Packaging type compressor

Abstract

A package-type compressor (1) is provided with, within a package (4): a compressor body (2); an oil collector (3) for collecting oil separated from the exhaust air of the compressor body (2); an oil level gauge (11) which is provided on the outer wall of the oil recovery device (3) and which confirms the oil level position of the oil accumulated in the oil recovery device (3); and an imaging unit (12) that acquires an image of the oil level gauge (11). The package-type compressor (1) is capable of outputting, to the outside of the package (4), information relating to the position of the oil surface on the basis of the image acquired by the imaging unit (12).

Description

Technical Field

[0001] This invention relates to encapsulated compressors. Background Technology

[0002] Patent Document 1 discloses a compressor comprising: an oil recovery unit that separates and recovers oil contained in the exhaust air discharged from the compressor body by means of centrifugal force; and an oil level gauge installed in the oil recovery unit that can visually display the oil level position of the oil accumulated in the oil recovery unit.

[0003] Existing technical documents Patent documents Patent Document 1: Japanese Patent No. 6266995. Summary of the Invention

[0004] The problem that the invention aims to solve The oil level gauge in the compressor of Patent Document 1, when the compressor assembly, including the compressor body, oil recovery unit, and oil level gauge, is housed within a package, means that the oil level cannot be visually checked without removing the cover constituting the package. In other words, without removing the cover, it cannot be confirmed whether an appropriate amount of oil has accumulated in the oil recovery unit (whether oil replenishment is needed). At least in this respect, the inspection of the oil recovery unit in the compressor of Patent Document 1 is complicated.

[0005] The objective of this invention is to simplify the inspection of the oil recovery device in an encapsulated compressor equipped with an oil level gauge and an oil recovery device.

[0006] Methods used to solve problems One technical solution of the present invention provides a packaged compressor comprising: a package; a compressor body housed within the package; an oil recovery unit housed within the package for recovering oil separated from exhaust air discharged from the compressor body; an oil level gauge disposed within the package on the outer wall of the oil recovery unit for determining the oil level position of the oil accumulated in the oil recovery unit; and a camera unit housed within the package for acquiring an image of the oil level gauge; and capable of outputting information about the oil level position based on the image to the outside of the package.

[0007] Since information about the oil level position based on the image of the oil level gauge obtained by the camera unit can be output to the outside of the enclosure, it is not necessary to remove the cover constituting the enclosure to visually inspect and confirm the oil level position. In other words, it is possible to confirm whether an appropriate amount of oil has accumulated in the oil recovery unit (whether oil replenishment is needed) without removing the enclosure cover. From this perspective, the inspection of the oil recovery unit is easier with this type of encapsulated compressor.

[0008] The information regarding the aforementioned oil level position can also be obtained from the image of the aforementioned oil level gauge captured by the aforementioned camera unit.

[0009] The information regarding the aforementioned oil level position can also be an image of the aforementioned oil level position processed from the image of the aforementioned oil level gauge obtained by the aforementioned camera unit.

[0010] The information regarding the aforementioned oil level position can also be obtained from the image of the aforementioned oil level gauge obtained by the aforementioned camera unit, and the oil level position falls within one of the multiple intervals defined by the upper and lower limits of the aforementioned oil level gauge.

[0011] The encapsulated compressor may also have a display unit on the outside of the aforementioned encapsulation to display information about the aforementioned oil level position.

[0012] Encapsulated compressors can also have a communication unit that can transmit information about the aforementioned oil level position to external devices via a communication line.

[0013] The encapsulated compressor may also include: a control unit that detects the oil level position based on the image of the oil level gauge obtained by the aforementioned camera unit, and performs a determination on whether the detected oil level position is higher than the upper limit position of the aforementioned oil level gauge, whether the detected oil level position is lower than the lower limit position, and whether the detected change in the aforementioned oil level position is greater than or equal to a predetermined value; and a reporting unit that reports the case where one of the aforementioned determinations is met.

[0014] With this structure, the reporting unit can automatically report excess oil in the oil recovery unit, insufficient oil due to oil leaks, and abnormal operation of the compressor body and the oil recovery unit.

[0015] The aforementioned control unit may also perform a determination on whether the detected oil level is higher than the aforementioned upper limit position and whether the detected oil level is lower than the aforementioned lower limit position when the aforementioned compressor body is under load operation. When the aforementioned compressor body is under load operation and no load operation, it may perform a determination on whether the detected change in the aforementioned oil level is above a predetermined value.

[0016] Alternatively, the aforementioned control unit may also perform a determination on whether the oil separation performance of the aforementioned oil separator is above a predetermined value; the aforementioned reporting unit may then report on the case where such determination is valid.

[0017] Invention Effects According to the present invention, it is possible to simplify the inspection of the oil recovery device in a packaged compressor equipped with an oil level gauge and an oil recovery device. Attached Figure Description

[0018] Figure 1This is a perspective view showing the appearance of the packaged compressor according to the first embodiment of the present invention.

[0019] Figure 2 This is a schematic diagram of the compressor body and oil recovery unit of the first embodiment.

[0020] Figure 3 This is a schematic diagram showing the main parts of the encapsulated compressor of the first embodiment.

[0021] Figure 4 This is a partial 3D view of the oil recovery unit.

[0022] Figure 5 This is a partial front view of the oil recovery unit.

[0023] Figure 6 This is a flowchart used to illustrate the anomaly detection and processing.

[0024] Figure 7 This is a schematic diagram showing the main parts of a first modified example of the encapsulated compressor of the first embodiment.

[0025] Figure 8 This is a schematic diagram showing the main parts of a second variation of the encapsulated compressor of the first embodiment.

[0026] Figure 9 This is a schematic diagram showing the main parts of a third variation of the encapsulated compressor of the first embodiment. Detailed Implementation

[0027] Next, embodiments of the present invention will be described with reference to the accompanying drawings.

[0028] Reference Figure 1 and Figure 2 In the encapsulated compressor 1 (hereinafter referred to as compressor) of the embodiment of the present invention, a device comprising a compressor body 2 and an oil recovery unit 3 constituting an oil-cooled compressor is housed within an encapsulation 4. An intake port and an exhaust port (not shown) are provided in the encapsulation 4.

[0029] Reference Figure 2 In this embodiment, the compressor body 2 has an intake port 2a and an outlet port 2b that communicate with a rotor chamber housing a pair of male and female rotors (driven by a motor 5). Air drawn in through the intake port 2a and compressed in the rotor chamber is discharged through the aforementioned intake port (not shown) and discharged through the outlet port 2b. The outlet port 2b of the compressor body 2 is connected to the oil recovery unit 3 via the discharge flow path 6.

[0030] Compressed air discharged from outlet 2b (discharge air) flows into oil recovery unit 3 through discharge flow path 6. In oil recovery unit 3, oil is separated from the discharge air by the centrifugal force caused by the swirling of the compressed air and by an oil separator (not shown), and is stored in the lower oil storage section. The compressed air separated from the oil is then sent from oil recovery unit 3 to the demand side through supply flow path 7 and exhaust port (not shown).

[0031] Using the differential pressure between the oil recovery unit 3 and the compressor body 2 (suction port 2a), the lubricating oil stored in the oil storage section of the oil recovery unit 3 flows to the compressor body 2 through the oil supply path 8.

[0032] Reference Figure 2 , Figure 4 and Figure 5 On the outer wall 3a of the oil recovery unit 3, which is housed within the package 4 as described above, an oil level gauge 11 is provided for confirming the level of oil accumulated in the oil recovery unit 3. That is, the oil level gauge 11 is also housed within the package 4.

[0033] The oil level gauge 11 of this embodiment includes an upper fluid connector 11a and a lower fluid connector 11b respectively installed in the upper connection hole 3b and the lower connection hole 3c of the oil recovery unit 3, and a transparent tube 11c (in this embodiment, a square tube) made of a transparent material such as glass. The upper and lower ends of the flow path inside the transparent tube 11c are fluidly connected to the interior of the oil recovery unit 3 via the upper fluid connector 11a and the lower fluid connector 11b. The oil level of the oil accumulated in the oil recovery unit 3 can be determined based on the oil level position of the oil introduced into the transparent tube 11c.

[0034] like Figure 4 and Figure 5 As shown, in the transparent tube 11c, the upper limit position 11d and the lower limit position 11e are displayed as lines that can be visually confirmed. The upper limit position 11d and the lower limit position 11e correspond to the upper and lower limits of the oil level of the oil recovery unit 3, which ensures the normal operation of the compressor body 11.

[0035] The oil level gauge 11 can also be a disc-type oil level gauge, that is, a pointer that rotates on a scale plate in conjunction with the rise and fall of a float floating on the oil surface of the oil recovery unit 3. The form of the oil level gauge 11 is not particularly limited as long as the oil level inside the oil recovery unit 3 can be visually confirmed from the outside of the oil recovery unit 3.

[0036] The package 4 houses a visible light camera 12 for capturing images of the oil level gauge 11, particularly the transparent tube 11c. In this embodiment, the visible light camera 12 is an example of an imaging unit that captures images of the oil level gauge 11. The visible light camera 12 is capable of color photography, but it can also be used for monochrome photography only.

[0037] In this embodiment, the visible light camera 12 is fixed to the upper part of the bracket 13, which is fixed to the base 4a of the package 4. The visible light camera 12 may also be held in a component other than the base 4a.

[0038] like Figure 2 and Figure 3 As shown only conceptually, within the package 4, a lamp 14 is housed, which illuminates at least the portion of the oil level gauge 11 that enters the shooting range of the visible light camera 12, particularly the transparent tube 11c. The lamp 14 can be held either in the same manner as the visible light camera 12 on the base 4a of the package 4, or in a component outside of it.

[0039] Reference Figure 2 and Figure 3 The control unit 21 is housed within the package 4. In addition, besides... Figure 2 and Figure 3 In addition, refer to Figure 1 Outside the package 4, there are: an input section 23 for the operator to input instructions, settings, etc. to the control section 21; and a display section 24, which is a display that visually displays information from the control section 21 (especially information about the oil level position, as described later).

[0040] The control unit 21 controls the equipment constituting the packaged compressor 1 based on inputs from various sensors and the input unit 23. The packaged compressor includes a motor 5 for driving the compressor body 2. Furthermore, as described later, the control unit 21 generates and outputs information about the oil level position in the oil level gauge 11 based on an image of the oil level gauge 11 obtained by the visible light camera 12. Alternatively, a separate board (control unit) other than the control unit 21 may be provided, which generates and outputs information about the oil level position in the oil level gauge 11 based on an image of the oil level gauge 11 obtained by the visible light camera 12.

[0041] Reference Figure 3 In this embodiment, the control unit 21 includes a processing unit 21A, a storage unit 21B, communication units 21C and 21D, and a power supply unit 21E. The processing unit 21A performs processing of the image of the oil level gauge 11 acquired by the visible light camera 12, based on the program and data stored in the storage unit 21B. The processing unit 21A can be constructed using a CPU or the like, and the storage unit 21B can be constructed using ROM, RAM, or the like. The communication unit 21C performs communication with the visible light camera 12 and the lamp 14. The power supply unit 21E supplies power to the visible light camera 12 and the lamp 14. The communication unit 21D performs communication with an external terminal 26 via the communication line 25.

[0042] Communication line 25 may also partially include a public line such as the Internet. Furthermore, communication line 25 may be partially or entirely wireless, or it may be a wired line. Communication line 25 functions as a connection known as M-to-M (Machine-to-Machine) for devices to exchange direct information with each other.

[0043] The external terminal 26 includes: a display unit 26A, which visually displays information from the control unit 21 (especially information about the oil level, as described later); and an alarm 26B, which is a buzzer that sounds according to the control of the control unit 21. Examples of external terminals 26 include personal computers and portable information terminals (including smartphones).

[0044] The control unit 21 outputs information about the oil level position based on the image of the oil level gauge 11 obtained by the visible light camera 12 to the outside of the enclosure 4. More specifically, it outputs the information to the display unit 24 and the display unit 26A of the external terminal 26, which are located outside the enclosure 4. The input information is displayed on the display units 24 and 26A. Since the information about the oil level position based on the image of the oil level gauge 11 obtained by the visible light camera 12 can be output to the outside of the enclosure 4 in this way, it is not necessary to remove the cover constituting the enclosure 4 in order to visually check and confirm the oil level position. In other words, it is possible to confirm whether an appropriate amount of oil has accumulated in the oil recovery unit 3 (whether oil replenishment is needed) without removing the cover of the enclosure 4. In this respect, the inspection of the oil recovery unit 3 is easier with the encapsulated compressor 1 of this embodiment. Furthermore, the simplification of the inspection of the oil recovery unit 3 in this embodiment does not require design changes to the oil recovery unit 3, which is a pressure vessel. Furthermore, the simplification of the inspection of the oil recovery unit 3 in this embodiment ensures space for the installation of the visible light camera 12 and the lamp 14 within the package 4. As long as the control unit 21 can communicate with the visible light camera 12, it can be implemented as an additional function of the existing packaged compressor.

[0045] Information about the oil level position based on the image of the oil level gauge 11 obtained by the visible light camera 12, or the image of the oil level gauge 11 obtained by the visible light camera 12 itself, an image of the oil level position generated by processing the image of the oil level gauge 11 obtained by the visible light camera 12, and which of the three intervals the oil level position is located in, divided by the upper limit position 11d and the lower limit position 11e.

[0046] By displaying the image of the oil level gauge 11 obtained by the visible light camera 12 on the display units 24 and 26A, the oil level can be monitored in real time by visually viewing the oil level gauge 11 without removing the cover of the package 4. In particular, by displaying the image of the oil level gauge 11 on the display unit 26A of the external terminal 26, the oil level can be monitored remotely in real time without going to the site where the packaged compressor 1 is installed.

[0047] The image of the oil level position is obtained by processing the image of the oil level gauge 11 acquired by the visible light camera 12. For example, it is obtained by converting the image acquired by the visible light camera 12 to grayscale and detecting the changes in brightness of the image as edges (contours). In this case, the oil level position can be monitored in real time without removing the cover of the package 4, and the oil level position can be monitored remotely in real time by the display unit 26A of the external terminal 26.

[0048] The oil level position is detected within one of the three intervals defined by the upper limit position 11d and the lower limit position 11e. Specifically, it is detected within the interval above the upper limit position 11d, the interval below the lower limit position 11e, or the interval between the upper limit position 11d and the lower limit position 11e. For example, the oil level position, the upper limit position 11d, and the lower limit position 11e are detected based on the grayscale of the image acquired by the visible light camera 12 and the changes in the brightness of the image are detected as edges (contours). The oil level position, the upper limit position 11d, and the lower limit position 11e are then detected. This detection determines which of the three intervals the oil level position falls within. By displaying the interval in which the oil level position falls on the display units 24 and 26A in this way, the data transmission capacity in the MtoM, i.e., the data transmission capacity from the control unit 21 via the communication line 25, can be reduced compared to the case of transmitting an image. In this case, the oil level position can also be monitored in real time without removing the cover of the package 4, and the oil level position can be monitored remotely in real time by the display unit 26A of the external terminal 26.

[0049] The position of the oil level within one of three intervals can be displayed, for example, as a two-digit binary number. For instance, if the first bit is set to "whether the oil level is below the upper limit position 11d" and the second bit is set to "whether the oil level is above the lower limit position 11e", with "yes" set to "1" and "no" set to "0" for each bit, then the case where the oil level is above the upper limit position 11d can be represented as "01", the case where the oil level is between the upper limit position 11d and the lower limit position 11e can be represented as "11", and the case where the oil level is below the lower limit position 11e can be represented as "10", thus indicating which interval the oil level is in. By sending only the oil level position obtained through image processing, the transmission capacity can be reduced to a few bytes.

[0050] Information about the oil level position based on the image of the oil level gauge 11 acquired by the visible light camera 12 can also include information on leveling the oil level position. An example is described below. First, the image acquired by the visible light camera 12 is grayscaled, and changes in image brightness are detected as edges (contours). Based on this, the oil level position, upper limit position 11d, and lower limit position 11e are detected. Next, it is determined which of the following levels is being considered (the lower limit position 11e is level 0, and the upper limit position 11d is level 10) between the upper limit position 11d and the lower limit position 11e. Assuming there are 100 pixels between the upper limit position 11d and the lower limit position 11e, if the oil level position is located 35 pixels above the lower limit position 11e, then the oil level position can be determined to be level 4.

[0051] The control unit 21 of this embodiment performs... Figure 6 The following describes the anomaly detection process. In the following description, details of the processes performed in each step will be omitted for brevity, as already described. First, the visible light camera 12 captures an image of the oil level gauge 11 (step S1), and the oil level position is detected based on this image (step S2). Next, it is determined whether the oil level position exceeds the upper limit position 11d, i.e., whether the oil level is excessive (step S4). If it does, a report is executed (step S3). Details of the report processing will be described later. Next, it is determined whether the oil level position is below the lower limit position 11e, i.e., whether the oil level is insufficient (step S5). If it is below, a report is executed (step S3). Furthermore, it is determined whether the change in the oil level position is within the normal range; more specifically, whether the horizontal change in the oil level position is above the reference value, i.e., whether there is a possibility of oil leakage (step S6). If it is determined to be outside the normal range, i.e., an anomaly, a report is executed (step S3). In step S6, if a change of more than 1 level within 30 seconds is assumed to be abnormal, the oil level data is held for 30 seconds and compared with the data from 30 seconds ago. If there is a change of more than 1 level (reference value), it is determined to be outside the normal range. Then, it is determined whether the oil separation performance of the oil recovery unit 3 is within the normal range, i.e., whether the oil separator component of the oil recovery unit 3 needs to be replaced (step S7). If it is determined to be outside the normal range, i.e., abnormal, a report is processed (step S3). In the evaluation of oil separation performance, the operating conditions (load rate, pressure, operating time, etc.) and the theoretical value of oil contained in the exhaust air discharged from the compressor body 2 (e.g., 0.002 cc / m³) are considered. 3 The theoretical value of the drop in oil level is calculated. If the change in oil level exceeds this theoretical value (if the amount of oil contained in the exhaust air discharged from the compressor body 2 is higher than the theoretical value), it is judged to be outside the normal range.

[0052] In the report processing of step S3, the abnormalities detected in steps S4 to S7 are displayed on display units 24 and 26A. In this report processing, the alarm installed on the encapsulated compressor 1 (e.g., a buzzer sounding under the control of the control unit 21) and the alarm 26B on the external terminal 26 may also sound simultaneously with or instead of the display on display units 24 and 26A.

[0053] It is normal for the oil level to be outside the upper limit position 11d and the lower limit position 11e during no-load operation. Therefore, steps S4 and S5 can be performed only during load operation, without executing them during no-load operation of the compressor body 2. Furthermore, steps S6 and S7 can be performed during compressor operation, i.e., during load operation and no-load operation. That is, the control unit can also determine whether the detected oil level is above the upper limit position 11d and whether the detected oil level is below the lower limit position 11e during load operation, and determine whether the change in the detected oil level is above a predetermined value during load operation and no-load operation.

[0054] Output of information about the oil level position based on the image of the oil level gauge 11 obtained by the visible light camera 12. Figure 6 Such anomaly detection and processing can be performed continuously using real-time images, or by taking still images at appropriate time intervals and comparing these still images. Since the oil level will not change significantly as long as there are no anomalies in the compressor body 2 and the oil recovery unit 3, from an energy-saving perspective, it can also be performed continuously for a certain period of time after the compressor body 2 starts, and then changed to execution at certain time intervals during continuous operation (process monitoring).

[0055] Figures 7 to 9 The figures represent variations of the first embodiment. In these figures, the same or identical elements are given the same reference numerals. Furthermore, the structures and functions of these variations, unless otherwise specifically mentioned, are the same as those of the first embodiment.

[0056] exist Figure 7 In the modified example shown, lamp 14 is powered by a Peltier element 51 installed in oil recovery unit 3. This structure, which uses electricity from the compressor as a heat source to compensate for the power supplied to lamp 14, improves energy efficiency.

[0057] exist Figure 8 In the variant shown, instead of a visible light camera 12 (for example, refer to...), Figure 3 Instead, an infrared camera 52 is used. With this structure, since the lamp 14 is no longer needed (see reference...), Figure 3 Therefore, energy efficiency is improved, and the device structure can be simplified.

[0058] exist Figure 9 In the variant shown, instead of a visible light camera 12 (for example, refer to...), Figure 3 Instead, a smart camera 53 is used. The smart camera 53 performs the function executed by the control unit 21 in the first embodiment: outputting information about the oil level position based on the image of the oil level gauge 11 to an external terminal. Figure 6 Such anomaly detection and handling.

[0059] This application claims priority based on Japanese Patent Application No. 2023-121966, filed on July 26, 2023. Japanese Patent Application No. 2023-121966 is incorporated herein by reference.

[0060] Explanation of reference numerals in the attached figures 1. Encapsulated compressor 2. Compressor body 2a Inlet 2b Discharge outlet 3. Oil recovery unit 3a Outer wall 3b Upper connecting hole 3C lower connection hole 4. Package 4a base 5 motors 6 Discharge flow path 7. Supply Flow Path 8. Oil supply path 11. Oil level gauge 11a Upper fluid connector 11b Lower fluid connector 11c transparent tube 11d upper limit position 11e lower limit position 12. Visible light camera (video department) 13 brackets 14 lights 21 Control Department 21A Processing Department 21B Storage Unit 21C, 21D Communications Department 21E Power Supply Section 22 Alarms 23 Input Section 24 Display Section 25 Communication lines 26 External Terminals 26A Display Section 26B Alarm 51 Peltier elements 52 Infrared Cameras 53. Intelligent camera (video recording unit).

Claims

1. A packaged compressor, characterized in that, have: Package components; The compressor body is housed within the aforementioned package. An oil recovery unit, housed within the aforementioned package, recovers oil separated from the exhaust air discharged from the aforementioned compressor body. An oil level gauge, disposed within the aforementioned package on the outer wall of the aforementioned oil recovery unit, is used to determine the oil level position of the oil accumulated in the aforementioned oil recovery unit; and The camera unit, housed within the aforementioned package, acquires images from the aforementioned oil level gauge. It can output information about the oil level position based on the aforementioned image to the outside of the aforementioned package.

2. The encapsulated compressor as described in claim 1, characterized in that, The information regarding the aforementioned oil level position is obtained from the image of the aforementioned oil level gauge captured by the aforementioned camera unit.

3. The encapsulated compressor as described in claim 1, characterized in that, The information regarding the aforementioned oil level position is an image of the aforementioned oil level position processed from the image of the aforementioned oil level gauge obtained by the aforementioned camera unit.

4. The encapsulated compressor as described in claim 1, characterized in that, The information regarding the oil level position refers to which of the multiple intervals defined by the upper and lower limits of the oil level gauge, the oil level position obtained from the image of the oil level gauge acquired by the aforementioned camera unit falls within.

5. The encapsulated compressor as described in any one of claims 1 to 4, characterized in that, A display section for displaying information about the oil level is provided on the outside of the aforementioned package.

6. The encapsulated compressor as described in any one of claims 1 to 4, characterized in that, It has a communication unit that can transmit information about the aforementioned oil level position to external devices via a communication line.

7. The encapsulated compressor as described in claim 1, characterized in that, have: The control unit detects the oil level position based on the image of the oil level gauge obtained by the aforementioned camera unit, and performs the following checks: whether the detected oil level position is higher than the upper limit position of the oil level gauge; whether the detected oil level position is lower than the lower limit position; and whether the detected change in the oil level position is greater than or equal to a predetermined value. The reporting department reports on any instance where the aforementioned determination has been established.

8. The encapsulated compressor as described in claim 7, characterized in that, When the compressor body is under load, the control unit performs a determination on whether the detected oil level is higher than the upper limit and whether the detected oil level is lower than the lower limit. When the compressor body is under load and under no load, the control unit performs a determination on whether the detected change in the oil level is above a predetermined value.

9. The encapsulated compressor as described in claim 7, characterized in that, The aforementioned control unit also performs a determination on whether the oil separation performance of the aforementioned oil separator is above a predetermined value; The aforementioned reporting department reported that the determination had been established.

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