Energy-saving explosion-proof air conditioner double-circulation refrigeration monitoring method and system, and medium

Abstract

The application provides an energy-saving explosion-proof air conditioner double-circulation refrigeration monitoring method, system and medium, relates to the technical field of energy-saving air conditioners, and comprises the following steps: obtaining initial state data of an explosion-proof air conditioner to perform explosion-proof safety self-checking; collecting multi-dimensional operation parameters of a double-circulation refrigeration device; dynamically scheduling the working modes of a first circulation loop and a second circulation loop according to the temperature difference between a target temperature and an actual ambient temperature; performing temperature rise prediction, and executing forced frequency reduction and power limitation when the surface temperature parameter reaches the preset explosion-proof temperature group limit value; calculating the real-time energy efficiency ratio of a real-time operation loop, and performing energy-saving adaptive adjustment of the real-time operation loop; and performing fault hierarchical diagnosis. The application can solve the technical problem that the explosion-proof air conditioner is passively powered off due to the lack of temperature rise prediction, achieve the technical target of advanced prediction based on the temperature change rate and flexible frequency reduction, and achieve the technical effect of maintaining the continuous operation of the device within the safety limit and improving the active defense capability.

Description

Technical Field

[0001] This application relates to the field of energy-saving air conditioning technology, and in particular to a method, system and medium for monitoring dual-cycle cooling of energy-saving and explosion-proof air conditioners. Background Technology

[0002] With the continuous upgrading of modern industrial manufacturing processes and the increasingly stringent safety regulations, explosion-proof air conditioners, as key electromechanical equipment for regulating the temperature and humidity of flammable and explosive special environments, are showing a significant increasing trend in deployment density in high-risk locations such as underground coal mines, fine chemical production workshops, and offshore oil drilling platforms. The long-term stable operation of special air conditioning equipment has become an indispensable basic condition for maintaining the continuous operation of industrial production lines.

[0003] Currently, existing explosion-proof air conditioners generally adopt a static threshold-triggered passive safety protection architecture when dealing with complex and ever-changing heat load conditions. The equipment control core only collects the surface temperature value of a single point on the outside of the explosion-proof shell in real time and compares the value with the fixed explosion-proof limit temperature stored internally. Once the current instantaneous temperature exceeds the limit value, it directly executes an extreme protection command to cut off the power supply of the whole unit. This single-dimensional temperature monitoring logic is completely divorced from the physical relationship between the continuous work and heat generation of the compressor and the dynamic decay of the condenser's heat dissipation efficiency inside the refrigeration system. It does not introduce calculations of the rate of temperature rise over time or models to predict future temperature rise trends. As a result, when the equipment faces progressively deteriorating conditions such as obstructed condensation heat dissipation or a sudden rise in ambient temperature, it cannot obtain early warning signals and take flexible adjustment measures such as reducing the compressor's operating frequency or reducing input power when the temperature is already on a rapid upward trajectory before exceeding the limit. It can only wait helplessly for the surface temperature to hard break through the safety threshold.

[0004] In summary, existing technologies suffer from the technical problem that explosion-proof air conditioners lack the ability to dynamically predict surface temperature change trends. This results in the equipment only being able to passively shut down and cut off power after the temperature exceeds the limit, rather than intervening in advance by reducing frequency and limiting power. This further affects the stability of continuous production processes in hazardous environments and the active defense capabilities of the equipment's own explosion-proof safety protection system. Summary of the Invention

[0005] The purpose of this application is to provide an energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method, system and medium to solve the technical problem in the prior art that the explosion-proof air conditioner lacks the ability to dynamically predict the trend of surface temperature changes, which leads to the equipment only being able to passively shut down and cut off power after the temperature exceeds the limit, and is unable to intervene in advance by reducing frequency and limiting power, which further affects the stability of continuous production processes in hazardous environments and the active defense capability of the equipment's own explosion-proof safety protection system.

[0006] In view of the above problems, this application provides an energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method, system and medium.

[0007] In a first aspect, this application provides a method for monitoring the dual-cycle cooling of an energy-saving explosion-proof air conditioner, implemented through an energy-saving explosion-proof air conditioner dual-cycle cooling monitoring system. The method includes: acquiring initial state data after the explosion-proof air conditioner is powered on to perform an explosion-proof safety self-test, obtaining a safety self-test result; based on the safety self-test result, after receiving a start command and entering the cooling operation state, collecting multi-dimensional operating parameters of the dual-cycle cooling equipment, including thermodynamic parameters of the first and second circulation loops, electrical parameters of the explosion-proof motor, actual ambient temperature, and surface temperature parameters of the explosion-proof casing; and dynamically scheduling the operation of the first and second circulation loops according to the temperature difference between the target temperature and the actual ambient temperature. The operating modes include at least a light-load single-cycle operation mode and a heavy-load dual-cycle parallel operation mode. According to the operating modes, during refrigeration operation, temperature rise prediction is performed based on the surface temperature parameters and their rate of change. When the predicted surface temperature parameters will reach the preset explosion-proof temperature group limit value, forced frequency reduction and power limiting are implemented to obtain explosion-proof safety dynamic monitoring results. The real-time energy efficiency ratio of the real-time operating circuit is calculated based on the thermodynamic and electrical parameters, and energy-saving adaptive adjustment of the real-time operating circuit is performed based on the real-time energy efficiency ratio. Based on the explosion-proof safety dynamic monitoring results and the changing trend of the real-time energy efficiency ratio, fault classification diagnosis is performed, and corresponding control commands and early warning information are output.

[0008] Preferably, the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method further includes: detecting the concentration of hazardous gases in the environment and detecting the explosion-proof electrical insulation of the initial state data to obtain a safety self-test result; if the safety self-test result is that the self-test fails, the explosion-proof air conditioner is locked and a fault is reported; if the safety self-test result is that the self-test passes, the air conditioner enters a standby state.

[0009] Preferably, the energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method further includes: acquiring the combustible gas concentration in the initial state data; when the combustible gas concentration reaches a preset lower explosion limit proportional threshold, obtaining an environmental explosion safety self-inspection result that fails the self-inspection; controlling the explosion-proof solenoid valve on the dual-cycle pipeline to remain in a de-energized and closed state according to the environmental explosion safety self-inspection result, and adding the environmental explosion safety self-inspection result to the safety self-inspection result.

[0010] Preferably, the energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method further includes: when the temperature difference is greater than a first preset temperature difference threshold, opening the first circulation loop and the second circulation loop to enter the heavy-load dual-cycle parallel operation mode; when the temperature difference is less than or equal to the first preset temperature difference threshold, opening either the first circulation loop or the second circulation loop to enter the light-load single-cycle operation mode; in the light-load single-cycle operation mode, alternately switching the first circulation loop and the second circulation loop according to the cumulative running time.

[0011] Preferably, the energy-saving and explosion-proof air conditioner dual-cycle refrigeration monitoring method further includes: if the dual-cycle refrigeration equipment uses a flammable refrigerant, the refrigerant concentration is monitored by a refrigerant leakage sensor installed at the pipeline node; when an abnormal increase in refrigerant concentration is detected, the power supply to the compressors of the first and second circulation loops and the explosion-proof solenoid valves of the corresponding pipelines are cut off, and an explosion-proof fault alarm is triggered, and the refrigerant leakage monitoring result is added to the explosion-proof safety dynamic monitoring result.

[0012] Preferably, the energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method further includes: calculating the compressor frequency and condenser fan speed to be adjusted based on the real-time energy efficiency ratio combined with the fuzzy PID control algorithm; outputting control signals to the compressor and condenser fan in the real-time operation loop according to the compressor frequency and condenser fan speed to be adjusted; setting a temperature dead zone centered on the target temperature, and maintaining the lowest operating frequency of the compressor in the real-time operation loop when the actual ambient temperature falls into the temperature dead zone.

[0013] Preferably, the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method further includes: if a first-level fatal fault is determined based on the explosion-proof safety dynamic monitoring results, a control command is output to cut off the main power supply of the whole unit and lock the restart logic, wherein the first-level fatal fault includes explosion-proof failure, refrigerant leakage, or surface temperature exceeding the limit; if a second-level performance fault is determined based on the change trend of the real-time energy efficiency ratio, a control command is output to block the current abnormal circulation loop and control the backup circulation loop to enter the light-load single-cycle operation mode, wherein the second-level performance fault includes the cooling capacity of the single-cycle loop decreasing to a preset proportion below the rated threshold; if a third-level warning fault is determined based on the change trend of the real-time energy efficiency ratio, a warning message for equipment maintenance is output, wherein the third-level warning fault includes the real-time energy efficiency ratio continuously falling below the historical benchmark average.

[0014] Preferably, the energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method further includes: electrically isolating the multi-dimensional operating parameters, the real-time energy efficiency ratio, and the fault classification diagnosis results through a safety barrier; transmitting the isolated data to the upper-level monitoring center via an explosion-proof communication bus to generate energy efficiency analysis reports and equipment life cycle prediction curves.

[0015] Secondly, this application also provides an energy-saving explosion-proof air conditioner dual-cycle cooling monitoring system, used to execute the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method as described in the first aspect, comprising: a safety self-test result acquisition module, used to acquire initial state data after the explosion-proof air conditioner is powered on to perform an explosion-proof safety self-test and obtain a safety self-test result; a multi-dimensional operating parameter acquisition module, used to acquire multi-dimensional operating parameters of the dual-cycle cooling equipment based on the safety self-test result, after receiving a start command and entering the cooling operation state, the multi-dimensional operating parameters including thermodynamic parameters of the first and second circulation loops, electrical parameters of the explosion-proof motor, actual ambient temperature, and surface temperature parameters of the explosion-proof casing; and a working mode scheduling module, used to dynamically schedule the first and second circulation loops according to the temperature difference between the target temperature and the actual ambient temperature. The system includes at least two operating modes: a light-load single-cycle operation mode and a heavy-load dual-cycle parallel operation mode. A module for obtaining explosion-proof safety dynamic monitoring results is used to predict temperature rise during refrigeration operation based on the surface temperature parameters and their rate of change, and to execute forced frequency reduction and power limiting when the predicted surface temperature parameters reach the preset explosion-proof temperature group limit value, thereby obtaining the explosion-proof safety dynamic monitoring results. An energy-saving adaptive adjustment module is used to calculate the real-time energy efficiency ratio of the real-time operating loop based on the thermodynamic and electrical parameters, and to execute energy-saving adaptive adjustment of the real-time operating loop based on the real-time energy efficiency ratio. An early warning information output module is used to perform fault classification diagnosis based on the explosion-proof safety dynamic monitoring results and the changing trend of the real-time energy efficiency ratio, and to output corresponding control commands and early warning information.

[0016] Thirdly, a computer-readable storage medium storing a computer program, which, when executed, implements the steps of the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method described in any one of the first aspects.

[0017] The technical solution provided in this application has at least the following technical effects or advantages: by achieving the technical goal of predicting temperature rise based on surface temperature change rate and flexibly intervening in frequency reduction, the technical effect of maintaining continuous frequency reduction operation of equipment within the explosion-proof safety temperature limit is achieved to ensure the stability of continuous production in hazardous environments and improve the active defense margin of the explosion-proof safety protection system.

[0018] The above description is merely an overview of the technical solution of this application. To enable a clearer understanding of the technical means of this application and to facilitate its implementation according to the description, and to make the above and other objects, features, and advantages of this application more apparent, specific embodiments of this application are described below. It should be understood that the content described in this section is not intended to identify key or important features of the embodiments of this application, nor is it intended to limit the scope of this application. Other features of this application will become readily apparent through the following description. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely exemplary. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0020] Figure 1 This is a flowchart illustrating the energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method of this application.

[0021] Figure 2 This is a schematic diagram of the structure of an energy-saving and explosion-proof air conditioning dual-cycle refrigeration monitoring system according to this application.

[0022] Figure labeling: Module 1 for obtaining safety self-test results, Module 2 for acquiring multi-dimensional operating parameters, Module 3 for scheduling working modes, Module 4 for obtaining explosion-proof safety dynamic monitoring results, Module 5 for energy-saving adaptive adjustment, and Module 6 for outputting early warning information. Detailed Implementation

[0023] This application provides an energy-saving and explosion-proof air conditioner dual-cycle refrigeration monitoring method, system, and medium. It solves the technical problem in existing technologies where explosion-proof air conditioners lack dynamic prediction capabilities for surface temperature changes, resulting in equipment only being able to passively shut down after temperature exceedances, unable to proactively reduce frequency and limit power, further impacting the stability of continuous production processes in hazardous environments and the active defense capabilities of the equipment's explosion-proof safety protection system. The application achieves the technical goal of predicting temperature rises proactively and flexibly reducing frequency based on surface temperature change rates, maintaining continuous frequency-reduced operation of the equipment within explosion-proof safety temperature limits to ensure the stability of continuous production in hazardous environments and improve the active defense margin of the explosion-proof safety protection system.

[0024] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. It should be understood that this application is not limited to the exemplary embodiments described herein. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application. It should also be noted that, for ease of description, only the parts related to this application are shown in the accompanying drawings, not all of them.

[0025] Example 1, please refer to the appendix. Figure 1 This application provides a method for monitoring the dual-cycle cooling of an energy-saving and explosion-proof air conditioner, which is applied to an energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring system, and specifically includes the following steps: The initial state data of the explosion-proof air conditioner after power-on is obtained to perform an explosion-proof safety self-test and obtain the safety self-test results.

[0026] Furthermore, this application also includes: performing environmental explosion hazard gas concentration detection and explosion-proof electrical insulation detection on the initial state data to obtain a safety self-test result; if the safety self-test result is that the self-test fails, then the explosion-proof air conditioner is locked and a fault is reported; if the safety self-test result is that the self-test passes, then it enters a standby state.

[0027] Specifically, an explosion-proof air conditioner refers to a special air conditioning device that has the ability to prevent internal electrical sparks from igniting external flammable and explosive gases. Powering on refers to the process of connecting the main power supply to obtain the working voltage for the control circuit. Initial state data includes the static values ​​collected by each sensor at the moment the device is powered on. Explosion-proof safety self-test refers to the procedure executed before the device is started and operated to verify whether various safety indicators meet the explosion-proof standards. Safety self-test result refers to the logical judgment value generated after the self-test procedure is completed, which represents the current safety status of the device.

[0028] Furthermore, the specific analysis of the initial state data includes two parallel dimensions: environmental explosion hazard gas concentration detection, which refers to the detection operation of measuring the percentage of combustible gas in the air around the equipment to the lower explosive limit using an intrinsically safe gas detector; and explosion-proof electrical insulation detection, which refers to the test operation of measuring the resistance value between the motor winding and the casing, as well as between strong and weak current circuits, to confirm that there is no leakage or short circuit. The comprehensive judgment data generated by the two operations together constitute the final safety self-inspection result.

[0029] Once the safety self-test result indicates that the equipment has a safety hazard, it is determined that the self-test has failed. Locking the explosion-proof air conditioner means that the control system cuts off all actuator drive signals except for the alarm circuit and prohibits the user from issuing start commands. Reporting the fault means that the abnormal information containing the specific fault code is sent to the central control room or display interface through the communication bus.

[0030] Conversely, when the safety self-test results confirm that all test items are within the normal allowable range, the self-test is considered to have passed. Standby state refers to the equipment main control board maintaining low-voltage power supply to continuously monitor external start and stop signals, but high-power loads such as compressors and fans are in a standby phase of power-off and quiescence.

[0031] Furthermore, the detection of hazardous gas concentrations in the environment refers to a safety screening procedure for assessing the content of flammable and explosive substances in the air within the equipment installation space. The specific execution process of the aforementioned procedure includes the following operational steps. Initial state data refers to the raw, unprocessed set of underlying values ​​collected at the initial stage of equipment power-on, and combustible gas concentration refers to the proportion of flammable and ignitable gaseous substances per unit volume of air.

[0032] Subsequently, in the event of a situation where the proportion of combustible gas exceeds the standard, the preset lower explosion limit threshold refers to a safety warning percentage value that is artificially set below the minimum ignition concentration. A failure to pass the self-inspection indicates that the current state does not meet the safety operation standards. The environmental explosion safety self-inspection result refers to an independent assessment report specifically generated for external gas risks.

[0033] Triggered by an independent assessment report, dual circulation pipelines refer to two independent and parallel physical channels for refrigerant flow; explosion-proof solenoid valves refer to electrical components with explosion-proof housings that rely on electromagnetic force to drive the valve core to open and close in order to cut off or conduct fluid flow; maintaining power-off closed state refers to the physical locking action of cutting off the power supply to the solenoid valve coil so that the spring force presses the valve core to block the flow of refrigerant; and safety self-inspection results refer to the final comprehensive equipment start-up permit certificate covering multiple inspection items.

[0034] Based on the safety self-test results, after receiving the start command and entering the refrigeration operation state, the multi-dimensional operating parameters of the dual-cycle refrigeration equipment are collected. The multi-dimensional operating parameters include the thermodynamic parameters of the first and second circulation loops, the electrical parameters of the explosion-proof motor, the actual ambient temperature, and the surface temperature parameters of the explosion-proof shell.

[0035] Specifically, the safety self-inspection result serves as a prerequisite for authorization; the start command refers to the level signal sent by the external control system to trigger the equipment compressor and fan to start running; and the refrigeration operation status refers to the working stage in which the refrigerant inside the equipment undergoes a phase change cycle and outputs cooling capacity.

[0036] During operation, a dual-cycle refrigeration system refers to an air conditioning unit containing two independent refrigerant compression and heat exchange systems. Multidimensional operating parameters refer to a comprehensive set of data reflecting the dynamic changes at various physical levels during the operation of the air conditioning unit. This comprehensive data set includes monitoring indicators for multiple physical flow paths. The first and second circulation loops refer to two independent and closed refrigerant flow paths connected in parallel within the equipment. Thermodynamic parameters are physical quantities characterizing the pressure and temperature states of the refrigerant within these flow paths.

[0037] Meanwhile, the comprehensive data set also includes monitoring indicators for drive components and safety protection components. Explosion-proof motors refer to power sources with structures that prevent internal electric arcs from igniting external explosive mixtures. Electrical parameters refer to electrical physical quantities that reflect the voltage, current, and power consumption status of the power source during operation. Actual ambient temperature refers to the real physical heat value of the air at the equipment's air inlet. Explosion-proof enclosures refer to protective structural components that enclose electrical components, can withstand internal explosion pressure, and limit external heating temperature. Surface temperature parameters refer to the real-time physical heat value of the outermost interface of the protective structural component that contacts the hazardous environment air.

[0038] Based on the temperature difference between the target temperature and the actual ambient temperature, the operating modes of the first and second circulating loops are dynamically scheduled. The operating modes include at least a light-load single-cycle operation mode and a heavy-load dual-cycle parallel operation mode.

[0039] Furthermore, this application also includes: when the temperature difference is greater than a first preset temperature difference threshold, opening the first circulation loop and the second circulation loop to enter the heavy-load dual-cycle parallel operation mode; when the temperature difference is less than or equal to the first preset temperature difference threshold, opening either the first circulation loop or the second circulation loop to enter the light-load single-cycle operation mode; in the light-load single-cycle operation mode, alternately switching the first circulation loop and the second circulation loop according to the cumulative running time.

[0040] Specifically, in the temperature comparison and judgment process, the target temperature refers to the desired space temperature value set by the user, the actual ambient temperature refers to the current physical heat value of the space measured by the sensor, the temperature difference refers to the absolute difference between the two temperature values, the first preset temperature difference threshold refers to the first limit value pre-stored in the system for judging the size of the cooling demand, the first circulation loop and the second circulation loop refer to two independent and closed physical paths for refrigerant flow inside the equipment, and the heavy-load dual-circulation parallel operation mode refers to the high-energy-consumption working state in which the two physical paths for refrigerant flow simultaneously drive their respective compressors to output maximum cooling capacity.

[0041] Conversely, when the absolute difference is within a small range, the light-load single-cycle operation mode refers to a low-energy-consumption operation mode that starts only one of the two independent refrigerant circulation physical paths while keeping the other physical path in a power-off and shutdown state.

[0042] During the low-energy operation mode, the cumulative running time refers to the total operating time of a single refrigerant circulation physical path continuously calculated from the start of power-on. Alternating switching refers to the periodic control action of using different physical paths in turn to balance equipment wear when the set rotation cycle is reached according to the aforementioned total operating time.

[0043] According to the working mode, during the cooling operation, the temperature rise is predicted based on the surface temperature parameters and the rate of change of the surface temperature parameters. When the predicted surface temperature parameters will reach the preset explosion-proof temperature group limit value, forced frequency reduction and power limiting are executed to obtain the explosion-proof safety dynamic monitoring results.

[0044] Furthermore, this application also includes: if the dual-cycle refrigeration equipment uses a flammable refrigerant, the refrigerant concentration is monitored by a refrigerant leakage sensor installed at the pipeline node; when an abnormal increase in refrigerant concentration is detected, the power supply to the compressors of the first and second circulation loops and the explosion-proof solenoid valves of the corresponding pipelines are cut off, and an explosion-proof fault alarm is triggered, and the refrigerant leakage monitoring result is added to the explosion-proof safety dynamic monitoring result.

[0045] Specifically, the operating mode refers to the current state of the equipment, whether it is operating in a single physical path or in parallel with two physical paths; the refrigeration operation process refers to the time period during which the refrigerant undergoes a phase change and continuously outputs cooling capacity; the surface temperature parameter refers to the real-time physical heat value of the outermost interface of the explosion-proof enclosure in contact with the hazardous ambient air; the surface temperature parameter change rate refers to the increase of the aforementioned real-time physical heat value per unit time; the temperature rise prediction refers to the mathematical calculation process of using the aforementioned real-time physical heat value and the increase rate to predict the physical heat at a certain future moment; the preset explosion-proof temperature group limit value refers to the maximum allowable temperature limit value of the equipment surface strictly stipulated by national explosion-proof standards; the forced frequency reduction and power limiting refers to the protective intervention operation that directly reduces the compressor operating frequency and limits the maximum input electrical energy regardless of the current refrigeration load demand; and the explosion-proof safety dynamic monitoring result refers to a comprehensive safety status data set that includes temperature prediction judgment conclusions and records of executed protective operations.

[0046] In addition to safety monitoring of the shell temperature, dual-cycle refrigeration equipment refers to a special air conditioning device that includes two independent refrigerant compression and heat exchange systems. Flammable refrigerant refers to a heat transfer fluid medium that has the property of burning or exploding when exposed to an open flame in the air. Pipeline node refers to the connection point or bend in the refrigerant flow pipeline that is prone to sealing failure. Refrigerant leak sensor refers to an explosion-proof detection probe that can sense the concentration of specific chemical gas molecules and output a corresponding electrical signal. Refrigerant concentration refers to the proportion of the aforementioned heat transfer fluid medium contained in a unit volume of air.

[0047] When faced with an abnormal content ratio, the first and second circulation loops refer to two independent and closed physical flow paths of refrigerant within the equipment; the compressor power supply refers to the electrical power supply line that drives the gas compression mechanical components; the corresponding pipeline refers to the physical pipeline network that is connected to the aforementioned two physical flow paths of refrigerant; the explosion-proof solenoid valve refers to a safety electrical component with an explosion-proof shell that relies on electromagnetic force to drive the valve core to open and close to cut off fluid flow; the explosion-proof fault alarm refers to an emergency notification action that issues an audible and visual signal or sends a danger level warning code to the central control system; and the refrigerant leakage monitoring results refer to an independent set of safety data that includes the conclusion of the gas concentration exceeding the standard and the record of the valve power-off action.

[0048] The real-time energy efficiency ratio of the real-time operating circuit is calculated based on the thermodynamic parameters and the electrical parameters, and energy-saving adaptive adjustment of the real-time operating circuit is performed based on the real-time energy efficiency ratio.

[0049] Furthermore, this application also includes: calculating the compressor frequency and condenser fan speed to be adjusted based on the real-time energy efficiency ratio combined with the fuzzy PID control algorithm; outputting control signals for the compressor and condenser fan in the real-time operation loop according to the compressor frequency and condenser fan speed to be adjusted; setting a temperature dead zone centered on the target temperature, and maintaining the minimum operating frequency of the compressor in the real-time operation loop when the actual ambient temperature falls into the temperature dead zone.

[0050] Specifically, in the energy efficiency optimization calculation process, the real-time energy efficiency ratio refers to the instantaneous ratio of the cooling capacity generated by the equipment per unit time to the electrical energy consumed; the fuzzy PID control algorithm refers to the mathematical calculation model that integrates fuzzy logic reasoning and proportional-integral-derivative adjustment laws; the compressor frequency to be adjusted refers to the target electrical frequency value generated by the calculation model that will be applied to the gas compression power source; and the condenser fan speed refers to the physical angular velocity value that drives the condenser cooling fan blades to rotate.

[0051] The target electrical frequency value and physical angular velocity value are then converted into specific execution instructions. The real-time operating loop refers to the collection of physical pipes and components that are currently energized and where the refrigerant is continuously circulating. The compressor refers to the mechanical power source responsible for compressing the gaseous refrigerant. The condenser fan refers to the mechanical power source that accelerates heat dissipation. The control signal refers to the voltage pulse or current pulse instruction output by the main control chip to change the operating state of the power source.

[0052] During the execution of the command, an anti-vibration mechanism also needs to be introduced. The target temperature refers to the desired constant temperature value of the space set by the user. The temperature dead zone refers to the temperature range that fluctuates around the desired constant temperature value of the space without triggering changes in the control logic. The actual ambient temperature refers to the physical heat value measured in real time in the space. The minimum operating frequency refers to the lower limit electrical frequency value that maintains the continuous operation of the gas compression power source without mechanical damage or lubrication failure.

[0053] Based on the dynamic monitoring results of explosion-proof safety and the changing trend of the real-time energy efficiency ratio, fault classification diagnosis is performed, and corresponding control commands and early warning information are output.

[0054] Furthermore, this application also includes: if a Level 1 fatal fault is determined based on the explosion-proof safety dynamic monitoring results, a control command is output to cut off the main power supply of the entire unit and lock the restart logic, wherein the Level 1 fatal fault includes explosion-proof failure, refrigerant leakage, or surface temperature exceeding the limit; if a Level 2 performance fault is determined based on the change trend of the real-time energy efficiency ratio, a control command is output to block the current abnormal circulation loop and control the backup circulation loop to enter the light-load single-cycle operation mode, wherein the Level 2 performance fault includes the cooling capacity of the single-cycle loop decreasing to a preset proportion below the rated threshold; if a Level 3 warning fault is determined based on the change trend of the real-time energy efficiency ratio, a warning message for equipment maintenance is output, wherein the Level 3 warning fault includes the real-time energy efficiency ratio continuously falling below the historical benchmark average.

[0055] Furthermore, this application also includes: electrically isolating the multidimensional operating parameters, the real-time energy efficiency ratio, and the fault classification diagnosis results through a safety barrier; transmitting the isolated data to the upper-level monitoring center via an explosion-proof communication bus to generate energy efficiency analysis reports and equipment life cycle prediction curves.

[0056] Specifically, under the highest level of abnormal conditions, the explosion-proof safety dynamic monitoring results refer to a comprehensive set of safety status data that includes the physical heat calculation conclusion of the equipment casing and the determination conclusion of the flammable refrigerant concentration. Level 1 fatal failure refers to a serious destructive state that directly endangers the explosion-proof safety performance and may lead to an explosion accident. The total power supply of the whole machine refers to the main power supply circuit that provides power to all electrical components of the special air conditioning device. The lock-and-restart logic refers to the system-level software forced holding mechanism that prohibits the system from performing any reset or power-on operation. The control command refers to the voltage level signal output by the main control chip to change the hardware on / off state. Explosion-proof failure refers to the state in which the protective structure of the equipment loses its ability to prevent internal sparks from igniting the external environment. Refrigerant leakage refers to the physical phenomenon of flammable heat transfer fluid medium abnormally overflowing into the external environment. Surface temperature exceeding the limit refers to the extreme situation in which the real-time physical heat value of the outermost interface of the protective structure in contact with the hazardous environment exceeds the limit specified by the national explosion-proof standard.

[0057] In the context of performance degradation assessment, the real-time energy efficiency ratio (RER) refers to the instantaneous ratio of cooling capacity generated by the equipment per unit time to electrical energy consumed. The trend of change refers to the trend of the instantaneous ratio data over continuous time. Level 2 performance failure refers to a local functional impairment state in which the equipment has not lost its explosion-proof safety performance but its cooling capacity has significantly decreased. Blocking refers to a protective operation that cuts off the control signals of specific physical pipelines and components to stop their operation. The current abnormal circulation loop refers to the refrigerant physical flow path in which the real-time EER data deviates from the normal range and is in a powered-on state. The standby circulation loop refers to another independent refrigerant physical flow path that was originally in a standby power-off state but can be activated at any time. The light-load single-cycle operation mode refers to a low-energy-consumption working state in which only one refrigerant physical flow path is activated while the other physical path is powered off and shut down. Cooling capacity decay refers to the physical phenomenon that the cooling capacity output to the target space per unit time shows a continuous decrease. The rated threshold refers to the minimum limit value of cooling capacity that should be achieved under normal operating conditions as specified by the manufacturer. The preset ratio refers to the percentage boundary line that is manually set below the rated limit.

[0058] For scenarios involving minor performance degradation, Level 3 fault indication refers to an early degradation state where the equipment is operating normally and there is no safety risk, but energy consumption indicators are deteriorating. Equipment maintenance refers to the physical intervention process of cleaning, maintaining, or replacing consumables for mechanical power sources or heat exchange components. Warning information refers to non-emergency status prompt codes or text content sent to the central control display interface or remote monitoring platform. Historical benchmark average refers to the statistical average value of real-time energy efficiency ratio data collected by the equipment under normal operating conditions over a long period of time.

[0059] In the data security transmission preparation phase, multidimensional operating parameters refer to a comprehensive set of data reflecting the dynamic changes of various physical levels during the operation of special air conditioning devices; real-time energy efficiency ratio refers to the instantaneous ratio of cooling capacity generated by the equipment per unit time to electrical energy consumed; fault classification diagnosis results refer to comprehensive status assessment data including the conclusion of equipment hazard level determination and response action records; safety barrier refers to electronic components that connect intrinsically safe circuits and non-intrinsically safe circuits and limit energy transfer; electrical isolation refers to safety protection measures that use physical or electronic means to cut off direct current loops to prevent dangerous energy from entering flammable and explosive areas.

[0060] After safety protection measures are completed, isolated data refers to digital signal streams that have been processed by energy-limiting components and meet intrinsic safety standards; explosion-proof communication bus refers to physical data transmission lines capable of preventing internal electrical sparks from igniting external gases; supervisory control center refers to a remote computer system located in a safe area with data reception and processing capabilities; energy efficiency analysis report refers to a chart file showing the relationship between the equipment's cooling capacity and power consumption over a specific time period; and equipment lifecycle prediction curve refers to a mathematical model image that combines historical operating data to extrapolate the remaining service life and performance degradation trend of mechanical components.

[0061] In summary, the energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method provided in this application has the following technical effects: by achieving the technical goal of predicting temperature rise based on surface temperature change rate and flexibly intervening in frequency reduction, it achieves the technical effect of maintaining continuous frequency reduction operation of equipment within the explosion-proof safety temperature limit to ensure the stability of continuous production in hazardous environments and improve the active defense margin of the explosion-proof safety protection system.

[0062] Example 2: Based on the same inventive concept as the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method in the foregoing examples, this application also provides an energy-saving explosion-proof air conditioner dual-cycle cooling monitoring system. Please refer to the appendix. Figure 2The system includes: a safety self-test result acquisition module 1, used to acquire initial state data after the explosion-proof air conditioner is powered on to perform an explosion-proof safety self-test and obtain the safety self-test result; a multi-dimensional operating parameter acquisition module 2, used to acquire multi-dimensional operating parameters of the dual-cycle refrigeration equipment based on the safety self-test result, after receiving a start command and entering the refrigeration operation state, the multi-dimensional operating parameters including the thermodynamic parameters of the first and second circulation loops, the electrical parameters of the explosion-proof motor, the actual ambient temperature, and the surface temperature parameters of the explosion-proof shell; and a working mode scheduling module 3, used to dynamically schedule the working modes of the first and second circulation loops according to the temperature difference between the target temperature and the actual ambient temperature, the working modes including at least a light-load single-cycle operation mode and a heavy-load dual-cycle operation mode. The system includes a parallel operation mode; a module 4 for obtaining explosion-proof safety dynamic monitoring results, which predicts temperature rise during refrigeration operation based on the surface temperature parameters and their rate of change, and executes forced frequency reduction and power limiting when the predicted surface temperature parameters reach the preset explosion-proof temperature group limit value, thus obtaining the explosion-proof safety dynamic monitoring results; an energy-saving adaptive adjustment module 5, which calculates the real-time energy efficiency ratio of the real-time operating loop based on the thermodynamic and electrical parameters, and performs energy-saving adaptive adjustment of the real-time operating loop based on the real-time energy efficiency ratio; and a warning information output module 6, which performs fault classification diagnosis based on the explosion-proof safety dynamic monitoring results and the changing trend of the real-time energy efficiency ratio, and outputs corresponding control commands and warning information.

[0063] Furthermore, the energy-saving explosion-proof air conditioner dual-cycle refrigeration monitoring system is also used to: detect the concentration of hazardous gases in the environment and the explosion-proof electrical insulation of the initial state data to obtain a safety self-test result; if the safety self-test result is that the self-test fails, the explosion-proof air conditioner is locked and a fault is reported; if the safety self-test result is that the self-test passes, the system enters a standby state.

[0064] Furthermore, the energy-saving and explosion-proof air conditioner dual-cycle refrigeration monitoring system is also used to: acquire the concentration of combustible gas in the initial state data; when the concentration of combustible gas reaches a preset lower explosion limit threshold, obtain an environmental explosion safety self-inspection result that fails the self-inspection; control the explosion-proof solenoid valve on the dual-cycle pipeline to remain in a de-energized and closed state according to the environmental explosion safety self-inspection result, and add the environmental explosion safety self-inspection result to the safety self-inspection result.

[0065] Furthermore, the energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring system is also used for: when the temperature difference is greater than a first preset temperature difference threshold, opening the first circulation loop and the second circulation loop to enter the heavy-load dual-cycle parallel operation mode; when the temperature difference is less than or equal to the first preset temperature difference threshold, opening either the first circulation loop or the second circulation loop to enter the light-load single-cycle operation mode; and in the light-load single-cycle operation mode, alternately switching the first circulation loop and the second circulation loop according to the cumulative running time.

[0066] Furthermore, the energy-saving and explosion-proof air conditioner dual-cycle refrigeration monitoring system is also used to: if the dual-cycle refrigeration equipment uses a flammable refrigerant, monitor the refrigerant concentration by means of a refrigerant leakage sensor installed at the pipeline node; when an abnormal increase in refrigerant concentration is detected, cut off the compressor power supply of the first and second circulation loops and the explosion-proof solenoid valve of the corresponding pipeline, trigger an explosion-proof fault alarm, and add the refrigerant leakage monitoring result to the explosion-proof safety dynamic monitoring result.

[0067] Furthermore, the energy-saving and explosion-proof air conditioner dual-cycle refrigeration monitoring system is also used for: calculating the compressor frequency and condenser fan speed to be adjusted based on the real-time energy efficiency ratio combined with the fuzzy PID control algorithm; outputting control signals to the compressor and condenser fan in the real-time operation loop according to the compressor frequency and condenser fan speed to be adjusted; setting a temperature dead zone centered on the target temperature, and maintaining the minimum operating frequency of the compressor in the real-time operation loop when the actual ambient temperature falls into the temperature dead zone.

[0068] Furthermore, the energy-saving explosion-proof air conditioner dual-cycle refrigeration monitoring system is also used for: if a first-level fatal fault is determined based on the explosion-proof safety dynamic monitoring results, a control command is output to cut off the main power supply of the whole unit and lock the restart logic, wherein the first-level fatal fault includes explosion-proof failure, refrigerant leakage, or surface temperature exceeding the limit; if a second-level performance fault is determined based on the change trend of the real-time energy efficiency ratio, a control command is output to block the current abnormal circulation loop and control the backup circulation loop to enter the light-load single-cycle operation mode, wherein the second-level performance fault includes the cooling capacity of the single-cycle loop decreasing to a preset proportion below the rated threshold; if a third-level warning fault is determined based on the change trend of the real-time energy efficiency ratio, a warning message for equipment maintenance is output, wherein the third-level warning fault includes the real-time energy efficiency ratio continuously falling below the historical benchmark average.

[0069] Furthermore, the energy-saving and explosion-proof air conditioner dual-cycle refrigeration monitoring system is also used to: electrically isolate the multi-dimensional operating parameters, the real-time energy efficiency ratio, and the fault classification diagnosis results through a safety barrier; and transmit the isolated data to the upper-level monitoring center via an explosion-proof communication bus to generate energy efficiency analysis reports and equipment life cycle prediction curves.

[0070] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method and specific examples in the aforementioned embodiment one are also applicable to the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring system of this embodiment. Through the foregoing detailed description of the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method, those skilled in the art can clearly understand the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring system of this embodiment. Therefore, for the sake of brevity, it will not be described in detail here.

[0071] In Example 3, based on the same inventive concept as the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method in the foregoing embodiments, this application also provides a computer-readable storage medium storing a computer program, which, when executed, implements the steps of the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method described in any one of the above embodiments.

[0072] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0073] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of this application and its equivalents, this application also intends to include such modifications and variations.

Claims

1. A method for monitoring dual-cycle cooling in an energy-saving and explosion-proof air conditioner, characterized in that, include: The initial state data of the explosion-proof air conditioner after power-on is obtained to perform an explosion-proof safety self-test and obtain the safety self-test results. Based on the safety self-test results, after receiving the start command and entering the refrigeration operation state, the multi-dimensional operating parameters of the dual-cycle refrigeration equipment are collected. The multi-dimensional operating parameters include the thermodynamic parameters of the first and second circulation loops, the electrical parameters of the explosion-proof motor, the actual ambient temperature, and the surface temperature parameters of the explosion-proof shell. Based on the temperature difference between the target temperature and the actual ambient temperature, the working modes of the first and second circulation loops are dynamically scheduled. The working modes include at least a light-load single-cycle operation mode and a heavy-load dual-cycle parallel operation mode. According to the working mode, during the cooling operation, the temperature rise is predicted based on the surface temperature parameters and the rate of change of the surface temperature parameters. When the predicted surface temperature parameters will reach the preset explosion-proof temperature group limit value, forced frequency reduction and power limiting are executed to obtain the explosion-proof safety dynamic monitoring results. The real-time energy efficiency ratio of the real-time operating circuit is calculated based on the thermodynamic parameters and the electrical parameters, and energy-saving adaptive adjustment of the real-time operating circuit is performed based on the real-time energy efficiency ratio. Based on the dynamic monitoring results of explosion-proof safety and the changing trend of the real-time energy efficiency ratio, fault classification diagnosis is performed, and corresponding control commands and early warning information are output.

2. The energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method as described in claim 1, characterized in that, Perform explosion-proof safety self-inspection, including: The initial state data were subjected to environmental explosion hazard gas concentration detection and explosion-proof electrical insulation testing to obtain safety self-test results; If the safety self-test result is that the self-test fails, the explosion-proof air conditioner will be locked and a fault will be reported. If the security self-test result is a pass, then it enters standby mode.

3. The energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method as described in claim 2, characterized in that, Conducting environmental explosion hazard gas concentration detection, including: Obtain the concentration of combustible gas in the initial state data; When the concentration of the combustible gas reaches a preset lower explosion limit threshold, an environmental explosion safety self-inspection result is obtained indicating that the self-inspection has failed. Based on the environmental explosion safety self-test results, the explosion-proof solenoid valve on the dual circulation pipeline is kept in a de-energized and closed state, and the environmental explosion safety self-test results are added to the safety self-test results.

4. The energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method as described in claim 1, characterized in that, The dynamic scheduling of the operating modes of the first and second loops includes: When the temperature difference is greater than the first preset temperature difference threshold, the first circulation loop and the second circulation loop are opened, and the heavy-load dual-circulation parallel operation mode is entered. When the temperature difference is less than or equal to the first preset temperature difference threshold, either the first circulation loop or the second circulation loop is activated, and the light-load single-cycle operation mode is entered. In the light-load single-cycle operation mode, the first cycle loop and the second cycle loop are alternately switched according to the cumulative running time.

5. The energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method as described in claim 1, characterized in that, The results of dynamic monitoring of explosion-proof safety are obtained, including: If the dual-cycle refrigeration equipment uses a flammable refrigerant, the refrigerant concentration is monitored by a refrigerant leakage sensor installed at the pipeline node; When an abnormal increase in refrigerant concentration is detected, the power supply to the compressors of the first and second circulation loops and the explosion-proof solenoid valves of the corresponding pipelines are cut off, and an explosion-proof fault alarm is triggered. The refrigerant leakage monitoring results are added to the explosion-proof safety dynamic monitoring results.

6. The energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method as described in claim 1, characterized in that, Implement energy-saving adaptive adjustment, including: Based on the real-time energy efficiency ratio combined with the fuzzy PID control algorithm, the compressor frequency and condenser fan speed to be adjusted are calculated. Based on the compressor frequency and condenser fan speed to be adjusted, output control signals to the compressor and condenser fan in the real-time operating circuit; A temperature dead zone is set with the target temperature as the center. When the actual ambient temperature falls into the temperature dead zone, the compressor in the real-time operation loop is maintained at the lowest operating frequency.

7. The energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method as described in claim 1, characterized in that, Perform fault classification diagnosis and output corresponding control commands and early warning information, including: If a Level 1 fatal fault is determined to occur based on the explosion-proof safety dynamic monitoring results, a control command is output to cut off the main power supply of the whole machine and lock the restart logic. The Level 1 fatal fault includes explosion-proof failure, refrigerant leakage, or surface temperature exceeding the limit. If a secondary performance fault is determined based on the change trend of the real-time energy efficiency ratio, a control command to block the current abnormal circulation loop is output, and the backup circulation loop is controlled to enter the light-load single-cycle operation mode. The secondary performance fault includes the cooling capacity of the single-cycle loop decreasing to a preset ratio below the rated threshold. If a Level 3 fault is detected based on the trend of the real-time energy efficiency ratio, a warning message for equipment maintenance is output. The Level 3 fault includes the real-time energy efficiency ratio being continuously lower than the historical average.

8. The energy-saving and explosion-proof air conditioner dual-cycle cooling monitoring method as described in claim 1, characterized in that, Also includes: The multi-dimensional operating parameters, the real-time energy efficiency ratio, and the fault classification and diagnosis results are electrically isolated through a safety barrier. The isolated data is transmitted to the upper-level monitoring center via an explosion-proof communication bus to generate energy efficiency analysis reports and equipment life cycle prediction curves.

9. An energy-saving and explosion-proof dual-cycle refrigeration monitoring system for air conditioners, characterized in that, The steps for implementing the energy-saving explosion-proof air conditioner dual-cycle cooling monitoring method according to any one of claims 1 to 8 include: The safety self-test result acquisition module is used to obtain the initial state data of the explosion-proof air conditioner after it is powered on, perform an explosion-proof safety self-test, and obtain the safety self-test result. The multi-dimensional operating parameter acquisition module is used to acquire multi-dimensional operating parameters of the dual-cycle refrigeration equipment based on the safety self-test results after receiving the start command and entering the refrigeration operation state. The multi-dimensional operating parameters include the thermodynamic parameters of the first and second circulation loops, the electrical parameters of the explosion-proof motor, the actual ambient temperature, and the surface temperature parameters of the explosion-proof shell. The working mode scheduling module is used to dynamically schedule the working modes of the first loop and the second loop according to the temperature difference between the target temperature and the actual ambient temperature. The working modes include at least a light-load single-loop operation mode and a heavy-load dual-loop parallel operation mode. The explosion-proof safety dynamic monitoring result acquisition module is used to predict the temperature rise during the cooling operation according to the working mode, based on the surface temperature parameter and the surface temperature parameter change rate. When the predicted surface temperature parameter will reach the preset explosion-proof temperature group limit value, forced frequency reduction and power limiting are executed to obtain the explosion-proof safety dynamic monitoring result. An energy-saving adaptive adjustment module is used to calculate the real-time energy efficiency ratio of the real-time operating loop based on the thermodynamic parameters and the electrical parameters, and to perform energy-saving adaptive adjustment of the real-time operating loop based on the real-time energy efficiency ratio. The early warning information output module is used to perform fault classification diagnosis based on the explosion-proof safety dynamic monitoring results and the changing trend of the real-time energy efficiency ratio, and output corresponding control commands and early warning information.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a computer program, which, when executed, implements the steps of the energy-saving and explosion-proof air conditioner dual-cycle refrigeration monitoring method according to any one of claims 1 to 8.

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