High-quality gas preparation system and method under complex working conditions

Abstract

The invention discloses a high-quality gas preparation system and method under complex working conditions, and the system comprises a nitrogen preparation subsystem which is used for preparing and primarily treating nitrogen; the moisture and organic matter adsorption and regeneration subsystem is used for deeply removing moisture and organic matters in the gas; the gas supply subsystem is used for finally adjusting the gas and conveying the gas to the equipment cabin; the heat management subsystem is used for providing cooling capacity for the system; the control and communication module is used for collecting sensor data and controlling the operation of each execution device; the subsystems are connected through pipelines and work cooperatively to achieve low-dew-point, low-organic-matter-content, constant-temperature and high-purity nitrogen preparation. The system integrates five subsystems of nitrogen preparation, deep adsorption and regeneration, precise gas supply and thermal management and control, and is uniformly regulated and controlled by the central controller, so that a high-purity nitrogen environment with preset conditions can be continuously provided for protected equipment in a full-temperature-range, high-humidity and high-altitude extreme composite environment; and the reliability, the stability and the environmental adaptability of environmental control are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of optical instrument technology, and in particular to a high-quality gas preparation system and method for complex operating conditions. Background Technology

[0002] Optical instruments, due to their inherent properties, have high requirements for atmospheric environments with low dew point, low organic matter content, and high nitrogen purity. Currently, the environmental control method for dew point, organic matter content, and nitrogen purity involves producing nitrogen using a nitrogen generator and then filling and purging the interior of the optical instrument installation chamber.

[0003] Depending on the platform and operating conditions, optical instruments are used in vehicle-mounted integrated equipment and in harsh environments such as -40℃ to 55℃ ambient temperatures, 98% humidity at 25℃, and altitudes of 0 to 5000m. Conventional nitrogen generators face the challenge of significantly increasing gas dew point temperatures (generally only reaching -45℃) in high-temperature and high-humidity environments. As altitude increases, air density decreases, reducing the compressor's output and causing a significant drop in inlet gas pressure at the nitrogen generator membrane, leading to decreased nitrogen purity and increased dew point. Furthermore, for membrane nitrogen generation methods, at high temperatures, the organic matter content in the outlet nitrogen can range from 1ppm to 10ppm, causing a decline in the performance and lifespan of optical instruments. Therefore, achieving the production of high-quality nitrogen with low dew point, low organic matter content, constant temperature, and high purity, adaptable to complex conditions across all temperature ranges, high humidity, and high altitudes, is crucial. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the existing technology. To achieve the above objective, a high-quality gas preparation system and method for complex working conditions are adopted to solve the problems mentioned in the background technology.

[0005] A high-quality gas preparation system for complex operating conditions, comprising: A nitrogen preparation subsystem is used to prepare and initially process nitrogen. A moisture and organic matter adsorption and regeneration subsystem, connected to the nitrogen preparation subsystem, is used for deep removal of moisture and organic matter from the gas. The gas supply subsystem, connected to the moisture and organic matter adsorption and regeneration subsystem, is used for final gas regulation and delivery to the equipment compartment. A thermal management subsystem is connected to the nitrogen preparation subsystem and the gas supply subsystem respectively, and is used to provide cooling to the system; The control and communication module is connected to each subsystem via input and output wiring harnesses, and is used to collect sensor data and control the operation of each actuator. The subsystems are connected by pipelines and work together to achieve the required gas environment control.

[0006] As a further embodiment of the present invention: the nitrogen preparation subsystem includes an air intake filter, an air compressor, a one-way valve, a first air-cooled radiator, a centrifugal water separator, a three-stage filter group, a first-stage heat exchanger, a first-stage temperature sensor, an electrically heated gas storage tank, a second-stage temperature sensor, a membrane pre-pressure sensor, a nitrogen-generating membrane, and a first dew point sensor, which are connected in sequence through pipelines. The bottom of the electrically heated gas storage tank is connected to a drain solenoid valve, and the outlet of the drain solenoid valve is connected to the atmosphere.

[0007] As a further aspect of the present invention: the moisture and organic matter adsorption and regeneration subsystem includes: The first adsorption tower and the second adsorption tower are filled with spherical 13X molecular sieves with a particle size of 3 to 5 mm. The control valve assembly includes a first intake solenoid valve, a second intake solenoid valve, a first exhaust solenoid valve, a second exhaust solenoid valve, a pressure equalizing solenoid valve, and a regenerator hand valve. A regenerative electric heater and a regenerative temperature sensor are used to heat and monitor the temperature of the regenerative gas. By controlling the state of the valve group and the regeneration electric heater, the first adsorption tower and the second adsorption tower can alternately perform adsorption and thermal regeneration.

[0008] As a further embodiment of the present invention: the gas supply subsystem includes a membrane pre-pressure regulating proportional valve, a two-stage filter group, a second dew point sensor, an oxygen concentration sensor, an organic matter concentration sensor, a two-stage plate heat exchanger, a gas supply electric heating tank, a gas supply temperature sensor, and a gas supply solenoid valve, which are connected in sequence through pipelines. The outlet of the gas supply solenoid valve is connected to the equipment compartment.

[0009] As a further aspect of the present invention: the thermal management subsystem includes: Refrigeration compressor; The second air-cooled radiator is connected to the air outlet of the refrigeration compressor; A dryer filter is connected to the second air-cooled radiator; The first branch includes a first refrigeration solenoid valve, a first expansion valve, and a first-stage heat exchanger connected in sequence. The second branch includes a second refrigeration solenoid valve, a second expansion valve, and a secondary plate heat exchanger connected in sequence. A gas-liquid separator is used to combine the refrigerant from the first branch and the second branch, and is connected to the inlet of the refrigeration compressor.

[0010] As a further aspect of the present invention: the control and communication module, with a programmable logic controller as its core, is configured as follows: The system collects parameters from various sensors in the system, including pressure, temperature, dew point, organic matter concentration, and oxygen concentration, and uploads them to the human-machine interface and the host computer. Control the execution status of solenoid valves, fans, air compressors, refrigeration compressors, and proportional valves in each subsystem, and monitor the operating status of electrical components; A PID control algorithm is used to perform closed-loop control on the current or speed of the air compressor, refrigeration compressor, and proportional control valve.

[0011] As a further aspect of the present invention: the control and communication module can be further configured to perform the following coordinated control on the nitrogen preparation subsystem and the thermal management subsystem: Based on the feedback from the primary temperature sensor, the air temperature at the outlet of the primary heat exchanger is controlled within a first target temperature range by controlling the first refrigeration solenoid valve and the refrigeration compressor. Based on the feedback from the secondary temperature sensor, the temperature of the gas entering the nitrogen generation membrane is controlled within the second target temperature range by controlling the electric heater in the electric heating gas storage tank. Based on the feedback from the inlet pressure sensor, the opening of the inlet pressure regulating proportional valve is adjusted by PID control to keep the inlet pressure of the nitrogen generation membrane within the target pressure range.

[0012] As a further aspect of the present invention: the control and communication module can be further configured to perform the following coordinated control on the moisture and organic matter adsorption and regeneration subsystem, the gas supply subsystem, and the thermal management subsystem: The first adsorption tower and the second adsorption tower are controlled to switch between adsorption and regeneration states according to a preset cycle, and the pressure equalization solenoid valve, the air inlet solenoid valve and the exhaust solenoid valve are controlled in sequence during the switching process. Based on the feedback from the regeneration temperature sensor, the regeneration electric heater is controlled to maintain the regeneration gas temperature at the target regeneration temperature.

[0013] As a further aspect of the present invention: the control and communication module is configured as follows: Based on the feedback from the gas supply temperature sensor, the gas temperature supplied to the equipment compartment is controlled at the target gas supply temperature by comprehensively controlling the second refrigeration solenoid valve, the refrigeration compressor, and the gas supply electric heating tank.

[0014] The second aspect of the technical solution provides a method for environmental control using a high-quality gas preparation system under complex operating conditions as described in any of the above-mentioned claims, comprising the following steps: A preliminary nitrogen gas is produced by compressing, cooling, separating water, filtering, performing primary cooling, heating, and membrane separation on ambient air through a nitrogen preparation subsystem. Through a water and organic matter adsorption and regeneration subsystem, and utilizing a dual-tower adsorption and regeneration mechanism, the initial nitrogen gas is subjected to deep dehydration and organic matter removal. The gas after deep processing is regulated in terms of pressure, purity, dew point and temperature through the gas supply subsystem, and then delivered to the equipment compartment. The thermal management subsystem provides cooling capacity to the primary heat exchanger of the nitrogen preparation subsystem and the secondary plate heat exchanger of the gas supply subsystem. The control and communication module collects sensor data from each node of the system in real time, and coordinates the actuators in each subsystem according to the preset control logic and target values ​​to achieve and maintain the gas preparation under preset conditions.

[0015] Compared with the prior art, the present invention has the following technical advantages: By employing the aforementioned technical solution, a gas preparation system is constructed. This system integrates five functional subsystems: nitrogen preparation, moisture and organic matter adsorption and regeneration, gas supply, thermal management, and control and communication, all under unified and coordinated control by a control module. Its core lies in utilizing the synergistic effect of each subsystem: first, the nitrogen preparation subsystem generates basic nitrogen; then, the adsorption and regeneration subsystem performs deep purification to remove moisture and organic matter; subsequently, the gas supply subsystem provides final temperature, pressure, and purity regulation; and the thermal management subsystem provides the necessary cooling for the preceding stages. This ensures a continuous and stable supply of high-purity nitrogen with ultra-low dew point, extremely low organic matter content, and constant temperature to the equipment compartment under extreme environmental conditions, effectively solving the industry problem of performance degradation or failure of individual equipment under complex and harsh operating conditions.

[0016] This invention primarily overcomes the shortcomings of existing industrial equipment in consistently providing high-quality nitrogen under extreme environmental conditions. To address this, the system, through the coordinated control and optimized design of its subsystems, aims to achieve and stably maintain a set of extremely high gas quality indicators, specifically including: gas dew point ≤ -73℃, nitrogen purity ≥ 99.5%, organic matter content ≤ 0.5ppm, and precise control of the gas supply temperature within ±2℃ of the ambient temperature. To achieve this goal, the system cannot rely on the performance of a single component; instead, it uses a control and communication module (based on a PLC) to precisely regulate multiple key points throughout the entire process. Simultaneously, the system implements PID closed-loop control for key parameters such as the outlet temperature of the first-stage heat exchanger, the pressure and temperature before the nitrogen generation membrane, and the gas supply temperature. It is through this multi-node, adaptive control strategy that the system can reliably achieve the aforementioned gas quality targets under extreme operating conditions, including a wide temperature range of -40℃ to 55℃, a maximum relative humidity of 98%, and altitude variations from 0 to 5000 meters. Attached Figure Description

[0017] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings: Figure 1 This is a schematic diagram of the structure of a gas preparation system according to an embodiment of this application.

[0018] In the diagram: 1. Inlet filter; 2. Air compressor; 3. Check valve; 4. First air-cooled radiator; 5. Centrifugal water separator; 6. Three-stage filter assembly; 7. First-stage heat exchanger; 8. First-stage temperature sensor; 9. Electrically heated air storage tank; 10. Second-stage temperature sensor; 11. Membrane pre-pressure sensor; 12. Nitrogen generating membrane; 13. First dew point sensor; 14. Drain solenoid valve; 15. Air inlet; 16. First inlet solenoid valve; 17. First adsorption tower; 18. First check valve; 19. Main outlet; 20. Regenerator manual valve; 21. Regeneration electric heater; 22. Third check valve; 23. Second adsorption tower; 24. Second exhaust solenoid valve; 25. Pressure equalization solenoid valve; 26. Second inlet solenoid valve; 27. Second check valve; 28. 29. Regeneration temperature sensor; 30. Fourth check valve; 31. First exhaust solenoid valve; 32. Membrane pre-pressure regulating proportional valve; 33. Two-stage filter assembly; 34. Second dew point sensor; 35. Oxygen concentration sensor; 36. Organic matter concentration sensor; 37. Second-stage plate heat exchanger; 38. Gas supply electric heating tank; 39. Gas supply temperature sensor; 40. Gas supply solenoid valve; 41. Equipment compartment; 42. Exhaust solenoid valve; 43. Refrigeration compressor; 44. Second air-cooled radiator; 45. Dryer filter; 46. First refrigeration solenoid valve; 47. First refrigerant check valve; 48. Second refrigeration solenoid valve; 49. Second expansion valve; 50. Second refrigerant check valve; 51. Gas-liquid separator; 52. Control and communication module. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Please refer to Figure 1 In this embodiment of the invention, a high-quality gas preparation system for complex operating conditions includes: A nitrogen preparation subsystem is used to prepare and initially process nitrogen. A moisture and organic matter adsorption and regeneration subsystem, connected to the nitrogen preparation subsystem, is used for deep removal of moisture and organic matter from the gas. The gas supply subsystem, connected to the moisture and organic matter adsorption and regeneration subsystem, is used for final gas regulation and delivery to the equipment compartment 40. A thermal management subsystem is connected to the nitrogen preparation subsystem and the gas supply subsystem respectively, and is used to provide cooling to the system; The control and communication module 52 is connected to each subsystem via input and output wiring harnesses and is used to collect sensor data and control the operation of each actuator. The subsystems are connected by pipelines and work together to achieve the required gas environment control.

[0021] Among them, the high-quality gas preparation system designed for complex operating conditions is specifically designed to operate stably in complex environments such as a full temperature range, high humidity, and high altitude. This system must fully meet the control requirements and data package specifications for all key process parameters, ensuring the preparation of nitrogen gas with an ultra-low dew point of -73℃, organic matter content controlled at <0.5ppm, a stable gas supply temperature within the range of 25±2℃, and a purity of not less than 99.5% under multiple harsh conditions, including a wide temperature range of -40℃ to 55℃, relative humidity up to 98% at 25℃, and an altitude range of 0 to 5000 meters. Furthermore, it must maintain stable and reliable performance over a long period.

[0022] In this embodiment, the nitrogen preparation subsystem includes an air intake filter 1, an air compressor 2, a one-way valve 3, a first air-cooled radiator 4, a centrifugal water separator 5, a three-stage filter group 6, a first-stage heat exchanger 7, a first-stage temperature sensor 8, an electrically heated gas storage tank 9, a second-stage temperature sensor 10, a membrane pre-pressure sensor 11, a nitrogen-generating membrane 12, and a first dew point sensor 13, all connected in sequence through pipelines. The bottom of the electrically heated gas storage tank 9 is connected to a drain solenoid valve 14, and the outlet of the drain solenoid valve 14 is connected to the atmosphere.

[0023] In this embodiment, the moisture and organic matter adsorption and regeneration subsystem includes: The first adsorption tower 17 and the second adsorption tower 23 are filled with spherical 13X molecular sieves with a particle size of 3 to 5 mm. Regarding the adsorption principle of 13X molecular sieves and the pre-dehumidification process: One of the core technologies of this system's deep purification stage lies in solving the competitive adsorption problem of moisture and organic matter by 13X molecular sieves. If the moisture content of the gas entering the adsorption tower is too high, the adsorption sites of the molecular sieve will be preferentially occupied by water molecules, causing its adsorption of organic matter to become almost ineffective. The synergistic process of the constructed "nitrogen preparation subsystem," "moisture and organic matter adsorption and regeneration subsystem," and "thermal management subsystem" is an innovative solution to this problem. The specific implementation path is as follows: After the ambient air is compressed by the air compressor, it passes through a centrifugal water separator and a three-stage filter group for preliminary water and dust removal. Then, it enters the first-stage heat exchanger cooled to about -7°C by the thermal management subsystem. This process can effectively condense and separate a large amount of moisture. The cooled and dried gas then enters the nitrogen generation membrane separation. This combined process can reduce the dew point of the gas entering the subsequent adsorption tank to an extremely low level of about -45°C.

[0024] This approach ensures that the gas flowing into the adsorption tower (filled with spherical 13X molecular sieves with a particle size of 3-5 mm) has extremely low water content, thereby fundamentally avoiding competitive adsorption of water. This allows the 13X molecular sieve to fully exert its core function of efficiently adsorbing residual organic matter, providing a key guarantee for ultimately achieving an ultra-low organic matter content of ≤0.5 ppm and an ultra-low dew point of ≤-73℃.

[0025] The control valve group includes a first intake solenoid valve 16, a second intake solenoid valve 26, a first exhaust solenoid valve 30, a second exhaust solenoid valve 24, a pressure equalization solenoid valve 25, and a regenerator hand valve 20. The regenerative electric heater 21 and the regenerative temperature sensor 28 are used to heat and monitor the temperature of the regenerative gas. By controlling the state of the valve group and the regeneration electric heater 21, the first adsorption tower 17 and the second adsorption tower 23 can alternately perform adsorption and thermal regeneration.

[0026] In this specific implementation, the system mainly consists of control valves, a regenerative electric heater, and parallel-connected working and regeneration dual adsorption towers (first adsorption tower 17 and second adsorption tower 23), which are connected by precision pipelines. The specific workflow is as follows: When the first adsorption tower 17 is in operation, the process gas enters the tower through the inlet and the first inlet solenoid valve 16 for adsorption and purification. The purified gas flows to the main outlet 19 through the first one-way valve 18. Simultaneously, a regeneration gas stream is split from the main outlet. This stream flows sequentially through the regenerator manual valve 20 and the regeneration electric heater 21, its temperature monitored by the regeneration temperature sensor 28, and is heated into regeneration gas. The regeneration gas is then led to the outlet pipeline of the second adsorption tower 23, which is in the regeneration stage, through the third one-way valve 22, where it back-purges the tower body to desorb accumulated moisture and organic matter. The regeneration gas carrying impurities is finally discharged to the atmosphere through the second exhaust solenoid valve 24 and the equalizing solenoid valve 25.

[0027] Conversely, when the second adsorption tower 23 switches to the working state, the gas flow path changes accordingly: the process gas enters the second adsorption tower through the second inlet solenoid valve 26, and after purification, it is output through the second one-way valve 27. The regeneration gas flow is drawn out from the main outlet, heated, and then enters the first adsorption tower 17 through the fourth one-way valve 29 for regeneration purging. The waste gas is finally discharged through the first exhaust solenoid valve 30 and the pressure equalization solenoid valve 25.

[0028] The adsorption tower is filled with 13X molecular sieves, which utilize their uniform nanoscale lattice structure to adsorb water. Spherical 13X molecular sieves with a particle size of 3-5 mm are selected, and a fixed-bed structure is used to reduce porosity and eliminate channeling hazards.

[0029] It should be noted that the nitrogen-generating membrane 12 will produce organic matter at high temperatures. Propane, butane, hexane, and many branched and cyclic hydrocarbons are removed using 13X molecular sieves.

[0030] In this embodiment, the gas supply subsystem includes a membrane pressure regulating proportional valve 31, a two-stage filter group 32, a second dew point sensor 33, an oxygen concentration sensor 34, an organic matter concentration sensor 35, a two-stage plate heat exchanger 36, a gas supply electric heating tank 37, a gas supply temperature sensor 38, a gas supply solenoid valve 39, an equipment compartment 40, and an exhaust solenoid valve 41, which are connected in sequence through pipelines. The outlet of the gas supply solenoid valve 39 is connected to the equipment compartment 40, and the equipment compartment 40 is also connected to the exhaust solenoid valve 41.

[0031] Specifically, the membrane inlet pressure regulating proportional valve 31 is used to control the membrane inlet pressure to 0.78 MPa, and the control system achieves this by controlling the opening degree of the proportional valve through PID control.

[0032] Among them, the gas supply electric heating tank 37 controls the gas supply temperature to 25℃.

[0033] In this embodiment, the thermal management subsystem includes: Refrigeration compressor 42; The second air-cooled radiator 43 is connected to the air outlet of the refrigeration compressor 42; Dryer filter 44 is connected to the second air-cooled radiator 43; The first branch includes a first refrigeration solenoid valve 45, a first expansion valve 46 and a first-stage heat exchanger 7 connected in sequence. The second branch includes a second refrigeration solenoid valve 48, a second expansion valve 49 and a secondary plate heat exchanger 36 connected in sequence. The gas-liquid separator 51 is used to combine the refrigerant after the first branch and the second branch, and is connected to the air inlet 15 of the refrigeration compressor 42.

[0034] Specifically, the thermal management subsystem is the core component ensuring precise temperature control across a wide temperature range, employing a highly efficient two-stage refrigeration cycle design. Specifically, this subsystem uses the refrigeration compressor 42 as its power source. The compressed, high-temperature, high-pressure refrigerant gas first flows through the second air-cooled radiator 43 for condensation and heat dissipation, and then passes through a dryer filter 44 to remove impurities and moisture. Subsequently, the refrigerant flow path is divided into two independently controllable branches: The first branch line connects sequentially to the first refrigeration solenoid valve 45 and the first expansion valve 46 via pipelines. After the refrigerant expands and throttles here, it enters the first-stage heat exchanger 7 to perform the main cooling exchange, and then passes through the first refrigerant check valve 47; The second branch is connected in sequence to the second refrigeration solenoid valve 48 and the second expansion valve 49 via pipelines. After being throttled, the refrigerant flows into the secondary plate heat exchanger 36 for auxiliary or secondary cooling, and then passes through the second refrigerant check valve 50; After the two branches merge, the gas-liquid mixed refrigerant is ensured to return to the refrigeration compressor inlet in a completely gaseous state via the gas-liquid separator 51, completing a full refrigeration cycle. This dual-branch architecture enables on-demand distribution and flexible adjustment of cooling capacity, improving the system's energy efficiency and stability in handling complex heat loads.

[0035] In this embodiment, the control and communication module 52, with a programmable logic controller as its core, is configured as follows: The system collects parameters from various sensors in the system, including pressure, temperature, dew point, organic matter concentration, and oxygen concentration, and uploads them to the human-machine interface and the host computer. Control the execution status of solenoid valves, fans, air compressor 2, refrigeration compressor 42, and proportional valves in each subsystem, and monitor the operating status of electrical components; A PID control algorithm is used to perform closed-loop control on the current or speed of the air compressor 2, the refrigeration compressor 42, and the proportional control valve.

[0036] The control and communication module 52 consists of a main controller, actuators, communication devices, and AC 220V and 380V power supplies. Based on the S7-1215C PLC controller, the PLC collects relevant sensor parameters such as pressure, temperature, dew point, organic matter concentration, and oxygen concentration, uploading them to the touchscreen and host computer. It also controls the operation of solenoid valves, fans, air compressors, refrigeration compressors, and proportional valves in each subsystem, and monitors the operating status of electrical components in the equipment. PID control is used to regulate the current and speed of the air compressor, refrigeration compressor, and proportional control valves.

[0037] In this embodiment, the control and communication module 52 can be further configured to perform the following coordinated control on the nitrogen preparation subsystem and the thermal management subsystem: Based on the feedback from the first-stage temperature sensor 8, the air temperature at the outlet of the first-stage heat exchanger 7 is controlled within a first target temperature range by controlling the first refrigeration solenoid valve 45 and the refrigeration compressor 42. Based on the feedback from the secondary temperature sensor 10, the temperature of the gas entering the nitrogen generation membrane 12 is controlled within the second target temperature range by controlling the electric heater in the electric heating gas storage tank 9. Based on the feedback from the inlet pressure sensor 11, the opening of the inlet pressure regulating proportional valve 31 is adjusted by PID control to control the inlet pressure of the nitrogen generation membrane 12 within the target pressure range, for example, the inlet pressure is controlled at 0.78MPa±0.1MPa.

[0038] In this embodiment, the control and communication module 52 can be further configured to perform the following coordinated control on the moisture and organic matter adsorption and regeneration subsystem, the gas supply subsystem, and the thermal management subsystem: The first adsorption tower 17 and the second adsorption tower 23 are controlled to switch between adsorption and regeneration states according to a preset cycle, and the pressure equalization solenoid valve 25, the air inlet solenoid valve and the exhaust solenoid valve are controlled in sequence during the switching process. Based on the feedback from the regeneration temperature sensor 28, the regeneration electric heater 21 is controlled to maintain the regeneration gas temperature at the target regeneration temperature. For example, the regeneration gas temperature is controlled to be around 150°C.

[0039] In this embodiment, the control and communication module 52 is configured as follows: Based on the feedback from the gas supply temperature sensor 38, the gas temperature supplied to the equipment compartment 40 is controlled at the target supply temperature by comprehensively controlling the second refrigeration solenoid valve 48, the refrigeration compressor 42, and the gas supply electric heating tank 37. For example, the gas temperature is controlled at around 25°C, and different control logics are used according to the ambient temperature range.

[0040] This invention provides a high-quality gas preparation system adaptable to combined conditions of full temperature range, high humidity, and high altitude, achieving gas preparation with an ultra-low dew point of -73℃, organic matter content <0.5ppm, gas supply temperature of ambient temperature ±2℃, and nitrogen purity of 99%. The system must meet the following control points: 1) Design a combination of a first air-cooled radiator and a centrifugal water separator on the exhaust pipe of the air compressor to cool the high-temperature and high-pressure air (temperature is ambient temperature +80℃, pressure is 0.8MPa) to ambient temperature +10℃; after cooling, the gas enters the centrifugal water separator. Since the air flow direction changes in the centrifugal water separator, more than 99% of the liquid water is removed by centrifugal force and discharged into the atmosphere, reducing the configuration requirements for downstream water adsorption capacity; 2) Design a primary heat exchanger that utilizes the evaporation of fluorinated refrigerant in the thermal management system to provide cooling capacity, thereby lowering the air temperature and causing the moisture in the air to condense into liquid water. This technology ensures that the air dew point temperature does not exceed 0°C. Using the primary temperature sensor T1 as the target point, the control and communication module controls the temperature of T1 to -7℃. The specific control logic is as follows: a) When the second air-cooled radiator, the first refrigeration solenoid valve, and the refrigeration compressor are started, the temperature value T2 will decrease; b) When the T1 temperature point is < -8.5℃, close the first refrigeration solenoid valve and reduce the operating frequency of the refrigeration compressor to reduce the refrigeration capacity; c) When temperature point T1 is greater than -5.5℃, open the first refrigeration solenoid valve and increase the operating frequency of the refrigeration compressor to increase the refrigeration capacity; d) Control the solenoid valve of the electric heating gas tank to open once every 3 minutes to remove internal water droplets and prevent liquid water from entering the next cycle; 3) Under the same nitrogen concentration and inlet working pressure, an increase in the inlet gas temperature of the nitrogen generator membrane will increase the nitrogen production. To maximize the efficiency of the nitrogen generator membrane, the inlet gas temperature is controlled at 48℃. An electrically heated gas storage tank is installed at the front end of the nitrogen generator membrane, with the secondary temperature sensor T2 as the target point. The specific method is as follows: a) When the secondary temperature sensor T2 < 46.5℃, turn on the electric heating; b) When the secondary temperature sensor T2 > 49.5℃, turn off the electric heating; 4) Under the same air intake conditions, increasing the inlet gas pressure of the nitrogen generator membrane is beneficial to increasing the purity of the produced nitrogen, which in turn is beneficial to decreasing the dew point of the produced nitrogen. In addition, when operating at high altitudes (0-5000m), the air compressor's exhaust volume decreases by 10% for every 1000m increase in altitude, causing a significant drop in the inlet gas pressure of the nitrogen generator membrane, which in turn leads to a decrease in nitrogen purity and an increase in dew point. To improve the nitrogen purity of the nitrogen produced by the nitrogen generator membrane to ≥99.5% and reduce the nitrogen dew point to ≤-45℃, a proportional valve for regulating the membrane pressure was installed. The control and communication module controls the inlet gas pressure of the nitrogen generator membrane to 0.78MPa. Using the measurement value of the inlet pressure sensor as the target point, the PID controller controls the opening of the proportional valve for regulating the membrane pressure in real time, precisely controlling the inlet pressure of the nitrogen generator membrane to 0.78MPa±0.1 MPa. The dew point of the nitrogen produced by the nitrogen generation membrane is monitored by the first dew point sensor, and the suitable value is ≤-45℃; 5) The moisture and organic matter adsorption and regeneration subsystem is used to achieve gas preparation with an ultra-low dew point of -73℃ and an organic matter content of <0.5ppm. The specific control method is as follows: I. Dual-Tower Operation and Regeneration Control Methods: a) The first adsorption tower is in operation, and the second adsorption tower is being regenerated: Open the first intake solenoid valve, the second exhaust solenoid valve, and the equalizing solenoid valve; close the second intake solenoid valve and the first exhaust solenoid valve. b) After working for 4 hours, switch to the second adsorption tower and regenerate the first adsorption tower; (1) The pressure equalization solenoid valve is closed for 3 minutes; (2) Open the second intake solenoid valve and the first exhaust solenoid valve, and close the first intake solenoid valve and the membrane pressure regulating proportional valve. (3) After 5 seconds, open the pressure equalization solenoid valve and close the first exhaust solenoid valve. II. Control of Regeneration Gas Volume and Regeneration Temperature The regeneration gas volume is controlled at 8% of the total intake gas volume, which can realize the regeneration of the adsorption tower and carry out the moisture inside the saturated adsorption tower. The regenerative electric heater is used to raise the temperature of the regeneration gas to 150℃, thereby improving the regeneration efficiency of the molecular sieve inside the adsorption tower. The control and communication module uses the secondary temperature sensor T4 as the target point to control the operation of the regenerative electric heater. The specific method is as follows: a) When the secondary temperature sensor T4 < 146℃, turn on the regenerative electric heating; b) When the secondary temperature sensor T2 > 154℃, the regenerative electric heating is turned off; 6) Gas supply temperature control; To adapt to an ambient temperature range of -40℃ to 55℃, the gas supply temperature can be controlled at 25℃; this invention technology has two energy transfer devices: fluorine compression refrigeration and gas supply electric heating tank; Using gas supply temperature sensor T3 as the target point, the control and communication module controls the temperature of T3 to 25℃. The specific control logic is as follows: a) Ambient temperature < 20℃ 1) When the T3 temperature point is <23.5℃, turn on the gas supply electric heater; 2) When the T3 temperature point is greater than 26.5℃, turn off the gas supply electric heater; b) 20℃≤Ambient temperature≤30℃ 1) When the second air-cooled radiator, the second refrigeration solenoid valve, and the refrigeration compressor are started, the temperature value T3 drops; 2) When the T3 temperature point is <23℃, close the second refrigeration solenoid valve, open the gas supply electric heater, and reduce the operating frequency of the refrigeration compressor to reduce the refrigeration capacity; 3) When the T3 temperature point is greater than 27℃, open the second refrigeration solenoid valve, close the gas supply electric heater, and increase the operating frequency of the refrigeration compressor to increase the refrigeration capacity; c) Ambient temperature > 30℃ 1) When the second air-cooled radiator, the second refrigeration solenoid valve, and the refrigeration compressor are started, the temperature value T3 drops; 2) When the T3 temperature point is <23.5℃, close the second refrigeration solenoid valve and reduce the operating frequency of the refrigeration compressor to reduce the refrigeration capacity; 3) When the T3 temperature point is greater than 26.5℃, open the second refrigeration solenoid valve and increase the operating frequency of the refrigeration compressor to increase the refrigeration capacity.

[0041] The key process control point data package for the high-quality gas preparation system, which is suitable for combined conditions of full temperature range, high humidity, and high altitude, is as follows:

[0042] The second aspect of the technical solution provides a method for environmental control using a high-quality gas preparation system under complex operating conditions as described in any of the above-mentioned claims, comprising the following steps: A preliminary nitrogen gas is produced by compressing, cooling, separating water, filtering, performing primary cooling, heating, and membrane separation on ambient air through a nitrogen preparation subsystem. Through a water and organic matter adsorption and regeneration subsystem, and utilizing a dual-tower adsorption and regeneration mechanism, the initial nitrogen gas is subjected to deep dehydration and organic matter removal. The gas after deep processing is regulated in terms of pressure, purity, dew point and temperature through the gas supply subsystem, and then delivered to the equipment compartment 40. The thermal management subsystem provides cooling capacity to the primary heat exchanger 7 of the nitrogen preparation subsystem and the secondary plate heat exchanger 36 of the gas supply subsystem. The control and communication module 52 collects sensor data from each node of the system in real time, and coordinates the actuators in each subsystem to achieve and maintain the gas preparation under preset conditions according to the preset control logic and target values.

[0043] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention. The scope of the invention is defined by the appended claims and their equivalents, all of which should be included within the scope of protection of the invention.

Claims

1. A high-quality gas preparation system for complex operating conditions, characterized in that, include: A nitrogen preparation subsystem is used to prepare and initially process nitrogen. A moisture and organic matter adsorption and regeneration subsystem, connected to the nitrogen preparation subsystem, is used for deep removal of moisture and organic matter from the gas. The gas supply subsystem, connected to the moisture and organic matter adsorption and regeneration subsystem, is used for final gas regulation and delivery to the equipment compartment (40). A thermal management subsystem is connected to the nitrogen preparation subsystem and the gas supply subsystem respectively, and is used to provide cooling to the system; The control and communication module (52) is connected to each subsystem through input and output wiring harnesses and is used to collect sensor data and control the operation of each actuator. The subsystems are connected by pipelines and work together to achieve the required gas environment control.

2. The high-quality gas preparation system under complex operating conditions according to claim 1, characterized in that, The nitrogen preparation subsystem includes an air intake filter (1), an air compressor (2), a one-way valve, a first air-cooled radiator (4), a centrifugal water separator (5), a three-stage filter group (6), a first-stage heat exchanger (7), a first-stage temperature sensor (8), an electrically heated gas storage tank (9), a second-stage temperature sensor (10), a membrane pre-pressure sensor (11), a nitrogen-generating membrane (12), and a first dew point sensor (13), all connected in sequence through pipelines. The bottom of the electrically heated gas storage tank (9) is connected to a drain solenoid valve (14), and the outlet of the drain solenoid valve (14) is connected to the atmosphere.

3. The high-quality gas preparation system under complex operating conditions according to claim 1, characterized in that, The moisture and organic matter adsorption and regeneration subsystem includes: The first adsorption tower (17) and the second adsorption tower (23) are filled with spherical 13X molecular sieves with a particle size of 3-5 mm. The control valve group includes a first intake solenoid valve (16), a second intake solenoid valve (26), a first exhaust solenoid valve (30), a second exhaust solenoid valve (24), a pressure equalization solenoid valve (25), and a regenerator hand valve (20). A regenerative electric heater (21) and a regenerative temperature sensor (28) are used to heat and monitor the temperature of the regenerative gas; By controlling the state of the valve group and the regeneration electric heater (21), the first adsorption tower (17) and the second adsorption tower (23) are alternately subjected to adsorption and thermal regeneration.

4. The high-quality gas preparation system under complex operating conditions according to claim 1, characterized in that, The gas supply subsystem includes a membrane pressure regulating proportional valve (31), a two-stage filter group (32), a second dew point sensor (33), an oxygen concentration sensor (34), an organic matter concentration sensor (35), a two-stage plate heat exchanger (36), a gas supply electric heating tank (37), a gas supply temperature sensor (38), and a gas supply solenoid valve (39) connected in sequence through pipelines. The outlet of the gas supply solenoid valve (39) is connected to the equipment compartment (40).

5. The high-quality gas preparation system under complex operating conditions according to claim 1, characterized in that, The thermal management subsystem includes: Refrigeration compressor (42); The second air-cooled radiator (43) is connected to the outlet of the refrigeration compressor (42); A dryer filter (44) is connected to the second air-cooled radiator (43); The first branch includes a first refrigeration solenoid valve (45), a first expansion valve (46), and a first-stage heat exchanger (7) connected in sequence. The second branch includes a second refrigeration solenoid valve (48), a second expansion valve (49), and a secondary plate heat exchanger (36) connected in sequence. A gas-liquid separator (51) is used to combine the refrigerant after the first branch and the second branch, and is connected to the air inlet (15) of the refrigeration compressor (42).

6. The high-quality gas preparation system under complex operating conditions according to claim 1, characterized in that, The control and communication module (52), with a programmable logic controller as its core, is configured as follows: The system collects parameters from various sensors in the system, including pressure, temperature, dew point, organic matter concentration, and oxygen concentration, and uploads them to the human-machine interface and the host computer. Control the execution status of solenoid valves, fans, air compressors (2), refrigeration compressors (42), and proportional valves in each subsystem, and monitor the operating status of electrical components; The PID control algorithm is used to perform closed-loop control on the current or speed of the air compressor (2), refrigeration compressor (42) and proportional regulating valve.

7. The high-quality gas preparation system under complex operating conditions according to claim 6, characterized in that, The control and communication module (52) can be further configured to perform the following coordinated control on the nitrogen preparation subsystem and the thermal management subsystem: Based on the feedback from the first-stage temperature sensor (8), the air temperature at the outlet of the first-stage heat exchanger (7) is controlled within the first target temperature range by controlling the first refrigeration solenoid valve (45) and the refrigeration compressor (42). Based on the feedback from the secondary temperature sensor (10), the temperature of the gas entering the nitrogen generation membrane (12) is controlled within the second target temperature range by controlling the electric heater in the electric heating gas storage tank (9). Based on the feedback from the inlet pressure sensor (11), the opening of the inlet pressure regulating proportional valve (31) is adjusted by PID control to control the inlet pressure of the nitrogen generation membrane (12) within the target pressure range.

8. The high-quality gas preparation system under complex operating conditions according to claim 7, characterized in that, The control and communication module (52) can be further configured to perform the following coordinated control on the moisture and organic matter adsorption and regeneration subsystem, the gas supply subsystem, and the thermal management subsystem: The first adsorption tower (17) and the second adsorption tower (23) are controlled to switch between adsorption and regeneration states according to a preset cycle, and the pressure equalization solenoid valve (25), the air inlet solenoid valve and the exhaust solenoid valve are controlled in sequence during the switching process. Based on the feedback from the regeneration temperature sensor (28), the regeneration electric heater (21) is controlled to maintain the regeneration gas temperature at the regeneration target temperature.

9. The high-quality gas preparation system under complex operating conditions according to claim 8, characterized in that, The control and communication module (52) is configured as follows: Based on the feedback from the gas supply temperature sensor (38), the gas temperature supplied to the equipment compartment (40) is controlled at the target gas supply temperature by comprehensively controlling the second refrigeration solenoid valve (48), the refrigeration compressor (42), and the gas supply electric heating tank (37).

10. A method for environmental control using a high-quality gas preparation system under complex operating conditions as described in any one of claims 1 to 9, characterized in that, Includes the following steps: A preliminary nitrogen gas is produced by compressing, cooling, separating, filtering, first-stage cooling, heating, and membrane separation of ambient air through a nitrogen preparation subsystem. Through a water and organic matter adsorption and regeneration subsystem, and utilizing a dual-tower adsorption and regeneration mechanism, the initial nitrogen gas is subjected to deep dehydration and organic matter removal. The gas after deep processing is regulated in terms of pressure, purity, dew point and temperature through the gas supply subsystem, and then delivered to the equipment compartment (40). The thermal management subsystem provides cooling capacity to the primary heat exchanger (7) of the nitrogen preparation subsystem and the secondary plate heat exchanger (36) of the gas supply subsystem. The control and communication module (52) collects sensor data from each node of the system in real time, and coordinates the actuators in each subsystem according to the preset control logic and target value to achieve and maintain the gas preparation under preset conditions.

Images