Online monitoring system for state of piston sealing element of industrial supercharger

Abstract

The invention relates to the technical field of superchargers, in particular to an online monitoring system for the state of a piston sealing element of an industrial supercharger. The movable part is arranged in the pressurizing pipe, the surface-mounted temperature sensor is arranged at the top of the movable part, the micro concentration sensor is arranged on the movable part, and the wall-attached flow sensor is arranged in the pressurizing pipe. Real-time sensing and prospective management of the performance of the piston sealing element of the industrial supercharger are achieved, through online monitoring, the performance attenuation trend of the sealing element can be mastered in real time, replacement early warning can be given out at the first time when the sealing element reaches the service life critical point, and a series of problems caused by sealing failure are fundamentally solved. The leakage of a compression medium caused by poor sealing is effectively avoided, and the energy loss of the supercharger is directly reduced; and secondly, misleading faults such as pressure fluctuation or purity abnormity and the like of the oxygen generation system caused by reduction of the sealing performance are prevented in advance, and the operation reliability of the oxygen generation system is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of turbocharger technology, and more specifically, to an online monitoring system for the condition of piston seals in industrial turbochargers. Background Technology

[0002] A booster compressor, a key gas compression device, primarily functions to compress gases, effectively increasing their pressure and density to meet the medium- or high-pressure gas requirements of various industrial processes. This type of equipment typically consists of key components such as an inlet, compression chamber, and exhaust port. Its working principle is based on the fundamental laws of gas dynamics, utilizing mechanical structures such as turbines and pistons to achieve the gas compression process. In fields such as biopharmaceuticals, booster compressors are particularly widely used in oxygen and nitrogen production systems to further pressurize and store the produced oxygen or nitrogen in storage tanks. This ensures stable gas supply pressure at downstream locations while reducing the operating load on the oxygen and nitrogen production equipment. The stored high-pressure gas, after depressurization, can then be delivered to various production process stages to meet specific pressure requirements.

[0003] Currently, piston booster compressors, as a common type, are divided into single-stage and multi-stage structures, and still face several technical challenges during operation. For example, the equipment operates with relatively high noise levels, affecting the working environment; the sealing status of the piston seals is difficult to monitor in real time, and damage cannot be identified promptly, easily leading to energy waste and sudden equipment failures; furthermore, it is difficult to monitor whether the booster power decreases during operation, affecting system energy efficiency and operational reliability. Therefore, there is an urgent need to build a centralized information acquisition and analysis system to achieve real-time monitoring and recording of key operating parameters, generate various parameter reports, and thus provide data support for equipment performance evaluation, fault early warning, and energy efficiency optimization, improving the overall system's intelligence and reliability. (Invention Content) The present invention aims to at least solve one of the technical problems existing in the prior art. Therefore, one aspect of the present invention is to provide an online monitoring system for the condition of piston seals in industrial turbochargers. The online monitoring system includes a valve, a booster tube, and detection sensors. The valve includes a ventilator, and the detection sensors include a patch temperature sensor, a micro-concentration sensor, and a wall-mounted flow sensor. The valve is located inside the booster tube, the patch temperature sensor is located at the top of the valve, the micro-concentration sensor is located on the ventilator, and the wall-mounted flow sensor is located inside the booster tube.

[0004] Preferably, the live part includes a bend, a connecting element, and a piston seal. One end of the connecting element is fixedly disposed inside the live part, and the other end of the connecting element is hinged to the bend. The piston seal is fixedly disposed at the top of the live part.

[0005] Preferably, the online monitoring system further includes a control unit, and the patch temperature sensor, miniature concentration sensor, and wall-mounted flow sensor are connected to the control unit via sensor wires.

[0006] Preferably, the control includes terminals, and the patch temperature sensor, miniature concentration sensor, and wall-mounted flow sensor are connected to the terminals via sensor wires.

[0007] Preferably, the control further includes a program control and a parameter display screen, wherein one end of the program control is connected to a terminal and the other end is connected to the parameter display screen, and the parameter display screen is mounted on the control.

[0008] Preferably, the control further includes an alarm, which is set on the control and connected to the program control.

[0009] The beneficial effects of this invention are as follows: This system enables real-time sensing and proactive management of the performance of piston seals in industrial booster compressors. Through online monitoring, it not only tracks the performance degradation trend of the seals in real time but also issues immediate replacement warnings when seals reach their critical lifespan. This fundamentally solves a series of problems caused by seal failure: First, it effectively avoids compressed medium leakage due to poor sealing, directly reducing the booster compressor's energy consumption. Second, it proactively prevents misleading malfunctions such as pressure fluctuations or purity abnormalities in the oxygen production system caused by deteriorating sealing performance, significantly improving the operational reliability of the oxygen production system. Ultimately, through precise condition monitoring and timely maintenance intervention, this system comprehensively ensures the continuous, stable, and efficient operation of the booster compressor and the entire related production equipment, achieving a leap from passive maintenance to proactive prevention.

[0010] Additional aspects and advantages of the invention will become apparent from the description which follows, or may be learned by practice of the invention. Attached Figure Description

[0011] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic diagram of the compression pipe structure of the booster compressor according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the compression pipe structure of the booster compressor according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the sensor connection according to an embodiment of the present invention; The correspondence between the reference numerals and component names in the figure is as follows: 1 is the piston, 11 is the vent, 12 is the crankshaft, 13 is the connecting rod, 14 is the piston seal, 2 is the booster pipe, 3 is the detection sensor, 31 is the patch temperature sensor, 32 is the miniature concentration sensor, 33 is the wall-mounted flow sensor, 4 is the control cabinet, 41 is the terminal block, 42 ​​is the programmable controller, 43 is the parameter display screen, and 44 is the alarm. Detailed Implementation

[0012] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0013] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be implemented in other ways different from those described herein. Therefore, the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0014] An online monitoring system for the status of piston seals in an industrial booster includes a piston 1, a vent 11, a crankshaft 12, a connecting rod 13, a piston seal 14, a booster pipe 2, a detection sensor 3, a patch-type temperature sensor 31, a miniature concentration sensor 32, a wall-mounted flow sensor 33, a control cabinet 4, a terminal block 41, a programmable controller 42, a parameter display screen 43, and an alarm 44.

[0015] like Figure 1 , Figure 2 As shown, piston 1 is installed inside pressurization pipe 2, one end of connecting rod 13 is fixed inside piston 1, the other end of connecting rod 13 is hinged to crankshaft 12, piston seal 14 is fixed on top of piston 1, patch temperature sensor 31 is installed on top of piston 1, miniature concentration sensor 32 is installed on vent 11, and wall-mounted flow sensor 33 is installed inside pressurization pipe 2.

[0016] like Figure 3 As shown, the surface-mount temperature sensor 31, the miniature concentration sensor 32, and the wall-mounted flow sensor 33 are connected to the terminal block 41 via sensor wires. One end of the program controller 42 is connected to the terminal block 41, and the other end is connected to the parameter display screen 43. The parameter display screen 43 is mounted on the control cabinet 4, and the alarm 44 is mounted on the control cabinet 4 and connected to the program controller 42.

[0017] 1. System startup and data monitoring System power-on: Ensure the booster compressor and control cabinet 4 are powered normally. Turn on the power, and the system will start.

[0018] Real-time monitoring: After the system is started, the patch temperature sensor 31 installed on the top of the piston 1, the miniature concentration sensor 32 on the vent 11, and the wall-mounted flow sensor 33 in the pressurization pipe 2 will start to work continuously.

[0019] Data Viewing: Real-time data collected by all sensors (piston top temperature, leakage medium concentration, pipeline flow rate) is transmitted to the programmable controller 42 inside control cabinet 4 for processing and dynamically displayed on the parameter display screen 43 on the cabinet surface. Operators can intuitively view the current values ​​and real-time change curves of various parameters through the screen.

[0020] 2. Data Analysis and Historical Records Data processing: The program controller 42 automatically analyzes, calculates and integrates the received sensor data according to a preset program.

[0021] Status assessment: The system continuously compares real-time data with a pre-programmed "optimal status parameter" model to assess the working health of the piston seal 14.

[0022] Historical Tracking: All collected data and analysis results are automatically saved to the system memory. Users can access historical data and historical trend curves through the parameter display screen 43 for fault analysis, performance evaluation, or maintenance cycle planning.

[0023] 3. Alarm and Maintenance Execution Alarm settings: The system program has set corresponding alarm thresholds for various monitoring parameters (such as abnormal temperature rise, excessive leakage concentration, abnormal flow fluctuation, etc.).

[0024] Automatic Alarm: When any monitored parameter reaches or exceeds its set alarm value, the program controller 42 will immediately trigger the linkage control: the alarm 44 on the control cabinet 4 will emit an audible and visual alarm signal to remind the operator. Simultaneously, a prominent alarm message will pop up on the parameter display screen 43, indicating the specific abnormal parameter and alarm location.

[0025] Maintenance Response: Upon receiving an alarm, the operator should immediately arrange for the compressor to be shut down and inspected according to the alarm information. The focus should be on checking the wear, aging, or damage of the piston seal 14, and replacing or repairing it in a timely manner to address the potential problem before it escalates.

[0026] 4. Key Points for Daily Use Regularly observe the parameter display screen 43 and pay attention to whether the data changes steadily within the normal range.

[0027] Pay attention to the data curves automatically generated by the system; trend changes (such as a slow and continuous rise in temperature) are often early signs of potential faults.

[0028] Ensure that the wiring connections from the sensor to terminal block 41, and from terminal block 41 to programmable controller 42 are secure and reliable.

[0029] After an alarm occurs, once maintenance is completed and the fault is confirmed to be resolved, the alarm status must be reset according to the procedure.

[0030] This system enables online monitoring of the status of the piston seals of the booster compressor through real-time monitoring, intelligent analysis, and automatic alarms. The user's main responsibility is to monitor the screen data daily, pay attention to alarm information, and respond promptly to perform maintenance, thereby ensuring the safe, stable, and efficient operation of the equipment.

[0031] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the invention by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. An online monitoring system for the condition of piston seals in industrial booster compressors, characterized in that: The online monitoring system includes a piston (1), a pressurization pipe (2), and a detection sensor (3). The piston (1) includes a vent (11). The detection sensor (3) includes a patch temperature sensor (31), a micro concentration sensor (32), and a wall-mounted flow sensor (33). The piston (1) is located inside the pressurization pipe (2). The patch temperature sensor (31) is located on the top of the piston (1). The micro concentration sensor (32) is located on the vent (11). The wall-mounted flow sensor (33) is located inside the pressurization pipe (2).

2. The online monitoring system for the condition of piston seals in industrial turbochargers according to claim 1, characterized in that: The piston (1) includes a crankshaft (12), a connecting rod (13) and a piston seal (14). One end of the connecting rod (13) is fixedly disposed inside the piston (1), and the other end of the connecting rod (13) is hinged to the crankshaft (12). The piston seal (14) is fixedly disposed on the top of the piston (1).

3. The online monitoring system for the condition of piston seals in industrial turbochargers according to claim 1, characterized in that: The online monitoring system also includes a control cabinet (4), and the patch temperature sensor (31), miniature concentration sensor (32) and wall-mounted flow sensor (33) are connected to the control cabinet (4) via sensor wires.

4. The online monitoring system for the condition of piston seals in industrial turbochargers according to claim 1, characterized in that: The control cabinet (4) includes a terminal block (41), and the patch temperature sensor (31), the miniature concentration sensor (32) and the wall-mounted flow sensor (33) are connected to the terminal block (41) via sensor wires.

5. The online monitoring system for the condition of piston seals in industrial turbochargers according to claim 4, characterized in that: The control cabinet (4) also includes a program controller (42) and a parameter display screen (43). One end of the program controller (42) is connected to the terminal block (41), and the other end is connected to the parameter display screen (43). The parameter display screen (43) is installed on the control cabinet (4).

6. The online monitoring system for the condition of piston seals in industrial turbochargers according to claim 5, characterized in that: The control cabinet (4) also includes an alarm (44), which is installed on the control cabinet (4) and connected to the program controller (42).

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