An air compressor control method and system

Abstract

This invention relates to the field of air compressor control technology, and particularly to an air compressor control method and system. If the user selects a single-unit rotation mode, the standby air compressor is started based on a first supply pressure, a preset first standby start pressure, and a preset first delay time. While the standby air compressor is running, the real-time supply pressure is acquired again to obtain a second supply pressure. The first air compressor is then shut down based on the second supply pressure and a preset first shutdown pressure. While the first air compressor is shut down, the cumulative running time of the first air compressor is acquired. An air compressor control mode is generated based on the cumulative running time, the preset rotation time, and the preset first standby shutdown pressure. The standby air compressor is started according to the pressure gradient and delay to avoid impact and reduce energy consumption and wear. The main air compressor is rotated evenly based on the cumulative running time to reduce excessive wear, extend the lifespan of the air compressor unit, and reduce maintenance costs.

Description

Technical Field

[0001] This invention relates to the field of air compressor control technology, and in particular to an air compressor control method and system. Background Technology

[0002] Existing air compressor control technology has many defects. It mostly adopts a single control logic, has poor reliability in mode switching, and lacks a strict mode verification mechanism, which is prone to false triggering. Pressure acquisition lacks standardized verification and is easily affected by sensor errors and instantaneous fluctuations, resulting in inaccurate equipment start-up and shutdown judgments, unstable connection between main and standby air compressors, easy to cause sudden drop in air supply pressure, excessive wear of individual equipment, high energy consumption, and difficulty in adapting to the stable operation requirements under various working conditions. Summary of the Invention

[0003] In order to overcome the shortcomings of the prior art, the purpose of this invention is to provide an air compressor control method and system.

[0004] The first aspect of this invention provides an air compressor control method, applied to an air compressor control system. The air compressor control system includes an air compressor unit, which includes a standby air compressor and a first air compressor. The air compressor control method includes: acquiring a user-selected mode and analyzing the user-selected mode; if the user-selected mode is a single-unit rotation mode, acquiring the real-time air supply pressure to obtain a first air supply pressure; starting the standby air compressor according to the first air supply pressure, a preset first standby start pressure, and a preset first delay time; acquiring the real-time air supply pressure again to obtain a second air supply pressure while the standby air compressor is running; shutting down the first air compressor according to the second air supply pressure and a preset first shutdown pressure; and acquiring the cumulative running time of the first air compressor while it is shut down.

[0005] The air compressor control mode is generated based on the cumulative running time, the preset rotation time, and the preset first standby shutdown pressure.

[0006] Further, the step of starting the standby air compressor according to the first air supply pressure, the preset first standby start pressure, and the preset first delay time includes: determining whether the first air supply pressure is less than or equal to the preset first start pressure; if the first air supply pressure is less than or equal to the first start pressure, then starting the first air compressor; in the first air compressor start state, acquiring the real-time air supply pressure again to obtain the third air supply pressure; determining whether the third air supply pressure is less than or equal to the first standby start pressure; if the third air supply pressure is less than or equal to the first standby start pressure, then starting the standby air compressor according to the first delay time.

[0007] Further, the step of shutting down the first air compressor based on the second air supply pressure and the preset first shutdown pressure includes: determining whether the second air supply pressure is greater than or equal to the preset second standby shutdown pressure; if the second air supply pressure is greater than or equal to the second standby shutdown pressure, then shutting down the standby air compressor; in the standby air compressor shutdown state, acquiring the real-time air supply pressure again to obtain the fourth air supply pressure; determining whether the fourth air supply pressure is greater than or equal to the first shutdown pressure; if the fourth air supply pressure is greater than or equal to the first shutdown pressure, then shutting down the first air compressor.

[0008] Furthermore, the air compressor unit also includes a second air compressor. The step of generating an air compressor control mode based on the cumulative running time, a preset rotation time, and a preset first standby shutdown pressure includes: starting the second air compressor based on the cumulative running time, the rotation time, and a preset second starting pressure; starting a standby air compressor based on a preset second delay time and a preset second standby starting pressure while the second air compressor is running; shutting down the standby air compressor based on the first standby shutdown pressure while the standby air compressor is running; and shutting down the second air compressor based on the preset second shutdown pressure while the standby air compressor is shut down, thereby obtaining the air compressor control mode.

[0009] Further, the step of starting the standby air compressor according to the preset second delay time and the preset second standby start pressure includes: acquiring the real-time air supply pressure again to obtain the fifth air supply pressure; determining whether the fifth air supply pressure is less than or equal to the second standby start pressure; if the fifth air supply pressure is less than or equal to the second standby start pressure, then starting the standby air compressor according to the second delay time.

[0010] Further, the step of shutting down the standby air compressor according to the first standby shutdown pressure includes: obtaining the real-time air supply pressure again to obtain the sixth air supply pressure; determining whether the sixth air supply pressure is greater than or equal to the first standby shutdown pressure; and shutting down the standby air compressor if the sixth air supply pressure is greater than or equal to the first standby shutdown pressure.

[0011] Furthermore, the step of shutting down the second air compressor according to the preset second shutdown pressure includes: acquiring the real-time air supply pressure again to obtain the seventh air supply pressure; determining whether the seventh air supply pressure is greater than or equal to the second shutdown pressure; and shutting down the second air compressor if the seventh air supply pressure is greater than or equal to the second shutdown pressure.

[0012] Further, the step of starting the second air compressor based on the cumulative running time, the rotation time, and the preset second starting pressure includes: determining whether the cumulative running time is greater than or equal to the rotation time; if the cumulative running time is greater than or equal to the rotation time, then obtaining the real-time air supply pressure again to obtain the eighth air supply pressure; determining whether the eighth air supply pressure is less than or equal to the second starting pressure; if the eighth air supply pressure is less than or equal to the second starting pressure, then starting the second air compressor.

[0013] Furthermore, the step of analyzing the user selection mode further includes: if the user selection mode is a sequential operation mode, then obtaining the real-time air supply pressure to obtain the ninth air supply pressure; starting the air compressor unit according to the preset start-up delay time, the ninth air supply pressure, and the sequential operation mode; while the air compressor unit is running, obtaining the real-time air supply pressure to obtain the tenth air supply pressure; determining whether the tenth air supply pressure is greater than or equal to the preset third shutdown pressure; if the tenth air supply pressure is greater than or equal to the third shutdown pressure, then shutting down the air compressor unit according to the preset shutdown delay time and the preset shutdown delay mode.

[0014] Furthermore, an air compressor control system executes an air compressor control method as described above, including a microcontroller and an air compressor unit electrically connected to the microcontroller; the air compressor unit includes a first air compressor, a second air compressor, and a standby air compressor.

[0015] In the technical solution of this invention, after the system passes through the microcontroller verification mode, it standardizes and collects the first air supply pressure to provide accurate basis for subsequent control; it starts the standby air compressor by combining the pressure gradient and the first delay time to avoid the impact of power grid equipment, filter pressure fluctuations, and reduce energy consumption and mechanical wear; after the standby air compressor starts, it relies on the second air supply pressure and the first shutdown pressure to achieve a smooth connection between the main air compressor and the standby air compressor, preventing sudden pressure drops and ensuring continuous production; after the first air compressor shuts down, it generates a control mode by combining the cumulative running time and the rotation time to achieve balanced rotation of the two main air compressors, avoiding excessive wear of a single unit, standardizing the process, improving the system's automation, standardization and versatility, extending the life of the air compressor unit and reducing operation and maintenance costs. Attached Figure Description

[0016] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0017] Figure 1 This is a first flowchart of an air compressor control method provided in an embodiment of the present invention;

[0018] Figure 2 This is a second flowchart of an air compressor control method provided in an embodiment of the present invention;

[0019] Figure 3 This is a third flowchart of an air compressor control method provided in an embodiment of the present invention;

[0020] Figure 4 This is a fourth flowchart of an air compressor control method provided in an embodiment of the present invention;

[0021] Figure 5A fifth flowchart of an air compressor control method provided in an embodiment of the present invention;

[0022] Figure 6 The sixth flowchart of an air compressor control method provided in an embodiment of the present invention;

[0023] Figure 7 A seventh flowchart of an air compressor control method provided in an embodiment of the present invention;

[0024] Figure 8 The eighth flowchart of an air compressor control method provided in an embodiment of the present invention;

[0025] Figure 9 A ninth flowchart of an air compressor control method provided in an embodiment of the present invention;

[0026] Figure 10 This is a schematic diagram of the structure of an air compressor control system provided in an embodiment of the present invention.

[0027] Figure Labels

[0028] 1-Microcontroller; 2-Air compressor unit; 21-First air compressor; 22-Second air compressor; 23-Standby air compressor. Detailed Implementation

[0029] The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" or "having" and any variations thereof are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0030] An air compressor control method is applied to an air compressor control system. The air compressor control system includes an air compressor unit, which includes a standby air compressor and a first air compressor. For ease of understanding, the specific process of the embodiment of the present invention is described below. Please refer to [link / reference]. Figure 1 One embodiment of an air compressor control method according to the present invention includes:

[0031] 101. Obtain the user selection pattern and analyze it;

[0032] 102. If the user selects the single-unit rotation mode, the real-time gas supply pressure is obtained to obtain the first gas supply pressure;

[0033] In this embodiment, the single-unit rotation mode means that the system operates only one main air compressor at a time, while the other main air compressor is in standby mode. When the operating main air compressor reaches a preset cumulative running time, it automatically switches to the other main air compressor to take over the air supply task. The two main air compressors work alternately and are used in a balanced manner. The standby air compressor only participates in supplementing the air supply when the air supply pressure is insufficient. This achieves balanced wear of the equipment, extends its service life, and ensures a stable and continuous air supply. This is an air compressor operation control mode. After the user selects the mode through the microcontroller touch screen, the system will assign the mode pointer. The data is stored in a register, and the microcontroller reads and verifies it in real time. Subsequent pressure acquisition and equipment control processes are only initiated when the "single-unit rotation mode" is confirmed. In single-unit rotation mode, the real-time supply pressure is obtained to determine the first supply pressure. This provides the initial pressure judgment basis for all subsequent equipment start-up and shutdown operations. The first supply pressure is acquired by a pressure sensor, and the average value is taken. It undergoes triple verification of range, fluctuation, and consistency to ensure the data is accurate and valid (avoiding misjudgments caused by sensor errors or instantaneous pressure fluctuations). The acquisition frequency is 100ms / time, balancing real-time performance and system load.

[0034] 103. Start the standby air compressor according to the first air supply pressure, the preset first standby start pressure, and the preset first delay time;

[0035] In this embodiment, the standby air compressor is started by combining the first supply pressure, the first backup start pressure, and the first delay time. The timing of replenishment is accurately determined by the pressure gradient to avoid invalid start-up. The soft start mode avoids the impact of the power grid and equipment. The delay design filters the instantaneous pressure fluctuations to prevent frequent start-up and shutdown of the standby air compressor, reduce mechanical wear, and save energy. At the same time, it ensures that the supply pressure rises steadily to avoid misjudgment, support the stability of downstream production, and improve the system's automation and versatility.

[0036] 104. With the standby air compressor running, obtain the real-time air supply pressure again to obtain the second air supply pressure;

[0037] 105. Shut down the first air compressor according to the second air supply pressure and the preset first shutdown pressure;

[0038] In this embodiment, when the standby air compressor is running, the second air supply pressure is obtained, and the first air compressor is shut down in combination with the preset first shutdown pressure, so as to achieve a smooth connection between the main and standby air compressors. This can not only ensure stable air supply pressure and avoid a sudden pressure drop caused by shutting down the first air compressor (main air compressor), but also accurately control the shutdown timing of the main air compressor, reduce ineffective energy consumption and equipment impact, extend the life of the air compressor unit, improve the level of system automation management and control, and ensure the continuity of downstream production.

[0039] 106. With the first air compressor in the off state, obtain the cumulative running time of the first air compressor;

[0040] 107. Generate an air compressor control mode based on the cumulative running time, the preset rotation time, and the preset first standby shutdown pressure;

[0041] In this embodiment, after the first air compressor is shut down, its cumulative running time is obtained. Combined with the preset rotation time and the first standby shutdown pressure, an air compressor control mode is generated. This mode can accurately count the operating load of the first air compressor (main air compressor), achieve balanced rotation of the two main air compressors (first air compressor and second air compressor), avoid excessive wear of a single main air compressor, standardize the rotation process, reduce ineffective energy consumption, ensure the automated and stable operation of the system, and improve the standardization of management and equipment durability.

[0042] In this embodiment, after the system passes the microcontroller verification mode, it standardizes and collects the first air supply pressure to provide accurate data for subsequent control. It then starts the backup air compressor based on the pressure gradient and the first delay time, avoiding grid equipment impacts, filtering pressure fluctuations, and reducing energy consumption and mechanical wear. After the backup air compressor starts, it relies on the second air supply pressure and the first shutdown pressure to achieve a smooth connection between the main air compressor and the backup air compressor, preventing sudden pressure drops and ensuring continuous production. After the first air compressor shuts down, it generates a control mode based on the cumulative running time and rotation time, achieving balanced rotation of the two main air compressors, avoiding excessive wear on a single unit, standardizing processes, improving system automation, standardization, and versatility, extending the lifespan of the air compressor unit, and reducing maintenance costs.

[0043] Please see Figure 2 A second embodiment of an air compressor control method according to the present invention specifically includes:

[0044] 201. Determine whether the first gas supply pressure is less than or equal to the preset first start-up pressure;

[0045] 202. If the first air supply pressure is less than or equal to the first starting pressure, then start the first air compressor;

[0046] In this embodiment, the first air supply pressure is the real-time air supply main pipeline pressure collected by the system (the average value is collected by a pressure sensor to eliminate single-point fault errors), and the collection frequency is 100ms / time to ensure data real-time performance; the first start-up pressure is the user-preset "minimum air supply guarantee threshold" (e.g., 0.6MPa). If it is lower than this value, it means that the pipeline pressure can no longer meet the basic production requirements, and the first air compressor (main air compressor) must be started to replenish air; the first air compressor starts in a soft start mode (the frequency converter controls the motor to linearly increase from 0Hz to the rated frequency), and the starting current is controlled at 1.1 to 1.2 times the rated current to avoid damage to the power grid or equipment from the current surge of direct start-up;

[0047] 203. With the first air compressor running, obtain the real-time air supply pressure again to obtain the third air supply pressure;

[0048] In this embodiment, the criteria for determining the start-up status of the first air compressor are that the output frequency of the first air compressor inverter reaches the rated frequency, the motor speed is stable, and the exhaust pressure begins to rise (lasting for more than 3 seconds); the timing for collecting the third air supply pressure is "after the first air compressor (main air compressor) has been running stably for 5 to 10 seconds", reserving a buffer time for pressure recovery to avoid false triggering caused by judging immediately after startup;

[0049] 204. Determine whether the third gas supply pressure is less than or equal to the first standby start-up pressure;

[0050] 205. If the third air supply pressure is less than or equal to the first standby start-up pressure, the standby air compressor shall be started according to the first delay time.

[0051] In this embodiment, the first standby start-up pressure is a "replenishment threshold" (e.g., 0.55 MPa) lower than the first start-up pressure. This requires the first standby start-up pressure to be less than the first start-up pressure (the difference is typically 0.03 MPa to 0.05 MPa) to create a pressure gradient and ensure the effectiveness of the tiered logic. If the third supply pressure is less than or equal to the first standby start-up pressure, it indicates that the maximum discharge capacity of the first air compressor (main air compressor) cannot meet the air demand, and the pipeline pressure continues to drop, necessitating the activation of the standby air compressor to replenish the discharge capacity. The first delay time (e.g., 3s to 10s) is the buffer time between "triggering replenishment" and "activating the standby compressor." Its core function is to filter instantaneous pressure fluctuations (e.g., a sudden pressure drop caused by a brief period of high-flow-rate air consumption at the air consumption end) and prevent frequent start-ups and shutdowns of the standby air compressor.

[0052] In this embodiment, relying on dual-layer pressure gradient judgment and start-up status verification, the start-up timing of the standby air compressor is precisely controlled, reducing ineffective energy consumption and improving the energy utilization efficiency of the gas supply system. Both the main and standby air compressors adopt soft-start mode, controlling the start-up current within the rated range to avoid damage to the power grid and equipment caused by high current surges. At the same time, the first delay time effectively filters instantaneous pressure fluctuations, preventing frequent start-ups and shutdowns of the standby unit, reducing mechanical wear and tear on the equipment, and extending the overall service life of the unit. By reserving a pressure recovery buffer time and clarifying the equipment start-up status judgment criteria, control errors caused by pressure misjudgment are effectively avoided, allowing the gas supply pressure to recover smoothly, reducing pressure fluctuation amplitude, and ensuring the stable operation of downstream production equipment. The entire start-up logic is automatically and standardizedly executed by the system, reducing human intervention errors, simplifying operation and maintenance, reducing labor costs, and the parameters can be preset as needed to adapt to different industrial gas conditions, improving the system's versatility and fault tolerance.

[0053] Please see Figure 3The third embodiment of an air compressor control method according to the present invention specifically includes:

[0054] 301. Determine whether the second gas supply pressure is greater than or equal to the preset second standby shutdown pressure;

[0055] 302. If the second air supply pressure is greater than or equal to the second standby shutdown pressure, then shut down the standby air compressor.

[0056] In this embodiment, the second air supply pressure is the main air supply line pressure collected in real time by the system (same as the start-up phase, the average value is collected by the pressure sensor to eliminate single-point errors, and the collection frequency is 100ms / time); the second standby shutdown pressure is the standby air compressor replenishment exit threshold preset by the user, which needs to match the first standby start-up pressure in the start-up phase (usually slightly higher than the first standby start-up pressure by 0.35MPa~0.05MPa, such as 0.58MPa~0.60MPa) to ensure that the standby air compressor "replenishment trigger is reasonable and exits in a timely manner"; the standby air compressor shutdown adopts a soft shutdown mode, and the frequency converter controls the motor to linearly reduce from the rated frequency to 0Hz to avoid a sudden decrease in exhaust volume caused by instantaneous shutdown and prevent secondary fluctuations in pipeline pressure;

[0057] 303. With the standby air compressor shut down, obtain the real-time air supply pressure again to obtain the fourth air supply pressure;

[0058] In this embodiment, the criteria for determining the standby air compressor shutdown state are that the output frequency of the standby air compressor inverter drops to 0Hz, the motor completely stops rotating, and the exhaust valve is closed (for more than 3 seconds); the fourth air supply pressure is collected 5 to 10 seconds after the standby air compressor is completely shut down, allowing for a buffer time for the pipeline pressure to stabilize, avoiding a second determination immediately after the standby air compressor is shut down and the pressure has not yet stabilized, thus ensuring the validity of the data;

[0059] 304. Determine whether the fourth gas supply pressure is greater than or equal to the first shutdown pressure;

[0060] 305. If the fourth air supply pressure is greater than or equal to the first shutdown pressure, then the first air compressor shall be shut down.

[0061] In this embodiment, the first shutdown pressure is the user-preset operating exit threshold of the first air compressor (main air compressor), which needs to match the first start-up pressure of the start-up process (usually slightly higher than the first start-up pressure by 0.03MPa~0.05MPa, such as 0.63MPa~0.65MPa), forming a pressure hysteresis of "low start-up threshold and high shutdown threshold" to avoid frequent start-up and shutdown of the equipment caused by small pressure fluctuations near the threshold; the first air compressor also adopts a soft shutdown mode, and the pipeline pressure is monitored in real time during the shutdown process. If the pressure drops sharply (below the first start-up pressure), the shutdown process is immediately terminated, and the main air compressor is restored to normal operation to ensure uninterrupted air supply;

[0062] In this embodiment, a progressive logic is followed, with the standby air compressor stopping first and the main air compressor stopping last. A soft shutdown mode is used to linearly reduce the exhaust volume, avoiding sudden pressure drops in the pipeline caused by instantaneous shutdown. Simultaneously, a pressure stabilization buffer time is reserved to reduce supply pressure fluctuations and ensure stable operation of downstream production equipment. The shutdown and startup thresholds are precisely matched to form a reasonable pressure hysteresis, effectively avoiding frequent equipment start-ups and shutdowns caused by pressure fluctuations near the thresholds, reducing mechanical and electrical shocks, and extending the overall service life of the air compressor's core components and the air supply network. The actual shutdown state of the equipment is used as a prerequisite for subsequent judgments, combined with real-time pressure data acquisition and verification, to achieve precise control of shutdown timing, avoiding ineffective shutdowns and idle operation, and improving energy efficiency. The entire process is automated and standardized, reducing human intervention errors. A pressure drop tolerance mechanism is included, and parameters can be preset as needed to adapt to various industrial conditions, while simplifying operation and maintenance and reducing labor costs.

[0063] Please see Figure 4 The fourth embodiment of an air compressor control method according to the present invention specifically includes:

[0064] 401. Start the second air compressor according to the cumulative running time, rotation time, and preset second start pressure;

[0065] In this embodiment, by combining the cumulative running time, rotation time and second starting pressure to start the second air compressor, the load of the two main air compressors can be balanced, avoiding long-term high-load operation of a single unit, extending the overall life of the air compressor unit. At the same time, relying on standardized pressure judgment, the compressor is started only when the pipeline pressure is insufficient, avoiding overpressure risk and ineffective energy consumption, ensuring smooth rotation and stable air supply, and improving the system automation level.

[0066] 402. When the second air compressor is in the start state, start the standby air compressor according to the preset second delay time and the preset second standby start pressure;

[0067] In this embodiment, the backup air compressor is started by combining the second delay time and the second backup start pressure. The replenishment demand is accurately determined by the pressure gradient. The delay design effectively filters instantaneous fluctuations and avoids frequent start-stop of the backup air compressor. This not only ensures timely replenishment and pressure stabilization when the second air compressor alone is insufficient, but also reduces equipment wear and ineffective energy consumption, and improves the economic efficiency of system operation.

[0068] 403. With the standby air compressor in the start-up state, shut down the standby air compressor according to the first standby shutdown pressure;

[0069] In this embodiment, when the standby air compressor is started to replenish the supply, the standby air compressor is precisely shut down according to the first standby shutdown pressure, accurately defining the replenishment completion node and improving energy efficiency; at the same time, a pressure hysteresis is formed to avoid frequent start-stop of the standby air compressor, reduce equipment impact, ensure stable air supply pressure, and allow the system to return to the efficient operation mode of a single main unit.

[0070] 404. With the standby air compressor in the off state, the second air compressor is shut down according to the preset second shutdown pressure to obtain the air compressor control mode;

[0071] In this embodiment, with the standby air compressor already shut down, the second air compressor is precisely shut down according to the second shutdown pressure, forming a pressure hysteresis, avoiding frequent start-ups and shutdowns of the equipment, extending the service life of the equipment, avoiding ineffective energy consumption, preventing overpressure risks, completing the rotation cycle, generating a new control mode, and ensuring the stable and automated operation of the system.

[0072] In this embodiment, the second air compressor is started by combining the cumulative running time, rotation time, and second start-up pressure to achieve load balancing between the two main air compressors, avoiding long-term high-load operation of a single unit and extending the overall lifespan of the air compressor unit. The standby air compressor is started based on pressure gradient and delay design to filter instantaneous pressure fluctuations, avoid frequent start-ups and shutdowns of the standby air compressor, ensure timely replenishment to maintain pressure stability, and reduce equipment wear and ineffective energy consumption. The standby air compressor is precisely shut down according to the first standby shutdown pressure, defining the replenishment node and allowing the system to return to an efficient single-unit mode. Finally, the second air compressor is shut down according to the second shutdown pressure, creating a pressure hysteresis, preventing overpressure, completing the rotation cycle, and generating an air compressor control mode. This process comprehensively improves the system's automation and standardization levels, ensures stable air supply, and balances operational economy and equipment durability.

[0073] Please see Figure 5 The fifth embodiment of an air compressor control method according to the present invention specifically includes:

[0074] 501. Obtain the real-time gas supply pressure again to obtain the fifth gas supply pressure;

[0075] In this embodiment, the acquisition standard for the fifth air supply pressure is the same as that for the previous pressure acquisition: the pressure of the main air supply line is acquired by a pressure sensor and the average value is taken to eliminate single-point fault errors. The acquisition frequency is 100ms / time, taking into account both real-time performance and data accuracy. The acquisition timing is strictly limited to "after the second air compressor has started stably" (the inverter output frequency reaches the rated value, the motor speed is stable, and the exhaust pressure rises for more than 3 seconds), and the acquisition should be carried out 5s~10s after the second air compressor has been running alone to allow for pressure recovery buffer time and avoid false triggering caused by judging the pressure before the new main unit has started and the pressure has stabilized.

[0076] 502. Determine whether the fifth gas supply pressure is less than or equal to the second standby start-up pressure;

[0077] 503. If the fifth air supply pressure is less than or equal to the second standby start-up pressure, then the standby air compressor shall be started according to the second delay time;

[0078] In this embodiment, the second standby start-up pressure is a user-preset replenishment threshold, with a value consistent with the first standby start-up pressure (e.g., 0.55 MPa), and must satisfy the condition that "second standby start-up pressure < second start-up pressure (e.g., 0.6 MPa)", with the difference controlled between 0.03 MPa and 0.05 MPa, forming a gradient match with the start-up pressure of the second air compressor to ensure the effectiveness of the graded replenishment logic; if the fifth air supply pressure is ≤ the second standby start-up pressure, it indicates that the exhaust volume of the second air compressor cannot meet the current air load, and the pipeline pressure is still continuously decreasing. The standby air compressor must be started to replenish the exhaust volume to prevent further pressure reduction and impact on production.

[0079] In this embodiment, the same pressure acquisition standard as before is adopted and the average value is taken. Combined with strictly limited acquisition timing and a pressure recovery buffer period of 5-10 seconds, single-point fault errors are effectively eliminated, and misjudgments caused by unstable pressure in the initial stage of startup of the new host (second air compressor) are avoided, ensuring the accuracy of the supplementary supply trigger determination. By setting a reasonable pressure gradient threshold, the standby air compressor is only triggered to supplement the supply when the second air compressor alone cannot meet the load and the pressure continues to drop, realizing on-demand startup. Relying on the buffering effect of the second delay time, instantaneous pressure fluctuations are filtered to avoid frequent start-stop of the standby air compressor. Combined with the soft start mode, the impact on equipment and power grid is reduced, which not only extends the service life of the standby air compressor, but also ensures the stability of the supply pressure after rotation. At the same time, the timing of supplementary supply is accurately controlled, ineffective energy consumption is reduced, and the stability and economy of system operation are improved.

[0080] Please see Figure 6 The sixth embodiment of an air compressor control method according to the present invention specifically includes:

[0081] 601. Obtain the real-time gas supply pressure again to obtain the sixth gas supply pressure;

[0082] In this embodiment, the acquisition of the sixth air supply pressure continues to follow a unified standard. The pressure sensor collects the pressure of the main air supply line and takes the average value to eliminate single-point detection errors. The acquisition frequency is maintained at 100ms / time to ensure real-time response to pressure rise. The timing of the sixth air supply pressure acquisition is strictly limited to "the standby air compressor is in a stable operating state", and the judgment is only made after the second air compressor and the standby air compressor have been supplying air for a certain period of time to avoid malfunctions caused by instantaneous pressure rise.

[0083] 602. Determine whether the sixth gas supply pressure is greater than or equal to the first standby shutdown pressure;

[0084] 603. If the sixth air supply pressure is greater than or equal to the first standby shutdown pressure, then shut down the standby air compressor.

[0085] In this embodiment, the first standby shutdown pressure is the system-level standby machine exit threshold, which is consistent with the standby air compressor exit standard before rotation (e.g., 0.58MPa~0.60MPa), and strictly follows the parameter matching principle of "first standby shutdown pressure > second standby start pressure", with the difference controlled within 0.03MPa~0.05MPa to form a reasonable pressure hysteresis. When the sixth air supply pressure is ≥ the first standby shutdown pressure, it indicates that the exhaust volume of the second air compressor and the standby air compressor has exceeded the current air load, the pipeline pressure has been restored to the safe margin range, the standby air compressor's replenishment is completed, and it meets the exit conditions.

[0086] In this embodiment, the standby air compressor is shut down through standardized pressure acquisition and precise threshold determination, providing crucial support for the stable air supply system during the second air compressor's operation. The system maintains a unified pressure acquisition standard, using average values ​​to eliminate single-point errors. A acquisition frequency of 100ms / time ensures real-time pressure response, while limiting acquisition timing and reserving time for air supply determination effectively avoids erroneous shutdowns caused by instantaneous pressure rises, ensuring accurate and reliable determination results. A system-wide unified first standby shutdown pressure is used, forming a reasonable pressure hysteresis with the second standby start-up pressure, precisely defining the critical state for standby compressor replenishment. The standby compressor is shut down only when the pressure reaches a safe margin, avoiding ineffective no-load operation and improving energy efficiency. The pressure hysteresis design prevents frequent start-stops of the standby air compressor near the threshold, reducing mechanical and electrical shocks to the equipment and extending the service life of the standby air compressor's core components. Simultaneously, the timely withdrawal of the standby air compressor allows the system to return to a single-unit high-efficiency operation mode, ensuring stable pipeline pressure and providing stable air supply support for downstream production.

[0087] Please see Figure 7 The seventh embodiment of an air compressor control method according to the present invention specifically includes:

[0088] 701. Obtain the real-time gas supply pressure again to obtain the seventh gas supply pressure;

[0089] In this embodiment, the acquisition of the seventh air supply pressure continues the unified system standard. The pressure sensor collects the main pipeline pressure and takes the average value to eliminate single-point fault errors. The acquisition frequency is 100ms / time to ensure a rapid response to pressure rises. The acquisition timing strictly follows the premise that "the standby air compressor is in a shut-down state". This means that the system is in "single-machine operation" mode at this time, and the change of the seventh air supply pressure is entirely determined by the exhaust volume of the second air compressor and the current air consumption.

[0090] 702. Determine whether the seventh gas supply pressure is greater than or equal to the second shutdown pressure;

[0091] 703. If the seventh air supply pressure is greater than or equal to the second shutdown pressure, then the second air compressor shall be shut down.

[0092] In this embodiment, the second shutdown pressure is the highest pressure protection threshold set for the second air compressor (e.g., 0.63MPa~0.65MPa). This threshold strictly follows the principle of "second shutdown pressure > second start-up pressure" (difference 0.03MPa~0.05MPa) to ensure that the second air compressor will not frequently start and stop due to small pressure fluctuations near the start-up point. When the seventh air supply pressure is ≥ the second shutdown pressure, it indicates that the current pipeline pressure is sufficient to meet production needs and has a surplus. Continuing to operate the second air compressor will lead to overpressure risk or ineffective no-load energy consumption, thus meeting the sufficient shutdown conditions.

[0093] In this embodiment, the steady-state shutdown of the second air compressor is achieved through standardized pressure acquisition and precise threshold determination. As the final step in the air compressor unit rotation cycle, this provides multiple safeguards for the operation of the gas supply system. By continuing the system's unified pressure acquisition standard, averaging is used to eliminate errors, and high-frequency acquisition is implemented. At the same time, the prerequisites for single-unit operation acquisition after the standby air compressor is shut down are strictly limited, ensuring that the pressure determination data is accurate and effective, and can respond quickly to pressure changes. By setting a dedicated maximum pressure protection threshold higher than the second start-up pressure, a reasonable pressure hysteresis is formed, which prevents the second air compressor from frequently starting and stopping due to small pressure fluctuations, reducing equipment start-up and shutdown impacts and electrical losses, and extending the service life of core components. The equipment is shut down only when the pipeline pressure reaches a surplus state, which avoids the safety risks of overpressure operation and prevents the air compressor from running unloaded, maximizing the reduction of energy consumption, improving the energy utilization efficiency of the gas supply system, achieving a smooth shutdown of the second air compressor, completing the rotation cycle, and the system can automatically reset to standby mode, improving the overall level of automation.

[0094] Please see Figure 8 The eighth embodiment of an air compressor control method according to the present invention specifically includes:

[0095] 801. Determine whether the cumulative running time is greater than or equal to the rotation time;

[0096] 802. If the cumulative running time is greater than or equal to the rotation time, the real-time gas supply pressure is obtained again to obtain the eighth gas supply pressure;

[0097] In this embodiment, the cumulative running time is the actual running time of the first air compressor from this start to the present. The rotation time is the host balanced operation threshold preset by the user (set according to equipment wear standards and production air consumption conditions). Its core purpose is to achieve load balance between the two main air compressors, avoid long-term high-load operation of a single host, and extend the overall service life of the air compressor unit. This step is a "necessary condition" for rotation. Only when the time limit is met can the basic authority to start the second air compressor be obtained.

[0098] 803. Determine whether the eighth gas supply pressure is less than or equal to the second starting pressure;

[0099] 804. If the eighth air supply pressure is less than or equal to the second starting pressure, then start the second air compressor;

[0100] In this embodiment, if the cumulative running time reaches the target, the real-time air supply pressure is collected again to obtain the eighth air supply pressure. The collection of the eighth air supply pressure continues the unified standard, with the pressure sensor collecting the pressure of the main air supply line and taking the average value to eliminate single-point fault errors. The collection frequency is maintained at 100ms / time to balance the real-time performance of the pressure response and the accuracy of the data. The collection timing implies the premise that "the first air compressor is already in the shutdown state" to ensure that the eighth air supply pressure can truly reflect the actual air pressure of the current pipeline.

[0101] In this embodiment, cumulative running time is used as a necessary condition to achieve load balancing between the two main air compressors (the first and second air compressors), avoiding long-term high-load operation of a single unit, effectively extending the overall service life of the air compressor unit, and reducing equipment depreciation and maintenance costs. A standardized pressure acquisition method is adopted, with high-frequency acquisition to ensure real-time performance. Combined with the timing of acquisition after the first air compressor is shut down, the eighth air supply pressure is ensured to be accurate and reliable, providing a precise basis for start-up determination. The second air compressor is only started when the pipeline pressure is insufficient, avoiding the risk of pipeline overpressure caused by blind start-up, avoiding ineffective no-load energy consumption, improving energy utilization efficiency, ensuring smooth main unit rotation, laying the foundation for subsequent backup air compressor replenishment and air compressor unit shutdown, improving rotation, enhancing the system's automation and standardization level, ensuring stable air supply, and not affecting downstream production.

[0102] Please see Figure 9 The ninth embodiment of an air compressor control method according to the present invention specifically includes:

[0103] 901. If the user selects the sequential operation mode, the real-time gas supply pressure is obtained to obtain the ninth gas supply pressure;

[0104] In this embodiment, the sequential operation mode is a control mode designed for the operation of multiple air compressor units. The system first determines the current gas load based on the real-time collected ninth gas supply pressure, and then starts the air compressor units one by one according to the preset fixed sequence, combined with the start-up delay time, to avoid the simultaneous start-up of multiple devices impacting the power grid or causing pipeline overpressure. When shutting down, the system shuts down the air compressor units one by one according to the real-time pressure and preset threshold, in the corresponding sequence. The core of this system is to achieve orderly switching of multiple air compressor units and staged gas supply, which is suitable for medium and high load continuous gas consumption conditions, and takes into account the stability of gas supply and the safety of power grid and equipment operation.

[0105] 902. Start the air compressor unit according to the preset start-up delay time, the ninth air supply pressure, and the sequential operation mode;

[0106] In this embodiment, when the system analyzes and confirms that the user has selected the sequential operation mode, the air compressor unit will be started according to the preset start-up delay time, the ninth gas supply pressure, and the sequential operation mode. The start-up delay time is the interval start-up time preset by the user based on the number of air compressor units, the power grid load, and the gas demand (e.g., 5s~10s / unit). The core purpose is to avoid starting multiple air compressors at the same time, prevent the superposition of large currents from impacting the power grid, and avoid the sudden increase in exhaust volume causing pipeline overpressure. The sequential operation mode clarifies the start-up order of the air compressor units (if the current gas supply pressure is lower than the preset first start-up pressure, the first air compressor is started first, and the second air compressor is started after the start-up delay time), ensuring that the air compressor units are put into operation in an orderly manner and avoiding start-up chaos.

[0107] 903. With the air compressor unit in startup mode, obtain the real-time air supply pressure to get the tenth air supply pressure;

[0108] 904. Determine if the tenth gas supply pressure is greater than or equal to the preset third shutdown pressure;

[0109] 905. If the tenth air supply pressure is greater than or equal to the third shutdown pressure, the air compressor unit shall be shut down according to the preset shutdown delay time and preset shutdown delay mode.

[0110] In this embodiment, the third shutdown pressure is the user-preset pressure threshold for the overall shutdown of the air compressor unit. It is a critical value where the pipeline pressure meets production needs and has a reasonable margin. When the tenth air supply pressure reaches this threshold, it indicates that the air compressor unit's exhaust volume has exceeded the current air load, and continued operation will result in ineffective energy consumption, thus meeting the shutdown conditions. If this judgment condition is met, the air compressor unit is shut down according to the preset shutdown delay time and shutdown delay mode. The shutdown delay mode clearly stipulates that after the shutdown delay time buffer, the second air compressor is stopped first to ensure that the shutdown process is orderly.

[0111] In this embodiment, the ninth gas supply pressure is first collected, and the startup sequence of the air compressor units is determined by combining the preset start-up delay time and sequential operation mode. This effectively avoids the high current impact on the power grid caused by the simultaneous startup of multiple units and the pipeline overpressure caused by the sudden increase in exhaust volume, ensuring the orderly commissioning of the units. During operation, the tenth gas supply pressure is collected, and the shutdown timing is accurately determined by combining it with the third shutdown pressure. Combined with the shutdown delay time and the mode of prioritizing the shutdown of the second air compressor, pressure fluctuations are filtered out and accidental shutdowns are avoided. Overall, on-demand start-up and shutdown are achieved, avoiding ineffective energy consumption, reducing the impact of air compressor unit start-up and shutdown, extending equipment life, and achieving fully automated management and control, simplifying operation and maintenance. At the same time, it ensures stable pipeline pressure, provides continuous and stable gas supply for downstream production, and adapts to multiple operating conditions.

[0112] The above describes an air compressor control method according to an embodiment of the present invention. The following describes an air compressor control system according to an embodiment of the present invention. Please refer to [link / reference]. Figure 10 One embodiment of an air compressor control system according to the present invention includes:

[0113] An air compressor control system executes an air compressor control method as described above, including a microcontroller 1 and an air compressor unit 2 electrically connected to the microcontroller 1; the air compressor unit 2 includes a first air compressor 21, a second air compressor 22 and a standby air compressor 23.

[0114] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the system, device, or unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0115] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for controlling an air compressor, characterized in that, An air compressor control system is applied to an air compressor control system, the air compressor control system including an air compressor unit, the air compressor unit including a standby air compressor and a first air compressor, the air compressor control method including: Obtain user selection patterns and analyze them; If the user selects the single-unit rotation mode, the real-time gas supply pressure is obtained to obtain the first gas supply pressure; The standby air compressor is started according to the first air supply pressure, the preset first standby start pressure, and the preset first delay time. With the standby air compressor running, the real-time air supply pressure is obtained again to obtain a second air supply pressure; The first air compressor is shut down according to the second air supply pressure and the preset first shutdown pressure. With the first air compressor in a shut-down state, obtain the cumulative running time of the first air compressor; The air compressor control mode is generated based on the cumulative running time, the preset rotation time, and the preset first standby shutdown pressure.

2. The air compressor control method as described in claim 1, characterized in that, The step of starting the standby air compressor according to the first air supply pressure, the preset first standby start pressure, and the preset first delay time includes: Determine whether the first gas supply pressure is less than or equal to the preset first start-up pressure; If the first air supply pressure is less than or equal to the first start-up pressure, then the first air compressor is started; With the first air compressor running, the real-time air supply pressure is obtained again to obtain the third air supply pressure; Determine whether the third gas supply pressure is less than or equal to the first standby start-up pressure; If the third air supply pressure is less than or equal to the first standby start-up pressure, the standby air compressor will be started according to the first delay time.

3. The air compressor control method as described in claim 1, characterized in that, The step of shutting down the first air compressor based on the second air supply pressure and the preset first shutdown pressure includes: Determine whether the second gas supply pressure is greater than or equal to the preset second standby shutdown pressure; If the second air supply pressure is greater than or equal to the second standby shutdown pressure, then the standby air compressor shall be shut down. With the standby air compressor shut down, the real-time air supply pressure is obtained again to obtain the fourth air supply pressure; Determine whether the fourth gas supply pressure is greater than or equal to the first shutdown pressure; If the fourth air supply pressure is greater than or equal to the first shutdown pressure, then the first air compressor is shut down.

4. The air compressor control method as described in claim 1, characterized in that, The air compressor unit also includes a second air compressor. The process of generating an air compressor control mode based on accumulated operating time, a preset rotation time, and a preset first standby shutdown pressure includes: The second air compressor is started based on the cumulative running time, rotation time, and preset second start pressure. When the second air compressor is in start-up state, the standby air compressor is started according to the preset second delay time and the preset second standby start-up pressure; When the standby air compressor is running, shut down the standby air compressor according to the first standby shutdown pressure. When the standby air compressor is shut down, the second air compressor is shut down according to the preset second shutdown pressure to obtain the air compressor control mode.

5. The air compressor control method as described in claim 4, characterized in that, The step of starting the standby air compressor according to the preset second delay time and the preset second standby start pressure includes: The real-time gas supply pressure is obtained again to obtain the fifth gas supply pressure; Determine whether the fifth gas supply pressure is less than or equal to the second standby start-up pressure; If the fifth air supply pressure is less than or equal to the second standby start pressure, the standby air compressor will be started according to the second delay time.

6. The air compressor control method as described in claim 4, characterized in that, The step of shutting down the standby air compressor according to the first standby shutdown pressure includes: Obtain the real-time gas supply pressure again to obtain the sixth gas supply pressure; Determine whether the sixth gas supply pressure is greater than or equal to the first standby shutdown pressure; If the sixth air supply pressure is greater than or equal to the first standby shutdown pressure, then the standby air compressor shall be shut down.

7. The air compressor control method as described in claim 4, characterized in that, The step of shutting down the second air compressor according to the preset second shutdown pressure includes: The real-time gas supply pressure is obtained again to obtain the seventh gas supply pressure; Determine whether the seventh gas supply pressure is greater than or equal to the second shutdown pressure; If the seventh air supply pressure is greater than or equal to the second shutdown pressure, then the second air compressor will be shut down.

8. The air compressor control method as described in claim 4, characterized in that, The step of starting the second air compressor based on the cumulative running time, rotation time, and preset second start-up pressure includes: Determine whether the cumulative runtime is greater than or equal to the rotation time; If the cumulative running time is greater than or equal to the rotation time, the real-time gas supply pressure is obtained again to obtain the eighth gas supply pressure; Determine whether the eighth gas supply pressure is less than or equal to the second starting pressure; If the eighth air supply pressure is less than or equal to the second starting pressure, then the second air compressor will be started.

9. The air compressor control method as described in claim 1, characterized in that, The step of analyzing user selection patterns further includes: If the user selects the sequential operation mode, the real-time gas supply pressure is obtained to obtain the ninth gas supply pressure; The air compressor unit is started according to the preset start-up delay time, the ninth air supply pressure, and the sequential operation mode; When the air compressor unit is running, the real-time air supply pressure is obtained to obtain the tenth air supply pressure; Determine if the tenth gas supply pressure is greater than or equal to the preset third shutdown pressure; If the tenth air supply pressure is greater than or equal to the third shutdown pressure, the air compressor unit will be shut down according to the preset shutdown delay time and preset shutdown delay mode.

10. An air compressor control system, executing an air compressor control method as described in any one of claims 1-9, characterized in that, It includes a microcontroller and an air compressor unit electrically connected to the microcontroller; the air compressor unit includes a first air compressor, a second air compressor, and a standby air compressor.

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