A full-time hot-standby fault zero-decay air supply system and method

Abstract

The application discloses a kind of full-time hot standby fault zero attenuation air supply system and method, it is related to air supply system technical field, the air supply system includes: main fan blade, vice fan blade, deceleration synchronization unit, switching control module, risk prediction module, air supply pressurization module and emergency backup unit.The deceleration synchronization unit is connected to the deceleration of main fan blade and vice fan blade, when main fan blade is fault-free operation, vice fan blade can follow it and rotate at low speed, when main fan blade appears fault or there is predicted fault risk, vice fan blade does not need to start quickly to promote speed from static, avoid the delay problem that vice fan blade starts to stable air supply when traditional double fan group switches, ensure that the airflow barrier of scene is not destroyed, guarantee target area air supply environment stability, simultaneously, vice fan blade is standby by main fan blade synchronous rotation, so that vice fan blade standby process does not need to be driven separately, realize the energy-saving standby effect of system, reduce the problem of traditional double fan simultaneous start energy consumption.

Description

Technical Field

[0001] This invention relates to the field of air supply system technology, specifically to an all-time hot standby air supply system and method with zero attenuation during faults. Background Technology

[0002] An air supply system is a mechanical system that delivers air in a specific state (such as temperature, humidity, and cleanliness) to a target area as needed to meet the requirements for ventilation, cooling, heating, cleaning, or process air supply. Air supply systems are widely used in civil buildings (such as residences, shopping malls, and office buildings), industrial plants, medical facilities, data centers, and various special equipment. The core objective is to maintain a stable air environment in the target area or meet specific process requirements.

[0003] To ensure stable airflow within the supply space, modern air supply systems employ a dual-fan unit configuration to handle fan switching in case of malfunction. One fan is the main fan, and the other is the auxiliary fan. When the main fan malfunctions, the auxiliary fan immediately activates and takes over. However, during the switching process, the auxiliary fan requires several seconds to reach stable airflow. This process can cause a brief interruption in airflow, particularly in cleanrooms that need to maintain constant cleanliness and airflow velocity. Such interruptions can damage the airflow barrier in clean areas, introducing contaminants and leading to product spoilage. Therefore, whether a single fan unit stops supplying air due to damage or multiple fan units switch over, the resulting airflow delay and attenuation can cause airflow attenuation during fan malfunctions, ultimately impacting the environment using the air supply system. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a real-time hot standby fault-free air supply system and method, which solves the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a full-time hot standby zero-attenuation air supply system, the air supply system comprising: a main fan blade, an auxiliary fan blade, a deceleration and synchronization unit, a switching control module, a risk prediction module, an air supply pressurization module, and an emergency backup unit;

[0006] The main fan blade and the auxiliary fan blade have the same specifications. The main fan blade and the auxiliary fan blade are arranged vertically in the two pipes of the air supply system to provide air supply to the air supply system.

[0007] The deceleration and synchronization unit is used to drive the main fan blade and the auxiliary fan blade to each other. The auxiliary fan blade rotates synchronously with the main fan blade and its speed is one-quarter of the speed of the main fan blade. When the main fan blade fails or the risk prediction module predicts that there is a risk of failure, the switching control module switches the main fan blade to the auxiliary fan blade for air supply.

[0008] The deceleration and synchronization unit enables the main fan blade and the auxiliary fan blade to operate synchronously during daily operation. The auxiliary fan blade does not require a separate energy device to drive it during daily standby. It only needs to be connected to the main fan blade through deceleration and synchronization to achieve zero energy consumption during daily standby. This reduces the operating energy consumption of the air supply system and achieves the effect of energy-saving operation of the air supply system.

[0009] The switching control module is used to switch the auxiliary fan blade to the highest speed for air supply when the main fan blade fails or the risk prediction module predicts the risk of failure, and to stop the main fan blade from supplying air. At the same time, the deceleration synchronization unit is disconnected.

[0010] The risk prediction module is used to predict the faults of the air supply system. It adopts a dual prediction model, which is a fusion of a time-series feature model and a physical mechanism model. When the fault of the main fan blade is predicted, the prediction information is sent to the switching control module to switch the air supply between the main fan blade and the auxiliary fan blade.

[0011] The air supply pressurization module is used to switch the air supply when the main fan blade fails, thereby increasing the air supply pressure in the pipeline during the start-up phase of the auxiliary fan blade.

[0012] The emergency backup unit is used to release high-pressure air when the main fan blade fails and the switching control module switches the auxiliary fan blade to supply air, and stops operation after the auxiliary fan blade starts successfully, if the start-up of the auxiliary fan blade is delayed.

[0013] Preferably, the air supply system consists of two pipes connected in parallel, one above the other. The upper pipe is the installation position of the main fan blade, and the lower pipe is the installation position of the auxiliary fan blade. The output port and input port of the lower pipe are connected to the bottom of the upper pipe, and an electromagnetic check valve is provided at the connection position.

[0014] Preferably, both the main fan blade and the auxiliary fan blade are equipped with servo motors for driving. The two servo motors have the same specifications. A small gear and a large gear are respectively arranged at the center position on the other side of the main fan blade and the auxiliary fan blade away from the servo motor. The time for the large gear to rotate once is four times the time for the small gear to rotate once. The large gear and the small gear are covered with gear belts for transmission.

[0015] Preferably, an electromagnetic separation unit is installed between the pinion and the auxiliary fan blade. When the main fan blade malfunctions, the electromagnetic separation unit de-energizes when the rotational speed of the auxiliary fan blade reaches a preset speed, thereby separating the connection between the auxiliary fan blade and the pinion.

[0016] Preferably, the air supply pressurization module includes an electric booster valve, a pressure feedback sensor, and a booster controller;

[0017] The electric booster valve is connected in series at the outlet of the pipeline of the auxiliary fan blade, and is used to boost the air supply in the pipeline when the auxiliary fan blade takes over the air supply of the main fan blade in the event of a failure of the main fan blade.

[0018] The pressure feedback sensor is integrated into the electric booster valve. It is used to detect the air pressure at the outlet position of the corresponding pipeline when the auxiliary fan blade is started. If the air pressure is lower than the set air pressure threshold, it will feed back the information of insufficient air pressure to the booster controller. If the air pressure is higher than the air pressure threshold, it will not feed back any information to the booster controller.

[0019] The booster controller is integrated into the electric booster valve. It is used to receive the information that the air supply pressure is insufficient from the pressure feedback sensor. After receiving the information, it sends a start command to the electric booster valve, so that the electric booster valve starts to boost the air supply of the auxiliary fan blades.

[0020] Preferably, the emergency backup unit includes: a high-pressure gas storage component, a gas replenishment control component, and a release regulation component;

[0021] The high-pressure air storage assembly is used to store high-pressure clean air, and the high-pressure air storage assembly includes: a high-pressure air storage tank made of 304 stainless steel.

[0022] The air replenishment control component includes an air compressor. The input port of the air compressor is connected to the air inlet of the air supply system through a connecting pipe. The output port of the air compressor is connected to the high-pressure air tank through a filter and a one-way check valve to maintain the pressure stability inside the air tank.

[0023] The release regulating component, used to control the high-pressure air release flow rate and airflow stability, consists of an electromagnetic proportional release valve and an airflow stabilizer. The release regulating component is connected to the corresponding pipeline of the auxiliary fan blade.

[0024] A method for providing air supply with zero attenuation during all-time hot standby failures, applied to the aforementioned all-time hot standby air supply system with zero attenuation during failures, includes the following steps:

[0025] The main fan blade rotates in the corresponding pipeline to deliver air, and the auxiliary fan blade is synchronized with the main fan blade and rotates at a low speed through the deceleration and synchronization unit.

[0026] During the rotation of the main fan blade and the auxiliary fan blade, the risk prediction module continuously predicts the faults of the main fan blade and the auxiliary fan blade. When the result of the fault prediction is that the main fan blade has a fault risk, the fault risk is sent to the switching control module.

[0027] The switching control module receives the fault risk detected by the risk prediction module, and the switching control module reduces the speed of the main fan blade and increases the speed of the auxiliary fan blade to deliver air.

[0028] If the air pressure of the auxiliary fan blade is lower than the required air pressure, the air supply pressurization module starts and increases the air pressure of the pipeline corresponding to the auxiliary fan blade. The air supply pressurization module stops pressurizing when the air pressure of the auxiliary fan blade stabilizes.

[0029] Preferably, when the rotational speed of the auxiliary fan blade increases, if the rotational speed of the auxiliary fan blade does not reach the preset rotational speed within a set time, the emergency backup unit is activated. The emergency backup unit increases the air pressure of the pipeline by spraying out air stored at high pressure.

[0030] Once the secondary fan blades reach the set speed, the emergency backup unit stops ejecting high-pressure air and refills the emergency backup unit with air while simultaneously pressurizing and storing it.

[0031] Preferably, the step of the risk prediction module continuously predicting faults in the main fan blade and the auxiliary fan blade includes:

[0032] Radial vibration signals of the main fan blade and the auxiliary fan blade are collected. A hot-wire anemometer is installed at the air outlet section of the pipeline to collect the turbulent pulsation frequency and velocity distribution uniformity of the airflow at the air outlet of the main fan blade and the auxiliary fan blade. At the same time, the instantaneous rotational speed fluctuation values ​​of the main fan blade and the auxiliary fan blade are collected to obtain the predicted collection data.

[0033] The predicted data is filtered using Kalman filtering and rotational period filtering to remove the vibration of the drive mechanism of the main fan blade and the auxiliary fan blade and the airflow disturbance of the pipeline. The instantaneous interference data of the sensor used for detection is eliminated by comparing multiple adjacent rotational periods using the 3σ criterion of normal distribution. The preprocessed vibration peak, airflow uniformity and speed fluctuation are normalized to obtain the processed data.

[0034] The processed data is subjected to extraction of temporal and physical mechanism features. The extracted temporal and physical mechanism features are then imported into the dual prediction model. The comprehensive failure risk value of the main fan blade and the auxiliary fan blade is calculated with the physical mechanism features having a weight of 60% and the temporal features having a weight of 40%.

[0035] When the overall risk value is less than the set risk threshold, the main fan blade and the auxiliary fan blade are determined to be normal. When the overall risk value is greater than the set risk threshold but less than the fault trigger threshold, an abnormal warning for the main fan blade and the auxiliary fan blade is triggered. When the overall risk value is greater than the fault trigger threshold, the main fan blade and the auxiliary fan blade are determined to be faulty.

[0036] If a fault is predicted in the main fan blade, the fault information is transmitted to the switching control module. The switching control module then switches the air supply between the main fan blade and the auxiliary fan blade based on the fault situation. If a fault is predicted in the auxiliary fan blade, a fault alarm is issued to remind timely maintenance.

[0037] Preferably, when the switching control module reduces the speed of the main fan blade and increases the speed of the auxiliary fan blade, the rate at which the speed of the main fan blade decreases is the same as the rate at which the speed of the auxiliary fan blade increases. When the speed of the auxiliary fan blade reaches half of the rated speed, the deceleration synchronization unit of the main fan blade and the auxiliary fan blade fails and is released.

[0038] This invention provides a real-time hot standby air supply system and method with zero attenuation during failure. It has the following beneficial effects:

[0039] (1) The air supply system achieves deceleration connection between the main fan blade and the auxiliary fan blade through the deceleration synchronization unit. When the main fan blade is running without fault, the auxiliary fan blade can follow it and rotate at a low speed in sync, instead of being stationary. When the main fan blade fails or there is a predicted risk of failure, the auxiliary fan blade does not need to start from a standstill and can quickly increase to the working speed. This avoids the delay problem of the auxiliary fan blade starting to stable air supply when switching between traditional dual fan units, prevents the air supply system from experiencing air supply attenuation or short-term interruption, ensures that the airflow barrier of the scene is not damaged, avoids product scrapping or environmental impact due to the introduction of pollutants, and ensures the stability of the air supply environment in the target area.

[0040] (2) This air supply system is equipped with an emergency backup unit. When the main fan blade fails and the auxiliary fan blade starts with a delay, it can release high-pressure air in time to supplement the air supply, so as to maintain the air supply volume before the auxiliary fan blade stabilizes. Even if the auxiliary fan blade starts for longer than expected, there will be no air supply attenuation problem when switching between traditional dual fan units. This ensures that the air supply system maintains a stable air supply state throughout the process, avoids the situation where air supply stability is disrupted by airflow speed fluctuations, and achieves the effect of zero air supply attenuation in critical scenarios.

[0041] (3) This air supply system is equipped with a risk prediction module to continuously predict the failure risk of the main fan blade and the auxiliary fan blade, so as to identify potential fan blade failures in advance and reserve preparation time for switching operations. It will not cause the auxiliary fan blade to start hastily due to a sudden failure of the main fan blade, further reducing the uncertainty of air supply connection during the switching process, avoiding the occurrence of air supply attenuation, maintaining the stable air supply of the air supply system to the target area, and ensuring the normal operation of production, equipment and environmental conditions that rely on stable air supply.

[0042] (4) In the daily operation of the main fan blade and the auxiliary fan blade in the air supply system, only the main fan blade needs to consume energy to drive the main fan blade to run, while the auxiliary fan blade achieves the effect of rotating and standing still together with the main fan blade through the deceleration synchronization unit. During the process, the auxiliary fan blade can achieve rotation and standby without the need for equipment drive. Compared with the continuous energy consumption and standby of the auxiliary fan blade of the dual fans in the traditional air supply system, the standby mode of the auxiliary fan blade in this solution can reduce the energy consumption of the air supply system, achieve more energy-saving operation, thereby reducing energy consumption, saving the operating cost of the air supply system, and achieving the effect of low energy consumption and energy-saving operation. Attached Figure Description

[0043] Figure 1 This is a system block diagram of a full-time hot standby fault-free air supply system and method according to the present invention;

[0044] Figure 2 This is a flowchart illustrating the steps of an all-time hot standby fault-free air supply system and method according to the present invention.

[0045] Figure 3 This is a structural diagram of the air supply system of the all-time hot standby fault-free air supply system and method of the present invention;

[0046] Figure 4 This invention relates to a full-time hot standby fault-free air supply system and method. Figure 3 Enlarged view of a specific area. Detailed Implementation

[0047] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and 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.

[0048] Example 1: Please refer to Figure 1 This invention provides a full-time hot standby zero-attenuation air supply system and method. To achieve the above objectives, this invention is implemented through the following technical solution: The air supply system includes: main fan blades, auxiliary fan blades, deceleration and synchronization unit, switching control module, risk prediction module, air supply pressurization module and emergency backup unit.

[0049] The main fan blades and auxiliary fan blades have the same specifications. The main fan blades and auxiliary fan blades are set up one above the other in the two pipes of the air supply system to provide air supply to the air supply system.

[0050] The deceleration and synchronization unit is used to drive and connect the main fan blade and the auxiliary fan blade to each other. The auxiliary fan blade rotates synchronously with the main fan blade and its speed is one-quarter of the main fan blade's speed. When the main fan blade malfunctions or the risk prediction module predicts a malfunction risk, the switching control module switches the main fan blade to the auxiliary fan blade for air supply.

[0051] The switching control module is used to switch the auxiliary fan blades to the highest speed to supply air when the main fan blades fail or the risk prediction module predicts the risk of failure, and to stop the main fan blades from supplying air. At the same time, the deceleration synchronization unit is disconnected.

[0052] The risk prediction module is used to predict the failure of the air supply system. It adopts a dual prediction model, which is a fusion of a time-series feature model and a physical mechanism model. When a failure of the main fan blade is predicted, the prediction information is sent to the switching control module to switch the air supply between the main fan blade and the auxiliary fan blade.

[0053] The air supply pressurization module is used to switch the air supply when the main fan blade fails, thereby increasing the air supply pressure in the pipeline during the start-up phase of the auxiliary fan blade.

[0054] The emergency backup unit is used to release high-pressure air when the main fan blade fails and the control module switches to the auxiliary fan blade for air supply. If the start-up of the auxiliary fan blade is delayed, the unit will stop operating after the auxiliary fan blade starts successfully.

[0055] In this embodiment, the main fan blade and the auxiliary fan blade have the same specifications. They are respectively adapted to two independent pipelines of the air supply system. The pipeline adopts a coaxial upper and lower arrangement structure. The rotation planes of the main fan blade and the auxiliary fan blade are kept parallel, and the air inlet ends of both face the same airflow input end. The air outlet ends of both point to the main air supply channel of the air supply system, ensuring that they can deliver airflow to the same target area when working, providing continuous and stable air supply to the air supply system.

[0056] The deceleration and synchronization unit consists of a transmission connector and a speed adjustment component. One end of the transmission connector is linked to the rotation shaft of the main fan blade, and the other end is connected to the rotation shaft of the auxiliary fan blade. The speed adjustment component has a built-in transmission ratio adaptation structure, which can transmit the rotational power of the main fan blade to the auxiliary fan blade according to a preset ratio. When the main fan blade is running normally without faults, the deceleration and synchronization unit drives the auxiliary fan blade to rotate synchronously through mechanical linkage, and precisely controls the speed of the auxiliary fan blade through the speed adjustment component, so that it is always maintained at a specific ratio of the speed of the main fan blade, ensuring that the auxiliary fan blade is in a hot standby state, rather than a stationary state.

[0057] The switching control module has a built-in fault identification algorithm and air supply status monitoring logic. It can receive the operating parameter signals of the main fan blade in real time and identify the fault type of the main fan blade (such as rotation jamming, abnormal speed drop, etc.) by parameter comparison. At the same time, the switching control module is also connected to the airflow monitoring component of the air supply system to collect the airflow velocity and pressure data of the main air supply channel in real time to confirm whether there is air supply attenuation. When the main fan blade is determined to be faulty and accompanied by air supply attenuation, the switching control module immediately sends an acceleration command to the drive component of the auxiliary fan blade to control the auxiliary fan blade to quickly increase to the maximum speed to take over the air supply. At the same time, it sends a shutdown command to the drive component of the main fan blade to stop the operation of the main fan blade and avoid the faulty main fan blade from interfering with the airflow.

[0058] The risk prediction module includes a data acquisition interface, a dual-model calculation unit, and a risk output unit. The data acquisition interface acquires real-time operating status data of the main and auxiliary fan blades (such as rotational vibration, airflow disturbance, etc.) and transmits the data to the dual-model calculation unit. The time-series characteristic model in the dual-model calculation unit extracts time-series patterns by analyzing the changing trends of historical operating data and real-time data, while the physical mechanism model establishes calculation formulas based on the mechanical principles of fan blade rotation and the laws of airflow dynamics. After the two are integrated, a fault risk assessment result is generated, and then the risk output unit transmits the result to the switching control module to provide a basis for responding to faults in advance.

[0059] The air supply pressurization module is integrated into the pipeline where the auxiliary fan blade is located and is linked with the drive component of the auxiliary fan blade. When the main fan blade fails and the auxiliary fan blade starts to accelerate, the air supply pressurization module starts synchronously. Through the internal pressure regulation structure, it pressurizes the airflow in the pipeline where the auxiliary fan blade is located to make up for the insufficient air pressure caused by the auxiliary fan blade not reaching a stable speed during the start-up phase, and ensures that the air supply pressure in the pipeline is always maintained at the required level.

[0060] The emergency backup unit is connected to the pipeline where the auxiliary fan blade is located and interacts with the switching control module. When the main fan blade fails or the start-up of the auxiliary fan blade is delayed (i.e., the speed increase rate of the auxiliary fan blade does not reach the preset requirement), the switching control module sends a start command to the emergency backup unit. The emergency backup unit immediately releases the stored high-pressure air and injects it into the pipeline where the auxiliary fan blade is located through a dedicated channel to replenish the air volume and air pressure in the pipeline and maintain the total air volume without attenuation. After the switching control module detects that the speed of the auxiliary fan blade has reached a stable working state, it immediately sends a stop command to the emergency backup unit. The emergency backup unit stops releasing high-pressure air and enters standby state.

[0061] Example 2: Specifically: Refer to Figure 3 and Figure 4 The air supply system consists of two parallel pipes connected vertically. The upper pipe is where the main fan blades are installed, and the lower pipe is where the auxiliary fan blades are installed. The output and input ports of the lower pipe are connected to the bottom of the upper pipe, and a solenoid check valve is installed at the connection point.

[0062] Both the main fan blade and the auxiliary fan blade are equipped with servo motors for driving. The two servo motors are identical in specifications. On the opposite side of the servo motor, the main fan blade and the auxiliary fan blade are respectively equipped with a pinion and a large gear. The time for the large gear to rotate once is four times the time for the pinion to rotate once. The large gear and the pinion are covered with gear belts for transmission.

[0063] An electromagnetic separation unit is installed between the pinion and the auxiliary fan blade. When the main fan blade malfunctions, the electromagnetic separation unit cuts off power when the auxiliary fan blade reaches a preset speed, thus separating the auxiliary fan blade from the pinion.

[0064] The air supply pressurization module includes an electric booster valve, a pressure feedback sensor, and a booster controller;

[0065] An electric booster valve is connected in series at the outlet of the auxiliary fan blade's pipe. It is used to boost the air supply in the pipe when the auxiliary fan blade takes over the air supply from the main fan blade in case of a main fan blade failure.

[0066] The pressure feedback sensor is integrated into the electric booster valve. It is used to detect the air pressure at the outlet of the corresponding pipeline when the auxiliary fan blades are started. If the air pressure is lower than the set air pressure threshold, it will send the information of insufficient air pressure to the booster controller. If the air pressure is higher than the air pressure threshold, it will not send any information to the booster controller.

[0067] The booster controller is integrated into the electric booster valve. It is used to receive information from the pressure feedback sensor that the air supply pressure is insufficient. After receiving the information, it sends a start command to the electric booster valve, causing the electric booster valve to start and boost the air supply of the auxiliary fan blades.

[0068] The emergency backup unit includes: a high-pressure gas storage component, a gas replenishment control component, and a release regulation component;

[0069] High-pressure air storage assembly, used to store high-pressure clean air, includes: a high-pressure air storage tank made of 304 stainless steel;

[0070] The air replenishment control component includes an air compressor. The air compressor's input port is connected to the air inlet of the air supply system via a connecting pipe. The air compressor's output port is connected to the high-pressure air tank via a filter and a one-way check valve to maintain stable pressure inside the air tank.

[0071] The release regulating component is used to control the release flow rate and airflow stability of high-pressure air. It consists of an electromagnetic proportional release valve and an airflow stabilizer. The release regulating component is connected to the corresponding pipeline of the auxiliary fan blade.

[0072] In this embodiment, the air supply system specifically includes: main pipe 1, secondary pipe 2, main fan blade 3, secondary fan blade 4, electromagnetic check valve 5, pinion 6, large gear 7, gear belt 8, electromagnetic separator 9, electric booster valve 10, servo motor 11, high-pressure air storage assembly 12, and several mounting brackets 13.

[0073] The main pipe 1's outlet is connected to the air supply environment, and its inlet is connected to the HVAC equipment. The outlet of the secondary pipe 2 is connected to the bottom of one end of the main pipe 1's outlet, and a solenoid check valve 5 is installed at the connection point. The inlet of the secondary pipe 2 is connected to the bottom of one end of the main pipe 1's inlet, and a solenoid check valve 5 is also installed there. A high-pressure gas storage component 12 is installed near the inlet end of the secondary pipe 2. The release end of the high-pressure gas storage component 12 is located near the inside of the secondary pipe 2. When switching the secondary fan blade 4, if the secondary fan blade 4 starts too slowly, the high-pressure gas storage component 12 will spray high-pressure gas to ensure stable air supply. The main fan blade 3 is installed on the main pipe 1 via a servo motor 11 and a mounting bracket 13. The blade 4 is installed in the secondary pipe 2 via the servo motor 11 and the mounting bracket 13. The main fan blade 3 and the secondary fan blade 4 are respectively equipped with a small gear 6 and a large gear 7. The small gear 6 and the large gear 7 are fitted with a gear belt 8. Therefore, when the main fan blade 3 rotates, the small gear 6 and the gear belt 8 drive the large gear 7. The gear belt 8 is connected through the side wall of the main pipe 1 and the secondary pipe 2, and a seal is provided at the connection to achieve the effect of gear reduction. Thus, when the main fan blade 3 rotates, the secondary fan blade 4 can rotate synchronously at 25% of the speed of the main fan blade 3. The electric booster valve 10 is installed at the air outlet of the secondary pipe 2. When switching the air supply of the secondary fan blade 4, the electric booster valve 10 is activated to increase the air supply pressure.

[0074] The connection between the auxiliary fan blade 4 and the large gear 7 is achieved through an electromagnetic separator 9. The electromagnetic separator 9 separates the connecting components by de-energizing them. The separation threshold of the electromagnetic separator 9 is set to 50% of the rated speed of the auxiliary fan blade 4. When the main fan blade 3 malfunctions and the auxiliary fan blade 4 needs to be switched, the servo motor 11 of the main fan blade 3 stops, and the servo motor 11 of the auxiliary fan blade 4 starts immediately. The speed reduction of the main fan blade 3 is controlled to be consistent with the speed increase of the auxiliary fan blade 4, thereby ensuring that the air volume of the fan blades in the entire air supply system is consistent. When the speed of the auxiliary fan blade 4 reaches half of the rated speed, the electromagnetic separator 9 de-energizes the large gear 7 and the auxiliary fan blade 4, and then the main fan blade 3 can stop, while the auxiliary fan blade 4 increases its speed, thereby better stabilizing the air supply effect.

[0075] Example 3: Reference Figure 3 A method for providing air supply with zero attenuation during all-time hot standby failures, applied to an all-time hot standby air supply system with zero attenuation during failures, includes the following steps:

[0076] The main fan blades rotate in the corresponding duct to deliver air, and the auxiliary fan blades are synchronized with the main fan blades and rotate at low speed through the deceleration and synchronization unit.

[0077] During the rotation of the main and auxiliary fan blades, the risk prediction module continuously predicts the faults of the main and auxiliary fan blades. When the fault prediction result indicates that there is a fault risk in the main fan blade, the fault risk is sent to the switching control module.

[0078] When the switching control module receives the fault risk detected by the risk prediction module, it reduces the speed of the main fan blades and increases the speed of the auxiliary fan blades to deliver air.

[0079] If the air pressure of the auxiliary fan blade is lower than the required air pressure, the air supply pressurization module will start and increase the air pressure of the pipe corresponding to the auxiliary fan blade. The air supply pressurization module will stop pressurizing when the air pressure of the auxiliary fan blade stabilizes.

[0080] In this embodiment, after the system starts, the main fan blade is driven by a servo motor to start rotating in its corresponding main pipeline, delivering airflow to the target area. When the main fan blade rotates normally to deliver air, the deceleration and synchronization unit starts synchronously. Through the meshing transmission of the pinion, gear belt and large gear, the auxiliary fan blade is driven to rotate synchronously in its corresponding auxiliary pipeline. And through the control of the gear transmission ratio, the speed of the auxiliary fan blade is always maintained at 25% of the speed of the main fan blade, ensuring that the auxiliary fan blade is in a low-speed hot standby state, avoiding the start-up delay caused by the stationary auxiliary fan blade in the traditional dual fan unit.

[0081] During the continuous rotation of the main and auxiliary fan blades, the risk prediction module is always in operation. It collects real-time operating data of the main and auxiliary fan blades (such as rotational vibration, airflow disturbance, and speed fluctuation) through built-in sensors and transmits the collected data to the dual prediction model (time-series characteristic model and physical mechanism model). After analyzing and processing the data, the dual prediction model generates the fault risk assessment results of the main and auxiliary fan blades. When the fault prediction results show that the main fan blade has a fault risk (such as the risk value reaching the preset warning threshold), the risk prediction module immediately transmits the risk information (including risk type and risk level) to the switching control module, so that the switching control module can enter the fault response preparation state in advance.

[0082] Upon receiving fault risk information from the main fan blade, the switching control module immediately formulates a switching strategy: on one hand, it sends a speed adjustment command to the servo motor of the main fan blade, controlling the speed of the main fan blade to gradually decrease at a steady rate; on the other hand, it simultaneously sends a speed increase command to the servo motor of the auxiliary fan blade, controlling the speed of the auxiliary fan blade to gradually increase at a rate matching the rate at which the speed of the main fan blade decreases, ensuring that the speed of the auxiliary fan blade increases synchronously during the process of the main fan blade speed decreasing, and that the total air volume of both remains stable, avoiding a sudden drop in air volume. During this process, the air supply pressurization module is linked with the servo motor of the auxiliary fan blade, and uses a pressure feedback sensor to detect the air outlet pressure of the auxiliary duct where the auxiliary fan blade is located in real time. When the detected air pressure is lower than the air supply pressure required for the target area, the air supply pressurization module is immediately activated, pressurizing the airflow in the auxiliary duct by adjusting the opening of the electric booster valve, increasing the air outlet pressure of the auxiliary duct corresponding to the auxiliary fan blade, ensuring that the airflow pressure delivered from the auxiliary duct to the main air supply channel always meets the requirements, and avoiding insufficient air pressure due to the auxiliary fan blade speed not reaching a stable state.

[0083] Throughout the entire process, the switching control module maintains constant signal interaction with each module: it receives risk updates from the risk prediction module in real time and adjusts the switching rhythm; it receives the speed data of the main and auxiliary fan blades in real time to ensure the coordination of speed regulation; and it receives the air pressure monitoring data from the air supply and pressurization module in real time to control the start and stop of the pressurization module and the pressurization intensity, forming a closed-loop control logic to ensure that each operation can be dynamically adjusted according to the actual operating status of the system.

[0084] Example 4: Specifically: When the speed of the auxiliary fan blade increases, if the speed of the auxiliary fan blade does not reach the preset speed within a set time, the emergency backup unit is activated. The emergency backup unit increases the air pressure of the pipeline by spraying out the stored high-pressure air.

[0085] Once the secondary fan blades reach the set speed, the emergency backup unit stops ejecting high-pressure air and refills the emergency backup unit with air while simultaneously pressurizing and storing it.

[0086] The risk prediction module performs continuous fault prediction for the main and auxiliary fan blades, including the following steps:

[0087] Radial vibration signals of the main fan blades and auxiliary fan blades are collected. A hot-wire anemometer is installed at the air outlet section of the pipeline to collect the turbulent pulsation frequency and velocity distribution uniformity of the airflow at the air outlet of the main fan blades and auxiliary fan blades. At the same time, the instantaneous speed fluctuation values ​​of the main fan blades and auxiliary fan blades are collected to obtain the predicted data.

[0088] The predicted data is filtered using Kalman filtering and rotational period filtering to remove vibrations from the drive mechanism of the main and auxiliary fan blades and airflow disturbances in the pipeline. The instantaneous interference data from the sensor is eliminated by comparing multiple adjacent rotational periods using the 3σ criterion of normal distribution. The preprocessed vibration peak, airflow uniformity, and speed fluctuation are normalized to obtain the processed data.

[0089] Temporal and physical mechanism features are extracted from the processed data. The extracted temporal and physical mechanism features are then imported into a dual prediction model. The comprehensive failure risk value of the main and auxiliary fan blades is calculated with a weight of 60% for physical mechanism features and 40% for temporal features.

[0090] When the overall risk value is less than the set risk threshold, the main and auxiliary fan blades are considered normal. When the overall risk value is greater than the set risk threshold but less than the fault trigger threshold, an abnormal warning for the main and auxiliary fan blades is triggered. When the overall risk value is greater than the fault trigger threshold, the main and auxiliary fan blades are considered to have malfunctioned.

[0091] If a fault is predicted in the main fan blade, the fault information is transmitted to the switching control module. The switching control module then switches the air supply between the main fan blade and the auxiliary fan blade based on the fault situation. If a fault is predicted in the auxiliary fan blade, a fault alarm is issued to remind timely maintenance.

[0092] When the switching control module reduces the speed of the main fan blade and increases the speed of the auxiliary fan blade, the rate at which the speed of the main fan blade decreases is the same as the rate at which the speed of the auxiliary fan blade increases. When the speed of the auxiliary fan blade reaches half of the rated speed, the deceleration synchronization unit of the main fan blade and the auxiliary fan blade fails and is released.

[0093] In this embodiment, when the auxiliary fan blade enters the start-up and acceleration phase, the switching control module monitors the speed change of the auxiliary fan blade in real time through a speed sensor and compares it with the preset post-switching speed threshold (i.e., the minimum stable speed that the auxiliary fan blade needs to reach) and threshold time (i.e., the maximum allowable time for the auxiliary fan blade to reach that speed). When it is detected that the speed of the auxiliary fan blade does not reach the preset post-switching speed threshold within the set threshold time (i.e., the auxiliary fan blade start-up is delayed), the switching control module immediately sends a start command to the emergency backup unit. After receiving the command, the electromagnetic proportional release valve inside the emergency backup unit immediately opens, and the high-pressure clean air stored in the high-pressure storage tank is injected into the auxiliary pipeline where the auxiliary fan blade is located after being stabilized by the airflow stabilizer. By supplementing the high-pressure air, the air pressure and air volume in the auxiliary pipeline are quickly increased, ensuring that the air volume delivered to the target area by the main air supply channel does not decrease.

[0094] Once the switching control module detects that the speed of the auxiliary fan blades has reached the preset switching speed threshold (i.e., the auxiliary fan blades have entered a stable working state) through the speed sensor, it immediately sends a stop command to the emergency standby unit. The electromagnetic proportional release valve of the emergency standby unit closes, stopping the release of high-pressure air. At the same time, the air replenishment control component of the emergency standby unit starts, and the air compressor draws clean air from the main air intake of the air supply system. After being filtered by the filter, the air is injected into the high-pressure air tank through the one-way check valve to replenish and pressurize the air tank, so that the pressure in the air tank is restored to the preset storage pressure, ensuring that the emergency standby unit can start and be used normally next time.

[0095] When the switching control module controls the main fan blade to reduce its speed while simultaneously increasing the speed of the auxiliary fan blade, it collects the speed data of the main and auxiliary fan blades in real time through speed sensors and converts the data into control signals, which are then transmitted to the servo motors of the main and auxiliary fan blades respectively. This ensures that the rate at which the speed of the main fan blade decreases is consistent with the rate at which the speed of the auxiliary fan blade increases, so that the total airflow of both is always maintained at the target level. When the speed of the auxiliary fan blade reaches half of its rated speed, the switching control module sends a command to the electromagnetic separation unit, causing the electromagnetic separation unit to initiate the separation action, releasing the deceleration synchronization connection between the main and auxiliary fan blades (i.e., the large gear separates from the auxiliary fan blade). At this time, the main fan blade can stop freely, while the auxiliary fan blade can quickly increase to a stable operating speed without being restricted by the deceleration structure.

[0096] Explanation of reference numerals in the embodiments:

[0097] 1. Main pipe; 2. Secondary pipe; 3. Main fan blade; 4. Secondary fan blade; 5. Solenoid check valve; 6. Pinion; 7. Main gear; 8. Gear belt; 9. Solenoid separator; 10. Electric booster valve; 11. Servo motor; 12. High-pressure gas storage assembly; 13. Mounting bracket.

[0098] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention.

Claims

1. A real-time hot standby air supply system with zero attenuation during failure, characterized in that: The air supply system includes: main fan blades, auxiliary fan blades, deceleration and synchronization unit, switching control module, risk prediction module, air supply and pressurization module, and emergency backup unit; The main fan blade and the auxiliary fan blade have the same specifications. The main fan blade and the auxiliary fan blade are arranged vertically in the two pipes of the air supply system to provide air supply to the air supply system. The deceleration and synchronization unit is used to drive the main fan blade and the auxiliary fan blade to each other. The auxiliary fan blade rotates synchronously with the main fan blade and its speed is one-quarter of the speed of the main fan blade. When the main fan blade fails or the risk prediction module predicts that there is a risk of failure, the switching control module switches the main fan blade to the auxiliary fan blade for air supply. The switching control module is used to switch the auxiliary fan blade to the highest speed for air supply when the main fan blade fails or the risk prediction module predicts the risk of failure, and to stop the main fan blade from supplying air. At the same time, the deceleration synchronization unit is disconnected. The risk prediction module is used to predict the faults of the air supply system. It adopts a dual prediction model, which is a fusion of a time-series feature model and a physical mechanism model. When the fault of the main fan blade is predicted, the prediction information is sent to the switching control module to switch the air supply between the main fan blade and the auxiliary fan blade. The air supply pressurization module is used to switch the air supply when the main fan blade fails, thereby increasing the air supply pressure in the pipeline during the start-up phase of the auxiliary fan blade. The emergency backup unit is used to release high-pressure air when the main fan blade fails and the switching control module switches the auxiliary fan blade to supply air, and stops operation after the auxiliary fan blade starts successfully if the start of the auxiliary fan blade is delayed. The air supply pressurization module includes an electric booster valve, a pressure feedback sensor, and a booster controller; The electric booster valve is connected in series at the outlet of the pipeline of the auxiliary fan blade, and is used to boost the air supply in the pipeline when the auxiliary fan blade takes over the air supply of the main fan blade in the event of a failure of the main fan blade. The pressure feedback sensor is integrated into the electric booster valve. It is used to detect the air pressure at the outlet position of the corresponding pipeline when the auxiliary fan blade is started. If the air pressure is lower than the set air pressure threshold, it will feed back the information of insufficient air pressure to the booster controller. If the air pressure is higher than the air pressure threshold, it will not feed back any information to the booster controller. The booster controller is integrated into the electric booster valve and is used to receive the information that the air supply pressure is insufficient from the pressure feedback sensor. After receiving the information, it sends a start command to the electric booster valve to start the electric booster valve to boost the air supply pressure of the auxiliary fan blades. The steps of the risk prediction module to continuously predict the failures of the main fan blade and the auxiliary fan blade include: Radial vibration signals of the main fan blade and the auxiliary fan blade are collected. A hot-wire anemometer is installed at the air outlet section of the pipeline to collect the turbulent pulsation frequency and velocity distribution uniformity of the airflow at the air outlet of the main fan blade and the auxiliary fan blade. At the same time, the instantaneous rotational speed fluctuation values ​​of the main fan blade and the auxiliary fan blade are collected to obtain the predicted collection data. The predicted data is filtered using Kalman filtering and rotational period filtering to remove the vibration of the drive mechanism of the main fan blade and the auxiliary fan blade and the airflow disturbance of the pipeline. The instantaneous interference data of the sensor used for detection is eliminated by comparing multiple adjacent rotational periods using the 3σ criterion of normal distribution. The preprocessed vibration peak, airflow uniformity and speed fluctuation are normalized to obtain the processed data. The processed data is subjected to extraction of temporal and physical mechanism features. The extracted temporal and physical mechanism features are then imported into the dual prediction model. The comprehensive failure risk value of the main fan blade and the auxiliary fan blade is calculated with the physical mechanism features having a weight of 60% and the temporal features having a weight of 40%. When the overall risk value is less than the set risk threshold, the main fan blade and the auxiliary fan blade are determined to be normal. When the overall risk value is greater than the set risk threshold but less than the fault trigger threshold, an abnormal warning for the main fan blade and the auxiliary fan blade is triggered. When the overall risk value is greater than the fault trigger threshold, the main fan blade and the auxiliary fan blade are determined to be faulty. If a fault is predicted in the main fan blade, the fault information is transmitted to the switching control module. The switching control module then switches the air supply between the main fan blade and the auxiliary fan blade based on the fault situation. If a fault is predicted in the auxiliary fan blade, a fault alarm is issued to remind timely maintenance.

2. The all-time hot standby zero-attenuation air supply system according to claim 1, characterized in that: The air supply system consists of two pipes connected in parallel, one above the other. The upper pipe is where the main fan blade is installed, and the lower pipe is where the auxiliary fan blade is installed. The output and input ports of the lower pipe are connected to the bottom of the upper pipe, and an electromagnetic check valve is installed at the connection point.

3. The all-time hot standby fault-free air supply system according to claim 1, characterized in that: Both the main fan blade and the auxiliary fan blade are equipped with servo motors for driving. The two servo motors have the same specifications. On the opposite side of the servo motor, the main fan blade and the auxiliary fan blade are respectively equipped with a small gear and a large gear. The time for the large gear to rotate once is four times the time for the small gear to rotate once. The large gear and the small gear are covered with gear belts for transmission.

4. The all-time hot standby fault-free air supply system according to claim 3, characterized in that: An electromagnetic separation unit is installed between the pinion and the auxiliary fan blade. When the main fan blade malfunctions, the electromagnetic separation unit de-energizes when the rotational speed of the auxiliary fan blade reaches a preset speed, thereby separating the connection between the auxiliary fan blade and the pinion.

5. The all-time hot standby fault-free air supply system according to claim 1, characterized in that: The emergency backup unit includes: a high-pressure gas storage component, a gas replenishment control component, and a release regulation component; The high-pressure air storage assembly is used to store high-pressure clean air, and the high-pressure air storage assembly includes: a high-pressure air storage tank made of 304 stainless steel. The air replenishment control component includes an air compressor. The input port of the air compressor is connected to the air inlet of the air supply system through a connecting pipe. The output port of the air compressor is connected to the high-pressure air tank through a filter and a one-way check valve to maintain the pressure stability inside the air tank. The release regulating component, used to control the high-pressure air release flow rate and airflow stability, consists of an electromagnetic proportional release valve and an airflow stabilizer. The release regulating component is connected to the corresponding pipeline of the auxiliary fan blade.

6. A method for providing air supply with zero attenuation during all-time hot standby failure, applied to an all-time hot standby air supply system with zero attenuation during failure as described in any one of claims 1-5, characterized in that: Includes the following steps: The main fan blade rotates in the corresponding pipeline to deliver air, and the auxiliary fan blade is synchronized with the main fan blade and rotates at a low speed through the deceleration and synchronization unit. During the rotation of the main fan blade and the auxiliary fan blade, the risk prediction module continuously predicts the faults of the main fan blade and the auxiliary fan blade. When the result of the fault prediction is that the main fan blade has a fault risk, the fault risk is sent to the switching control module. The switching control module receives the fault risk detected by the risk prediction module, and the switching control module reduces the speed of the main fan blade and increases the speed of the auxiliary fan blade to deliver air. If the air pressure of the auxiliary fan blade is lower than the required air pressure, the air supply pressurization module starts and increases the air pressure of the pipeline corresponding to the auxiliary fan blade. The air supply pressurization module stops pressurizing when the air pressure of the auxiliary fan blade stabilizes.

7. The method for providing air supply with zero attenuation during all-time hot standby faults according to claim 6, characterized in that: During the process of increasing the rotational speed of the auxiliary fan blades, if the rotational speed of the auxiliary fan blades does not reach the preset rotational speed within a set time, the emergency backup unit is activated. The emergency backup unit increases the air pressure of the pipeline by ejecting high-pressure air. Once the secondary fan blades reach the set speed, the emergency backup unit stops ejecting high-pressure air and refills the emergency backup unit with air while simultaneously pressurizing and storing it.

8. The method for providing air supply with zero attenuation during all-time hot standby faults according to claim 6, characterized in that: When the switching control module reduces the speed of the main fan blade and increases the speed of the auxiliary fan blade, the rate at which the speed of the main fan blade decreases is the same as the rate at which the speed of the auxiliary fan blade increases. When the speed of the auxiliary fan blade reaches half of the rated speed, the deceleration synchronization unit of the main fan blade and the auxiliary fan blade fails and is released.

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