Gas-liquid discharging device based on air compressor

Abstract

The invention relates to the technical field of air compressor gas-liquid separation, in particular to a gas-liquid discharging device based on an air compressor. The device comprises an outer barrel, an air inlet assembly, a drying assembly and a detection assembly. A data acquisition module collects separator parameter data in real time; the separation efficiency analysis module evaluates the clearing capacity and determines the initial cleanliness according to the comprehensive self-cleaning index of the separator; the load influence analysis module evaluates the composite influence degree according to the system risk superposition load coefficient and determines a system load evaluation value; the system state diagnosis module judges the internal flow state health degree based on the separation flow resistance health index; the operation parameter optimization module optimizes a system load evaluation value according to the system working condition matching coefficient; and the discharge strategy generation module adjusts the opening frequency or the single discharge duration of the discharge valve through the index ratio according to the liquid dynamic accumulation index. According to the invention, intelligent monitoring and accurate regulation and control of the gas-liquid separation process of the air compressor are realized, and the separation efficiency and the system reliability are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of air compressor gas-liquid separation, in particular to an air compressor gas-liquid discharge device. BACKGROUND

[0002] As an important power source in industrial production, the compressed air generated by the air compressor often contains liquid impurities such as oil and water, which need to be purified by a gas-liquid separation device. The traditional gas-liquid separation device mainly has the following technical defects: in terms of structural design, a single-stage separation structure is often used, which relies only on centrifugal force or gravity to achieve gas-liquid separation, and the ability to capture fine droplets is insufficient. In addition, the inlet structure design is simple and cannot form an effective rotational flow field; in terms of state monitoring, it mainly relies on a liquid level sensor for simple monitoring, and cannot obtain real-time multi-dimensional state information inside the separator, especially lacking effective monitoring means for residual liquid attached to the inner wall. The accumulation of wall residual liquid not only reduces the effective flow area and increases the system pressure drop, but also may be re-rolled by high-speed airflow to cause secondary pollution; in terms of control strategy, a fixed-time discharge or a control method based on a simple liquid level threshold is often used, which lacks precise perception of the actual running state of the separator, and may lead to delayed discharge affecting separation effect or excessive frequent discharge causing waste of compressed air; in terms of system synergy, there is a lack of effective synergy mechanism between the air compressor operating condition and the separator state, which cannot adaptively adjust the operating parameters according to the load change; in terms of energy efficiency optimization, the existing device often ignores the influence of wall effect on system energy consumption, and lacks corresponding optimization mechanism. The existing technology still has obvious deficiencies in intelligent monitoring and precise control, especially in real-time monitoring of wall residual liquid, intelligent decision-making of multi-parameter fusion, and system energy efficiency optimization, and there is no effective solution.

[0003] Therefore, it is a technical problem to be solved in the field to develop an air compressor gas-liquid discharge device that can realize fine perception, intelligent regulation and control, and energy efficiency optimization.

[0004] Chinese Patent Publication No. CN118049358A discloses an oil-gas separation device for an air compressor, which comprises a separation cylinder shell, a heating cavity is formed in the inside of the separation cylinder shell, circuit connection blocks are symmetrically installed on the top and bottom of the heating cavity, heating wires are arranged on the outside of the circuit connection blocks, a first oil storage shell is installed at the bottom of the separation cylinder shell, a rotating disc is movably installed on the bottom inner wall of the first oil storage shell, a fixed block is installed on the top of the rotating disc, and a scraper is installed on the top of the fixed block. The heating wires can convert electrical energy into heat energy after being powered on, heat the inner wall of the separation cylinder shell, and melt the oil liquid condensed on the inner wall, which can effectively prevent the oil liquid in the oil-gas from condensing on the inner wall and flowing downward, and accumulate on the inner wall to cause inconvenience in discharging.

[0005] Therefore, the air compressor oil-gas separation device machine separation method has the following problems: 1. Lack of accurate perception of the actual running state of the separator during separation, which can easily lead to delayed discharge affecting separation effect or too frequent discharge causing compressed air waste, and lack of effective coordination mechanism between air compressor operating conditions and separator state, leading to inability to adaptively adjust operating parameters according to load changes; 2. Not fully considering heating and melting of residual oil in the inner cylinder wall to reduce the effective flow area, increase the system pressure drop, and possibly be re-coiled by high-speed airflow to cause secondary pollution, and the melted oil after heating can cause changes in the dynamic accumulation of liquid in the separator to affect the oil discharge timing of the separator. SUMMARY

[0006] Therefore, the present application provides an air compressor gas-liquid discharge device based on the air compressor gas-liquid discharge device to overcome the problems in the prior art that the working state of the air compressor is not matched and the residual oil in the cylinder wall is not fully considered. The dynamic accumulation of liquid in the separator changes to cause the inability to adaptively adjust the operating parameters according to the load changes and affect the oil discharge timing of the separator.

[0007] To achieve the above-mentioned purpose, the present application provides an air compressor gas-liquid discharge device. It comprises an outer cylinder and an air inlet assembly, and further comprises, a drying assembly comprising an inner cylinder arranged inside the outer cylinder for secondary drying of gas and a water-absorbing sponge arranged on the upper part of the inner cylinder for tertiary drying of gas; a detection assembly for detecting the wall surface residual liquid equivalent concentration and the liquid content of the compressed gas entering the inside of the separator, and for detecting the liquid level height at the bottom of the separator and the initial volume of the residual liquid concentration; a load influence analysis module for calculating the system risk superimposed load coefficient based on the initial volume of the residual liquid concentration at the bottom of the outer cylinder and the wall surface residual liquid equivalent concentration of the inner wall of the outer cylinder and the new liquid concentration, determining the combined influence degree of the current operating load and the wall surface residual risk on the efficiency of the separator and determining the system load evaluation value; a system state diagnosis module for calculating the separation flow resistance health index based on the system pressure drop data and the wall surface residual liquid equivalent concentration of the inner wall of the outer cylinder to determine whether the internal flow state of the separator is healthy; an operating parameter optimization module for calculating the operating condition matching coefficient based on the system operating data and the wall surface residual liquid equivalent concentration of the inner wall of the outer cylinder to determine whether the current operating condition of the air compressor matches the separator, and to determine the optimized system load evaluation value according to the difference between the operating condition matching coefficient and the operating condition matching coefficient threshold value; an emission strategy generation module configured to calculate a liquid dynamic accumulation index based on the liquid concentration change data and the wall surface residual liquid equivalent concentration of the inner wall of the outer cylinder, determine whether the accumulation trend of the liquid in the separator meets a standard, and determine an adjustment of the opening frequency of the emission valve or the length of a single emission according to a ratio of the liquid dynamic accumulation index to a preset liquid dynamic accumulation index.

[0008] Further, the system further comprises, a data acquisition module configured to acquire, in real time, the volume initial residual liquid concentration, the wall surface residual liquid equivalent concentration, the new liquid concentration, the system pressure drop data, the system operation data, and the liquid concentration change data of a plurality of monitoring periods during the operation of the air compressor; a separation efficiency analysis module configured to determine whether the cleaning ability of the separator for the historical residual liquid meets a standard and determine an initial cleanliness based on a comprehensive self-cleaning index of the separator obtained based on the volume initial residual liquid concentration and the wall surface residual liquid equivalent concentration.

[0009] Further, the separation efficiency analysis module determines that the cleaning ability of the separator for the historical residual liquid meets the standard in response to the comprehensive self-cleaning index being greater than or equal to a preset comprehensive self-cleaning index, and determines a ratio of the comprehensive self-cleaning index to the preset comprehensive self-cleaning index as a first initial cleanliness.

[0010] Further, the separation efficiency analysis module determines that the cleaning ability of the separator for the historical residual liquid does not meet the standard in response to the comprehensive self-cleaning index being less than the preset comprehensive self-cleaning index, and determines a ratio of the comprehensive self-cleaning index to the preset comprehensive self-cleaning index as a second initial cleanliness.

[0011] Further, the load influence analysis module determines that the combined influence of the current operating load and the wall surface residual risk on the separation efficiency is within an allowable range in response to the system risk superimposed load coefficient being less than or equal to a preset risk superimposed load coefficient, and determines a ratio of the system risk superimposed load coefficient to the initial cleanliness as a first system load evaluation value.

[0012] Further, the load influence analysis module determines that the combined influence of the current operating load and the wall surface residual risk on the separation efficiency exceeds the allowable range in response to the system risk superimposed load coefficient being greater than the preset risk superimposed load coefficient, and determines a ratio of the system risk superimposed load coefficient to the initial cleanliness as a second system load evaluation value.

[0013] Further, the system state diagnosis module determines that the internal flow state of the separator is healthy in response to the separation flow resistance health index being greater than or equal to a separation flow resistance health index threshold value.

[0014] Further, the operation parameter optimization module determines that the current operation condition of the air compressor does not match the separator based on the condition that the separator internal flow state health is determined and the working condition matching coefficient is less than the working condition matching coefficient threshold, and determines to optimize the system load evaluation value according to the comparison result of the difference between the working condition matching coefficient and the working condition matching coefficient threshold and the preset difference value, wherein, determining to reduce the system load evaluation value to a corresponding value by a first preset evaluation value optimization coefficient based on the difference being less than or equal to the preset difference value; determining to reduce the system load evaluation value to a corresponding value by a second preset evaluation value optimization coefficient based on the difference being greater than the preset difference value.

[0015] Further, the discharge strategy generation module determines that the liquid accumulation trend in the separator is not up to standard in response to the liquid dynamic accumulation index being greater than the preset liquid dynamic accumulation index, and determines to increase the opening frequency of the discharge valve to a corresponding value by a preset opening frequency adjustment coefficient based on the ratio of the liquid dynamic accumulation index to the preset liquid dynamic accumulation index being less than or equal to a preset ratio.

[0016] Further, the discharge strategy generation module determines that the liquid accumulation trend in the separator is not up to standard in response to the liquid dynamic accumulation index being greater than the preset liquid dynamic accumulation index, and determines to increase the single discharge time length to a corresponding value by a preset discharge time length adjustment coefficient based on the ratio of the liquid dynamic accumulation index to the preset liquid dynamic accumulation index being greater than a preset ratio.

[0017] Compared with the prior art, the present application has the beneficial effects that the present application realizes fine perception and intelligent regulation of the air compressor gas-liquid separation state through multi-module cooperation. The separation efficiency analysis module evaluates the self-cleaning ability of the separator based on the volume and wall surface residual concentration, the load influence analysis module quantifies the instantaneous load risk of the system in combination with the initial, wall surface and new concentration, the system state diagnosis module judges the internal flow health state of the separator according to the pressure drop and wall surface data, the operation parameter optimization module optimizes the system load evaluation in combination with the operation data, and the discharge strategy generation module evaluates the dynamic accumulation trend according to the periodic concentration change and wall surface residual and adjusts the discharge strategy, which improves the gas-liquid separation efficiency and reliability, provides protection for the energy-saving and safe operation of the air compressor system, avoids waste of compressed air and equipment corrosion risk, optimizes the discharge timing and intensity, a multi-dimensional index system is constructed to improve the intelligent management level of the air compressor system, and thus the accuracy and economy of gas-liquid discharge are improved.

[0018] Further, the application realizes precise monitoring of the initial liquid concentration retained in the volume, the equivalent concentration of the residual liquid on the wall surface and the concentration of the new liquid by setting the air inlet, the inner cylinder and the water absorption sponge with a continuous slope design to form a three-stage drying structure, combining the detection system composed of the capacitive humidity sensor array, the liquid concentration sensor and the liquid level force sensor, significantly improving the gas-liquid separation efficiency, effectively maintaining the stability of the liquid content in the outlet gas, and providing a complete and reliable data basis for intelligent regulation and control, solving the technical problem of insufficient monitoring of the residual liquid on the wall surface of the traditional separation device.

[0019] Further, the application calculates the separator comprehensive self-cleaning index based on the initial liquid concentration retained in the volume and the equivalent concentration of the residual liquid on the wall surface through the separation efficiency analysis module to determine whether the cleaning capacity of the separator for the historical residual liquid meets the standard, automatically triggers a maintenance warning when the comprehensive self-cleaning index is less than the preset comprehensive self-cleaning index, and judges the combined influence degree of the current operating load and the wall residual risk on the separator efficiency based on the system risk superposition load coefficient obtained from the initial liquid concentration retained in the volume, the equivalent concentration of the residual liquid on the wall surface and the concentration of the new liquid through the load influence analysis module, which can significantly shorten the maintenance response time, significantly improve the load evaluation accuracy, and effectively prevent the continuous degradation of the separation performance.

[0020] Further, the application calculates the separation flow resistance health index from the system pressure drop data and the equivalent concentration of the residual liquid on the wall surface through the system state diagnosis module, determines the health state according to the separation flow resistance health index being greater than or equal to the separation flow resistance index threshold, calculates the operating condition matching coefficient based on the system operating data and the wall residual concentration through the operating parameter optimization module, dynamically adjusts the system load evaluation value with the first preset evaluation optimization value and the second preset evaluation optimization value when the system operating condition matching coefficient is less than the operating condition matching coefficient threshold, and calculates the liquid dynamic accumulation index from the liquid concentration change data and the equivalent concentration of the residual liquid on the wall surface through the discharge strategy generation module, determines the preset opening frequency adjustment coefficient and the preset discharge time adjustment coefficient to intelligently adjust the discharge strategy according to the comparison result of the liquid dynamic accumulation index and the preset liquid dynamic accumulation index, and the multi-level collaborative optimization mechanism can significantly reduce the system energy consumption and waste of compressed air, realizing the technical leap from traditional fixed-time discharge to on-demand precise discharge. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 The functional block diagram of the air compressor gas-liquid discharge device based on the embodiment of the application is shown in the figure. Figure 2 The isometric structural schematic diagram of the air compressor gas-liquid discharge device based on the embodiment of the application is shown in the figure. Figure 3 The right side sectional structural schematic diagram of the air compressor gas-liquid discharge device based on the embodiment of the application is shown in the figure. Figure 4A schematic view of a front view cross-sectional structure of an air compressor gas-liquid discharge device according to an embodiment of the present application; Figure 5 A schematic view of a bottom structure of an air compressor gas-liquid discharge device according to an embodiment of the present application; Figure 6 A logic block diagram for determining whether the cleaning ability of a separator for historical residual liquid meets the standard according to a comprehensive self-cleaning index according to an embodiment of the present application; Figure 7 A logic block diagram for determining the combined influence degree of a current running load and wall residual risk on the efficiency of a separator according to a system risk superimposed load coefficient according to an embodiment of the present application; Figure 8 A logic block diagram for determining whether the internal flow state of a separator is healthy according to a separation flow resistance health index according to an embodiment of the present application; Figure 9 A logic block diagram for determining whether the matching of a current running condition of an air compressor and a separator is qualified according to a condition matching coefficient according to an embodiment of the present application; Figure 10 A logic block diagram for determining the optimization of a system load evaluation value according to the difference between a condition matching coefficient and a condition matching coefficient threshold value according to an embodiment of the present application; Figure 11 A logic block diagram for determining whether the liquid accumulation trend in a separator meets the standard according to a liquid dynamic accumulation index according to an embodiment of the present application; Figure 12 A logic block diagram for determining the adjustment of the opening frequency or single discharge duration of a discharge valve according to the ratio between a liquid dynamic accumulation index and a preset liquid dynamic accumulation index according to an embodiment of the present application; In the figure, 1 is an outer cylinder, 2 is an inner cylinder, 3 is an air inlet, 4 is a liquid concentration sensor, 5 is a capacitive humidity sensor, 6 is an upper cover plate, 7 is an air outlet mesh, 8 is a liquid outlet, 9 is a secondary air inlet, 10 is a lower cover plate, 11 is a water-absorbing sponge, 12 is a liquid level sensor, and 13 is a discharge valve. DETAILED DESCRIPTION

[0022] In order to make the objects and advantages of the present application clearer, the present application will be further described below with reference to embodiments. It should be understood that the specific embodiments described herein are merely used to explain the present application and do not limit the present application.

[0023] The preferred embodiments of the present application will be described below with reference to the accompanying drawings. It should be understood by those skilled in the art that the embodiments are merely used to explain the technical principles of the present application and do not limit the protection scope of the present application.

[0024] It should be noted that in the description of the present application, the terms "upper", "lower", "left", "right", "inner", "outer" and the like indicate the direction or positional relationship of the terms based on the direction or positional relationship shown in the drawings, which is only for the convenience of description, and does not indicate or imply that the device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0025] Please refer to Figures 1 to 5 shown, Figure 1 The functional block diagram of the air compressor gas-liquid discharge device is shown in the embodiment of the present application. Figure 2 The isometric structural schematic diagram of the air compressor gas-liquid discharge device is shown in the embodiment of the present application. Figure 3 The right side sectional structural schematic diagram of the air compressor gas-liquid discharge device is shown in the embodiment of the present application. Figure 4 The front sectional structural schematic diagram of the air compressor gas-liquid discharge device is shown in the embodiment of the present application. Figure 5 The bottom structural schematic diagram of the air compressor gas-liquid discharge device is shown in the embodiment of the present application.

[0026] The air compressor gas-liquid discharge device in the embodiment of the present application comprises an outer cylinder 1 and an air inlet assembly, The air inlet assembly comprises a plurality of air inlets 3 embedded at one end inside one side of the outer cylinder 1 and protruding at the other end outside one side of the outer cylinder 1 to introduce compressed gas into the inside of the separator.

[0027] In the embodiment of the present application, the end of the air inlet 3 arranged inside one side of the outer cylinder 1 is designed as a continuous inclined surface to form an effective rotating flow field to make the introduced compressed gas rotate downward along the inner wall of the outer cylinder 1 for primary drying.

[0028] The drying assembly comprises an inner cylinder 2 arranged inside the outer cylinder 1, the inner cylinder 2 is provided at one end away from the air inlet 3 with a secondary air inlet 9 for the gas dried once along the inner wall of the outer cylinder 1 to enter the inner cylinder for secondary drying, and the inner cylinder 2 is provided at one end close to the air inlet with a lower cover plate 10 for fixing the inner cylinder 2, and the upper part of the lower cover plate 10 is provided with a water-absorbing sponge 11 for tertiary drying after secondary drying in the inner cylinder 2.

[0029] In the embodiment of the present application, the inner cavity of the inner cylinder 2 is arranged in communication with the water-absorbing sponge 11 through the lower cover plate 10, and the surface of the lower cover plate 10 is provided with a mesh opening for gas to pass through.

[0030] A detection assembly includes a capacitive humidity sensor array 5 arranged on the inner surface of the outer cylinder 1 to detect the equivalent concentration of residual liquid on the inner wall of the inner cylinder 1, a liquid concentration sensor 4 arranged inside the air inlet 3 to detect the liquid content of the compressed gas entering the separator, and a liquid level sensor 12 arranged at the bottom of the outer cylinder to detect the liquid level at the bottom of the separator.

[0031] In the embodiment of the present application, the end of the outer cylinder 1 close to the air inlet 3 is provided with an upper cover plate 6, the surface of the upper cover plate 6 is provided with a gas outlet mesh 7 for discharging dry gas and preventing foreign matter from falling into the interior of the separator, and the end of the outer cylinder 1 away from the air inlet 3 is also provided with a liquid outlet 8 for discharging liquid accumulated at the bottom of the separator, and the liquid outlet 8 is provided with a discharge valve 13 inside to control the opening and closing of the liquid outlet.

[0032] A data acquisition module is used to acquire the initial volume retention liquid concentration, the equivalent concentration of residual liquid on the wall, the new liquid concentration, the system pressure drop data, the system operation data, and the liquid concentration change data of several monitoring periods in real time during the operation of the air compressor. A separation efficiency analysis module is connected to the data acquisition module to determine whether the cleaning ability of the separator for the historical residual liquid meets the standard and the initial cleanliness based on the comprehensive self-cleaning index of the separator calculated based on the initial volume retention liquid concentration at the bottom of the outer cylinder and the equivalent concentration of residual liquid on the wall of the inner cylinder. A load impact analysis module is connected to the data acquisition module and the separation efficiency analysis module to determine the combined influence degree of the current operating load and the residual risk on the separation efficiency of the separator and determine the system load evaluation value based on the system risk superposition load coefficient calculated based on the initial volume retention liquid concentration at the bottom of the outer cylinder, the equivalent concentration of residual liquid on the wall of the inner cylinder, and the new liquid concentration of the gas newly introduced through the air inlet assembly. A system state diagnosis module is connected to the data acquisition module to determine whether the flow state inside the separator is healthy based on the separation flow resistance health index calculated based on the system pressure drop data and the equivalent concentration of residual liquid on the wall of the inner cylinder. An operating parameter optimization module is connected to the system state diagnosis module to determine whether the current operating condition of the air compressor matches the separator based on the working condition matching coefficient calculated based on the system operation data and the equivalent concentration of residual liquid on the wall of the inner cylinder, and to determine the optimization of the system load evaluation value according to the difference between the working condition matching coefficient and the working condition matching coefficient threshold. a discharge strategy generation module connected with the operation parameter optimization module, configured to determine whether the accumulation trend of the liquid in the separator meets the standard based on the liquid dynamic accumulation index obtained based on the liquid concentration change data and the wall surface residual liquid equivalent concentration of the inner wall of the outer cylinder, and determine the adjustment of the opening frequency of the discharge valve or the length of single discharge according to the ratio of the liquid dynamic accumulation index to a preset liquid dynamic accumulation index.

[0033] Specifically, the present application realizes the fine perception and intelligent regulation of the air compressor gas-liquid separation state through multi-module cooperation. The separation efficiency analysis module evaluates the self-cleaning ability of the separator based on the volume and wall surface residual concentration, the load influence analysis module quantifies the instantaneous load risk of the system in combination with the initial, wall surface and new concentration, the system state diagnosis module judges the internal flow health state of the separator according to the pressure drop and wall surface data, the operation parameter optimization module optimizes the system load evaluation in combination with the operation data, and the discharge strategy generation module adjusts the discharge strategy according to the dynamic accumulation trend evaluated based on the periodic concentration change and wall surface residual, thereby improving the gas-liquid separation efficiency and reliability, providing protection for the energy-saving and safe operation of the air compressor system, avoiding the waste of compressed air and the corrosion risk of equipment, optimizing the discharge timing and intensity, building a multi-dimensional index system to improve the intelligent management level of the air compressor system, and thus improving the accuracy and economy of gas-liquid discharge.

[0034] In the embodiment of the present application, the volume initial residual liquid concentration and the new liquid concentration are obtained by liquid concentration sensors arranged at the bottom of the separator and at the air inlet of the separator, and the wall surface residual liquid equivalent concentration is obtained by a capacitive humidity sensor array arranged on the inner wall of the separator.

[0035] In the embodiment of the present application, the preset monitoring period is 60s-180s, and the preferred value is 120s.

[0036] Please refer to Figure 6 As shown in the figure, it is a logic block diagram for determining whether the cleaning ability of the separator for the historical residual liquid meets the standard according to the comprehensive self-cleaning index of the embodiment of the present application.

[0037] Specifically, the separation efficiency analysis module determines whether the cleaning ability of the separator for the historical residual liquid meets the standard and determines the initial cleanliness according to the comparison result of the comprehensive self-cleaning index of the separator obtained based on the volume initial residual liquid concentration and the wall surface residual liquid equivalent concentration and the preset comprehensive self-cleaning index, wherein, If the comprehensive self-cleaning index is greater than or equal to the preset comprehensive self-cleaning index, it is determined that the cleaning ability of the separator for the historical residual liquid meets the standard, at which time the first initial cleanliness is determined; If the comprehensive self-cleaning index is less than the preset comprehensive self-cleaning index, it is determined that the cleaning ability of the separator for the historical residual liquid is not up to standard, and at this time, the second initial cleanliness is determined.

[0038] In the embodiment of the present application, the comprehensive self-cleaning index is the ratio of the total mass of the liquid discharged in the discharge period to the sum of the mass of the initial volume of the residual liquid plus the product of the equivalent mass of the wall residual liquid and the difficulty compensation coefficient, wherein the total mass of the liquid is obtained by real-time measurement through the liquid mass flow meter installed in the discharge pipeline, the mass of the initial volume of the residual liquid is the mass of the liquid accumulated at the bottom of the separator at the beginning of the discharge period, which is obtained by multiplying the liquid level height measured by the liquid level sensor at the bottom of the separator by the area of the bottom of the separator and then by the density of the liquid, and the equivalent mass of the wall residual liquid is the equivalent mass of the liquid adhering to the inner wall of the separator at the beginning of the discharge period, which is obtained by multiplying the average relative humidity value measured by the capacitive humidity sensor array installed on the inner wall of the separator, the total area of the inner wall of the separator and the liquid holding coefficient per unit area.

[0039] Wherein, the determination method of the liquid holding coefficient per unit area is: in an experimental environment, simulate the internal working condition of the separator, measure the liquid mass that can be adsorbed and held by the unit area of the separator inner wall material under different constant relative humidity, and obtain the proportional coefficient between humidity and liquid holding amount by linear regression fitting, and the obtained slope is the liquid holding coefficient per unit area, the value range of which is 0.1 g / m²·%RH-0.3 g / m²·%RH, the preferred value of which is 0.15 g / m²·%RH, and the preferred value range and the preferred value can be determined according to the actual situation, which is not limited specifically here.

[0040] Wherein, the value range of the difficulty compensation coefficient is 1.2-1.5, and the preferred value of the difficulty compensation coefficient is 1.4, and the preferred value range and the preferred value can be determined according to the actual situation, which is not limited specifically here.

[0041] In the embodiment of the present application, the value range of the preset comprehensive self-cleaning index is 0.85-0.95, and the preferred value of the preset comprehensive self-cleaning index is 0.9, and the preferred value range and the preferred value can be determined according to the actual situation, which is not limited specifically here.

[0042] In the embodiment of the present application, the first initial cleanliness is the ratio of the first comprehensive self-cleaning index to the preset comprehensive self-cleaning index under the condition that the comprehensive self-cleaning index is greater than or equal to the preset comprehensive self-cleaning index.

[0043] In the embodiment of the present application, the second initial cleanliness is the ratio of the second comprehensive self-cleaning index to the preset comprehensive self-cleaning index under the condition that the comprehensive self-cleaning index is less than the preset comprehensive self-cleaning index.

[0044] Please refer toFigure 7 Fig. 4 is a logic block diagram showing the determination of the combined influence of the current operating load and the wall residue risk on the separator efficiency according to the system risk superimposed load coefficient in an embodiment of the present application.

[0045] Specifically, the load influence analysis module determines the combined influence of the current operating load and the wall residue risk on the separator efficiency according to the ratio of the system risk superimposed load coefficient obtained from the initial volume-reserved liquid concentration, the wall-residue liquid equivalent concentration and the newly-added liquid concentration, and the preset risk superimposed load coefficient, and determines the system load evaluation value, wherein, If the system risk superimposed load coefficient is less than or equal to the preset risk superimposed load coefficient, it is determined that the combined influence of the current operating load and the wall residue risk on the separator efficiency is within the allowable range, and a first system load evaluation value is determined at this time. If the system risk superimposed load coefficient is greater than the preset risk superimposed load coefficient, it is determined that the combined influence of the current operating load and the wall residue risk on the separator efficiency exceeds the allowable range, and a second system load evaluation value is determined at this time.

[0046] In an embodiment of the present application, the system risk superimposed load coefficient is obtained by first calculating the sum of the newly-added load component, the volume-reserved load component and the wall risk load component to obtain the total load amount, and then calculating the ratio of the total load amount to the maximum processing load amount of the separator, wherein the newly-added load component is obtained by multiplying the newly-added liquid concentration collected in the monitoring period, the exhaust flow value in the same period and the monitoring period length, the volume-reserved load component is obtained by multiplying the initial volume-reserved liquid concentration measured at the beginning of the discharge period and the internal geometric volume of the separator, and the wall risk load component is obtained by first obtaining the relative humidity values of the monitoring points of the capacitive humidity sensor array installed on the inner wall of the separator, calculating the ratio of the standard deviation to the average value as the inner wall humidity distribution uniformity index, determining the risk amplification coefficient according to the preset corresponding relationship according to the inner wall humidity distribution uniformity index, and finally calculating the product of the wall-residue liquid equivalent concentration, the volume of the separator and the risk amplification coefficient.

[0047] The maximum processing load amount of the separator is the upper limit of the mass of liquid that can be processed by the separator in a unit of time under the initial clean state and under the rated operating condition, and is a constant determined in advance according to the structural parameters of the separator and the design condition.

[0048] The value range of the risk amplification coefficient is 1.0-2.0, and the preferred value is 1.5. The preferred value range and the preferred value can be determined according to the actual situation, which is not limited here.

[0049] In the embodiment of the present application, the preset risk superimposed load coefficient has a value range of 0.9-1.0, and the preferred value is 0.95. The preferred value range and the preferred value can be determined according to actual conditions, and are not specifically limited here.

[0050] In the embodiment of the present application, the system load evaluation value is obtained by calculating the ratio of the system risk superimposed load coefficient to the initial cleanliness.

[0051] Please refer to Figure 8 Fig. 2 is a logic block diagram for determining whether the internal flow state of the separator is healthy according to the separation flow resistance health index in the embodiment of the present application.

[0052] Specifically, under the condition of determining the system load evaluation value, the system state diagnosis module determines whether the internal flow state of the separator is healthy according to the comparison result of the separation flow resistance health index obtained from the system pressure drop data and the wall surface residual liquid equivalent concentration and the separation flow resistance health index threshold value, wherein, If the separation flow resistance health index is less than the separation flow resistance health index threshold value, it is determined that the internal flow state of the separator is unhealthy. If the separation flow resistance health index is greater than or equal to the separation flow resistance health index threshold value, it is determined that the internal flow state of the separator is healthy.

[0053] In the embodiment of the present application, the separation flow resistance health index is obtained by first calculating the product of the current measured pressure drop and the wall surface influence factor, and then calculating the ratio of the expected pressure drop of the separator in the theoretical clean state to the product.

[0054] The expected pressure drop is the theoretical calculation value of the pressure difference between the inlet and the outlet of the separator when the internal flow channel of the separator is clean and free of residues and runs at the rated operating condition. The internal flow channel of the separator is equivalent to a series flow path composed of straight pipe sections, elbow sections and reducing joint sections. The frictional pressure drop and the local pressure drop of each flow path section under the rated operating flow rate are calculated respectively, and the pressure drops of all flow path sections are summed to obtain the expected pressure drop. The wall surface influence factor is the value 1 plus the ratio of the wall surface residual liquid equivalent concentration to the wall surface residual critical concentration.

[0055] In the embodiment of the present application, the separation flow resistance health index has a value range of 0.75-0.85, and the preferred value is 0.8. The preferred value range and the preferred value can be determined according to actual conditions, and are not specifically limited here.

[0056] Please refer to Figure 9 Fig. 4 is a logic block diagram for determining whether the matching of the current operating condition of the air compressor and the separator is qualified according to the operating condition matching coefficient in the embodiment of the present application.

[0057] Specifically, the operation parameter optimization module determines whether the matching of the current operation condition of the air compressor and the separator is qualified according to a comparison result of a working condition matching coefficient obtained according to the system operation data and the wall residual liquid equivalent concentration and a working condition matching coefficient threshold under the condition that the health of the internal flow state of the separator is determined, wherein, If the working condition matching coefficient is less than the working condition matching coefficient threshold, it is determined that the matching of the current operation condition of the air compressor and the separator is unqualified. If the working condition matching coefficient is greater than or equal to the working condition matching coefficient threshold, it is determined that the matching of the current operation condition of the air compressor and the separator is qualified.

[0058] In the embodiment of the present application, the system operation data at least includes a real-time air compressor load rate and a real-time exhaust flow rate.

[0059] The real-time air compressor load rate is obtained by measuring the ratio of the operating current of the motor to the rated current, and the real-time exhaust flow rate is measured by a flow meter installed on the air compressor exhaust pipeline.

[0060] In the embodiment of the present application, the working condition matching coefficient is obtained by first calculating the ratio of the real-time air compressor load rate to the rated load rate of the air compressor as an air compressor load matching factor, and calculating the ratio of the real-time exhaust flow rate to the design flow rate of the separator as a flow matching factor; then calculating the ratio of the sum of the value 1 and the system risk superimposed load coefficient plus the buffer constant 0.5 as a system load influence factor, and calculating the difference between the quotient of the value 1 and the wall residual liquid equivalent concentration and twice the wall residual critical concentration as a wall state influence factor; finally, the air compressor load matching factor, the flow matching factor, the system load influence factor and the wall state influence factor are multiplied to obtain the working condition matching coefficient.

[0061] In the embodiment of the present application, the working condition matching coefficient threshold has a value range of 0.93-0.97, and the preferred value is 0.94. The preferred value range and the preferred value can be determined according to actual conditions, which are not limited here.

[0062] Please refer to Figure 10 The figure is a logic block diagram for determining the optimized system load evaluation value according to the difference between the working condition matching coefficient and the working condition matching coefficient threshold.

[0063] Specifically, the operation parameter optimization module determines the optimized system load evaluation value according to a comparison result of the difference between the working condition matching coefficient and the working condition matching coefficient threshold and a preset difference value under the condition that the matching of the current operation condition of the air compressor and the separator is unqualified, wherein, If the difference is less than or equal to the preset difference value, it is determined that the system load evaluation value is reduced to a corresponding value by the first preset evaluation value optimization coefficient 0.95. If the difference value is greater than a preset difference value, it is determined that the system load evaluation value is reduced to a corresponding value by a second preset evaluation value optimization coefficient 0.93.

[0064] In the embodiment of the present application, the difference value is the difference between the working condition matching coefficient and the working condition matching coefficient threshold.

[0065] In the embodiment of the present application, the preset difference value has a value range of 0.1-0.2, and the preferred value is 0.15. The preferred value range and the preferred value can be determined according to actual conditions, which are not specifically limited here.

[0066] In the embodiment of the present application, the reduced system load evaluation value is the product of the system load evaluation value and a preset evaluation value optimization coefficient, the preset evaluation value optimization coefficient includes a first preset evaluation value optimization coefficient and a second preset evaluation value optimization coefficient, the first preset evaluation value optimization coefficient is 0.95, and the second preset evaluation value optimization coefficient is 0.93.

[0067] Please refer to Figure 11 As shown in the figure, it is a logic block diagram for determining whether the liquid accumulation trend in the separator meets the standard according to the liquid dynamic accumulation index in the embodiment of the present application.

[0068] Specifically, the discharge strategy generation module acquires liquid concentration change data of a plurality of cycle periods under the condition of optimizing the system load evaluation value, and obtains a liquid dynamic accumulation index in combination with the equivalent concentration of residual liquid on the wall surface, and determines whether the liquid accumulation trend in the separator meets the standard according to the comparison result of the liquid dynamic accumulation index and a preset liquid dynamic accumulation index, wherein, If the liquid dynamic accumulation index is less than or equal to the preset liquid dynamic accumulation index, it is determined that the liquid accumulation trend in the separator meets the standard. If the liquid dynamic accumulation index is greater than the preset liquid dynamic accumulation index, it is determined that the liquid accumulation trend in the separator does not meet the standard.

[0069] In the embodiment of the present application, the liquid dynamic accumulation index is obtained by first calculating the difference between the liquid concentration measured in the current monitoring period and the liquid concentration measured in the last monitoring period, and then dividing the liquid concentration change rate by the monitoring period length, then multiplying the liquid concentration change rate by the monitoring period length, and then multiplying the sum of the value 1 and the equivalent concentration of residual liquid on the wall surface by the ratio of the critical concentration of residual liquid on the wall surface to obtain the liquid dynamic accumulation index.

[0070] In the embodiment of the present application, the preset liquid dynamic accumulation index has a value range of 1.3-1.6, and the preferred value is 1.5. The preferred value range and the preferred value can be determined according to actual conditions, which are not specifically limited here.

[0071] Referring to Figure 12 Fig. 6 is a logic block diagram of determining adjustment of opening frequency of the discharge valve or single discharge duration according to the ratio of the liquid dynamic accumulation index to the preset liquid dynamic accumulation index according to an embodiment of the present application.

[0072] Specifically, the discharge strategy generation module determines adjustment of opening frequency of the discharge valve or single discharge duration according to a comparison result of the ratio of the liquid dynamic accumulation index to the preset liquid dynamic accumulation index to the preset ratio under the condition that the liquid accumulation value in the separator is not up to standard, wherein, If the ratio is less than or equal to the preset ratio, it is determined that the opening frequency of the discharge valve is increased to a corresponding value by a preset opening frequency adjustment coefficient 1.25. If the ratio is greater than the preset ratio, it is determined that the single discharge duration is increased to a corresponding value by a preset discharge duration adjustment coefficient 1.35.

[0073] In an embodiment of the present application, the ratio is the ratio of the liquid dynamic accumulation index to the preset liquid dynamic accumulation index.

[0074] In an embodiment of the present application, the preset ratio has a value range of 1.1-1.3, and the preferred value is 1.2. The preferred value range and the preferred value can be determined according to actual conditions, which are not limited specifically herein.

[0075] In an embodiment of the present application, the increased opening frequency of the discharge valve is the product of the original opening frequency of the discharge valve and a preset opening frequency adjustment coefficient, and the increased single discharge duration is the product of the original discharge duration and a preset discharge duration adjustment coefficient. The preset opening frequency adjustment coefficient is 1.25, and the preset discharge duration adjustment coefficient is 1.35.

[0076] So far, the technical solution of the present application has been described in combination with the preferred embodiments shown in the drawings, but those skilled in the art can easily understand that the protection scope of the present application is obviously not limited to these specific embodiments. Those skilled in the art can make equivalent changes or replacements to related technical features without deviating from the principles of the present application, and the technical solutions after the changes or replacements will fall within the protection scope of the present application.

Claims

1. An air compressor gas-liquid discharge device based on an air compressor, comprising an outer cylinder and an air inlet assembly, characterized in that, Also comprising, a drying assembly comprising an inner cylinder arranged inside the outer cylinder for secondary drying of the gas, and a water-absorbing sponge arranged at the upper part of the inner cylinder for tertiary drying of the gas; a detection assembly for detecting the wall surface residual liquid equivalent concentration and the liquid content of the compressed gas entering the inside of the separator, and for detecting the liquid level height at the bottom of the separator and the initial volume retention liquid concentration; a load impact analysis module for calculating the system risk superimposed load coefficient based on the initial volume retention liquid concentration at the bottom of the outer cylinder, the wall surface residual liquid equivalent concentration of the inner wall of the outer cylinder, and the new liquid concentration, determining the combined influence degree of the current operating load and the wall surface residual risk on the efficiency of the separator, and determining the system load evaluation value; a system state diagnosis module for calculating the separation flow resistance health index based on the system pressure drop data and the wall surface residual liquid equivalent concentration of the inner wall of the outer cylinder, and determining whether the flow state inside the separator is healthy; an operating parameter optimization module for calculating the working condition matching coefficient based on the system operating data and the wall surface residual liquid equivalent concentration of the inner wall of the outer cylinder, determining whether the current operating working condition of the air compressor matches the separator, and determining the adjustment of the system load evaluation value according to the difference between the working condition matching coefficient and the working condition matching coefficient threshold value; an emission strategy generation module for calculating the liquid dynamic accumulation index based on the liquid concentration change data and the wall surface residual liquid equivalent concentration of the inner wall of the outer cylinder, determining whether the accumulation trend of the liquid in the separator meets the standard, and determining the adjustment of the opening frequency of the emission valve or the single emission time length according to the ratio of the liquid dynamic accumulation index to the preset liquid dynamic accumulation index.

2. The air compressor gas-liquid discharge device according to claim 1, comprising an outer cylinder, characterized in that, Also comprising, a data acquisition module for acquiring the initial volume retention liquid concentration, the wall surface residual liquid equivalent concentration, the new liquid concentration, the system pressure drop data, the system operating data, and the liquid concentration change data of a plurality of monitoring periods in real time during the operation of the air compressor; a separation efficiency analysis module for determining whether the cleaning ability of the separator for the historical residual liquid meets the standard and determining the initial cleanliness based on the comprehensive self-cleaning index of the separator obtained based on the initial volume retention liquid concentration and the wall surface residual liquid equivalent concentration.

3. The air compressor gas-liquid discharge device according to claim 2, wherein In response to the comprehensive self-cleaning index being greater than or equal to the preset comprehensive self-cleaning index, the separation efficiency analysis module determines that the cleaning ability of the separator for the historical residual liquid meets the standard, and determines the ratio of the comprehensive self-cleaning index to the preset comprehensive self-cleaning index as the first initial cleanliness.

4. The air compressor gas-liquid discharge device according to claim 3, wherein In response to the comprehensive self-cleaning index being less than the preset comprehensive self-cleaning index, the separation efficiency analysis module determines that the cleaning ability of the separator for the historical residual liquid does not meet the standard, and determines the ratio of the comprehensive self-cleaning index to the preset comprehensive self-cleaning index as the second initial cleanliness.

5. The air compressor gas-liquid discharge apparatus according to claim 1, wherein The load influence analysis module determines that the combined influence of the current operating load and the wall surface residual risk on the separator efficiency is within the allowable range in response to the system risk superimposed load coefficient being less than or equal to a preset risk superimposed load coefficient, and determines the ratio of the system risk superimposed load coefficient to the initial cleanliness as a first system load evaluation value.

6. The air compressor gas-liquid discharge device according to claim 5, wherein The load influence analysis module determines that the combined influence of the current operating load and the wall surface residual risk on the separator efficiency exceeds the allowable range in response to the system risk superimposed load coefficient being greater than the preset risk superimposed load coefficient, and determines the ratio of the system risk superimposed load coefficient to the initial cleanliness as a second system load evaluation value.

7. The air compressor gas-liquid discharge apparatus according to claim 1, wherein The system state diagnosis module determines that the internal flow state of the separator is healthy in response to the separation flow resistance health index being greater than or equal to a separation flow resistance health index threshold.

8. The air compressor gas-liquid discharge device according to claim 7, wherein The operating parameter optimization module determines that the current operating condition of the air compressor does not match the separator based on the operating condition matching coefficient being less than an operating condition matching coefficient threshold when the internal flow state of the separator is determined to be healthy, and determines to optimize the system load evaluation value based on the ratio of the difference between the operating condition matching coefficient and the operating condition matching coefficient threshold to a preset difference value, wherein, a first preset evaluation value optimization coefficient is determined based on the difference being less than or equal to the preset difference value to reduce the system load evaluation value to a corresponding value; a second preset evaluation value optimization coefficient is determined based on the difference being greater than the preset difference value to reduce the system load evaluation value to a corresponding value.

9. The air compressor gas-liquid discharge apparatus according to claim 8, wherein The discharge strategy generation module determines that the liquid accumulation trend in the separator is not up to standard in response to the liquid dynamic accumulation index being greater than a preset liquid dynamic accumulation index, and determines to increase the opening frequency of the discharge valve to a corresponding value based on the ratio of the liquid dynamic accumulation index to the preset liquid dynamic accumulation index being less than or equal to a preset ratio.

10. The air compressor gas-liquid discharge apparatus according to claim 9, wherein The discharge strategy generation module determines that the liquid accumulation trend in the separator is not up to standard in response to the liquid dynamic accumulation index being greater than a preset liquid dynamic accumulation index, and determines to increase the single discharge time to a corresponding value based on the ratio of the liquid dynamic accumulation index to the preset liquid dynamic accumulation index being greater than a preset ratio.

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