain the theoretical displacement corresponding to the operating speed. Retrieve the three-dimensional standard characteristic curves of pressure, displacement and opening degree of the gas compressor, locate the coordinate point corresponding to the theoretical displacement and the target exhaust pressure in the curve, read the opening degree corresponding to the coordinate point, and record it as the initial opening degree. If the initial opening is greater than the rated minimum stable opening of the gas compressor, the initial opening is used as the exhaust valve opening; otherwise, the rated minimum stable opening is used as the exhaust valve opening.

7. A high-efficiency energy-saving gas compressor according to claim 1, characterized in that: The specific contents of the exhaust pressure conformity analysis module are as follows: The actual exhaust pressure is compared with the target exhaust pressure. If the real-time exhaust pressure is within the preset fluctuation range of the target exhaust pressure, the actual exhaust pressure is determined to meet the exhaust requirements, a pressure control trigger signal is generated, and it is transmitted to the control center. If the real-time exhaust pressure exceeds the preset fluctuation range of the target exhaust pressure, it is determined that the actual exhaust pressure does not meet the exhaust requirements.

8. A high-efficiency energy-saving gas compressor according to claim 1, characterized in that: The analysis of the timeliness of the control response to the exhaust pressure is as follows: The control time interval between the start and end time points is calculated, with the start time point being the moment when the control parameters of the gas compressor are adjusted and the end time point being the moment when the exhaust pressure of the gas compressor meets the exhaust requirements. If the control time interval is less than the response reference time, the control response of the exhaust pressure is considered timely; otherwise, the control response of the exhaust pressure is considered untimely.

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