Air compressor system with remote monitoring function

Abstract

The utility model relates to the technical field of industrial automation control, in particular to an air compressor system with a remote monitoring function. The system comprises an air compressor, an air compressor controller, an RS-232 isolator, a communication protocol converter, an RS-485 isolator, a DCS (Distributed Control System), a data receiving counter, a running state indicator, an exhaust pressure gauge, an oil pressure gauge, an exhaust thermometer, an internal thermometer and a motor ampere meter, and the air compressor controller is respectively connected with the data receiving counter, the running state indicator, the exhaust pressure gauge, the oil pressure gauge, the exhaust thermometer, the internal thermometer and the motor ampere meter. According to the scheme, remote control over the air compressor and the DCS is achieved, the operation efficiency and the production quality of the air compressor are improved, and the flexibility and the response capacity of equipment management are enhanced.

Description

Technical Field

[0001] The utility model relates to the technical field of industrial automation control, and particularly relates to an air compressor system with a remote monitoring function. Background Technique

[0002] The statements in this part are only to provide background information related to the technical solution of the present application for the purpose of helping understanding, and they do not necessarily constitute the prior art for the technical solution of the present application.

[0003] Air compressors play a key role in industrial production. However, some equipment faces challenges such as non-standardization and remote control limitations, which directly affect their application and efficiency in the modern automation environment. First of all, there are non-standard communication problems with air compressors. Compared with standardized communication protocols such as Modbus or Profibus, some communication protocols adopted by air compressors may be customized or atypical, which leads to compatibility problems with other industrial equipment or control systems. The non-standardization of communication interfaces also increases the complexity of integration and upgrading, reduces their standardization degree in the market, and thus limits the applicability of general solutions. Secondly, the current situation that air compressors cannot be remotely controlled further exacerbates the complexity of their management and operation. Remote control is crucial for modern industrial automation systems, which can achieve real-time monitoring, remote diagnosis, and operation adjustment, thereby improving the response speed and efficiency of equipment. However, some air compressors cannot communicate with the existing remote control system (DCS) due to communication protocol limitations and the aging of equipment. In addition, the DCS system cannot collect and control various parameters of the air compressor, so the air compressor cannot be remotely controlled and can only be locally controlled, which is very inconvenient. Content of the Utility Model

[0004] Aiming at the problems of non-standard protocol communication, non-standard communication message format of existing air compressor equipment, and the aging of equipment that cannot communicate with the remote control system (DCS) and achieve remote monitoring, the present application proposes an air compressor system with a remote monitoring function, which can convert the communication protocol of the air compressor controller into a communication protocol adapted to the DCS, and convert non-standard format communication messages into standard communication data, so that the DCS system can receive the data transmitted by the air compressor and make corresponding responses. At the same time, it can remotely control various parameters of the air compressor to maintain the stable operation of the air compressor, thereby realizing the remote monitoring of the air compressor and the DCS system, not only improving the operation efficiency and production quality of the air compressor, but also enhancing the flexibility and response ability of equipment management.

[0005] One aspect of the present application relates to an air compressor system with remote monitoring function, which includes: an air compressor, an air compressor controller, an RS-232 isolator, a communication protocol converter, an RS-485 isolator, a DCS system, a data receiving counter, an operating status indicator for indicating the operating status of the air compressor, an exhaust pressure gauge for measuring the pressure in the exhaust pipeline of the air compressor, an oil pressure gauge for measuring the oil pressure in the lubricating oil pipeline of the air compressor, an exhaust temperature gauge for measuring the temperature in the exhaust pipeline of the air compressor, an internal temperature gauge for measuring the internal temperature of the air compressor, and a motor ammeter for measuring the current when the air compressor motor is running. The air compressor is connected to the air compressor controller, the air compressor controller is connected to the RS-232 isolator through a cable, the RS-232 isolator is connected to the communication protocol converter through a cable, the communication protocol converter is connected to the RS-485 isolator through a cable, the RS-485 isolator is connected to the DCS system through a cable, and the air compressor controller is respectively connected to the data receiving counter, the operating status indicator, the exhaust pressure gauge, the oil pressure gauge, the exhaust temperature gauge, the internal temperature gauge, and the motor ammeter.

[0006] In one embodiment, the exhaust pressure gauge, the oil pressure gauge, the exhaust temperature gauge, and the motor ammeter are connected to the RS-232 interface of the air compressor controller.

[0007] In one embodiment, the air compressor controller is connected to the RS-232 isolator through an RS-232 serial connection cable. One end of the RS-232 serial connection cable is connected to the RS-232 serial port of the air compressor controller, and the other end is connected to the RS-232 serial port of the RS-232 isolator.

[0008] In one embodiment, an RS-232 serial cable is used to connect the RS-232 serial port of the RS-232 isolator to the RS-232 serial port of the communication protocol converter.

[0009] In one embodiment, the RS-485 interface of the communication protocol converter is connected to the RS-485 interface of the RS-485 isolator through an RS-485 serial cable.

[0010] In one embodiment, the RS-485 serial cable includes an A line and a B line. The A line of the RS-485 interface of the communication protocol converter is connected to the A line of the RS-485 interface of the RS-485 isolator, and the B line of the RS-485 interface of the communication protocol converter is connected to the B line of the RS-485 interface of the RS-485 isolator, and the ground wire is connected at the same time.

[0011] In one embodiment, the RS-485 isolator has two sets of RS-485 interfaces, one set being the input interface and the other set being the output interface.

[0012] In one embodiment, through an RS-485 serial cable, the A wire of the output interface of the RS-485 isolator is connected to the A wire of the RS-485 interface of the DCS system, and the B wire of the output interface of the RS-485 isolator is connected to the B wire of the RS-485 interface of the DCS system, while connecting the ground wire.

[0013] In one embodiment, the DCS system has a human-machine interface.

[0014] In view of the problems of non-standard protocol communication, non-standard communication message format of existing air compressor equipment, and the inability of old equipment to communicate with the remote control system DCS and achieve remote monitoring, the present utility model designs an air compressor system with remote monitoring function. Through a communication protocol converter and multiple signal isolators, the communication protocol of the air compressor controller is converted into a communication protocol adapted to the DCS, and the communication messages of the air compressor communication serial port are converted into standard communication data, so that the DCS system can receive the data transmitted by the air compressor and make corresponding responses. At the same time, various parameters of the air compressor can be remotely controlled to maintain the stable operation of the air compressor, thereby realizing the remote control of the air compressor and the DCS system. This not only improves the operation efficiency and production quality of the air compressor, but also enhances the flexibility and response ability of equipment management. This solution is particularly applicable to scenarios where the communication protocol of the air compressor is non-standard, the message format is also non-standard, and the old equipment cannot achieve remote monitoring with the DCS system. Description of the Drawings

[0015] The following further describes the embodiments of the present utility model with reference to the drawings, where:

[0016] Figure 1 Shows a schematic structural diagram of an air compressor system with remote monitoring function according to one embodiment. Detailed Embodiments

[0017] In order to make the purpose, technical solutions and advantages of the present utility model clearer, the following further details the present utility model through specific embodiments with reference to the drawings. It should be understood that the specific embodiments described herein are only used to explain the present utility model and are not used to limit the present utility model.

[0018] Figure 1The structural schematic diagram of an air compressor system with remote monitoring function according to an embodiment is shown. The system includes: an air compressor (not shown in the figure), an air compressor controller 1, an RS-232 isolator 2, a communication protocol converter 3, an RS-485 isolator 4, a DCS system 5, a data receiving counter 8, an operating status indicator 9 for indicating the operating status of the air compressor, an exhaust pressure gauge 10 for measuring the pressure in the exhaust pipeline of the air compressor, an oil pressure gauge 11 for measuring the oil pressure in the lubricating oil pipeline of the air compressor, an exhaust temperature gauge 12 for measuring the temperature in the exhaust pipeline of the air compressor, an internal temperature gauge 13 for measuring the internal temperature of the air compressor, and a motor ammeter 14 for measuring the current when the air compressor motor is running.

[0019] The air compressor controller 1 is connected to the air compressor and controls the air compressor. The air compressor controller 1 is connected to the RS-232 isolator 2 through a cable, the RS-232 isolator 2 is connected to the communication protocol converter 3 through a cable, the communication protocol converter 3 is connected to the RS-485 isolator 4 through a cable, and the RS-485 isolator 4 is connected to the DCS system 5 through a cable.

[0020] The air compressor controller 1 is respectively connected to the data receiving counter 8, the operating status indicator 9, the exhaust pressure gauge 10, the oil pressure gauge 11, the exhaust temperature gauge 12, the internal temperature gauge 13, and the motor ammeter 14, and can receive information or data from the data receiving counter 8, the operating status indicator 9, the exhaust pressure gauge 10, the oil pressure gauge 11, the exhaust temperature gauge 12, the internal temperature gauge 13, and the motor ammeter 14.

[0021] In one embodiment, the exhaust pressure gauge 10, the oil pressure gauge 11, the exhaust temperature gauge 12, and the motor ammeter 14 are respectively connected to the RS-232 interface of the air compressor controller 1 for communication.

[0022] The air compressor controller 1 is responsible for monitoring the status of the air compressor and collecting and storing various required information, such as the operating status of the air compressor, the pressure in the exhaust pipeline of the air compressor, the oil pressure in the lubricating oil pipeline of the air compressor, the temperature in the exhaust pipeline of the air compressor, the internal temperature of the air compressor, the current when the air compressor motor is running, and so on.

[0023] In one embodiment, the air compressor controller 1 is connected to the RS-232 isolator 2 through an RS-232 serial connection cable (usually a serial port cable), and this cable usually has two terminals, one end is connected to the RS-232 serial port of the air compressor controller 1, and the other end is connected to the RS-232 serial port of the RS-232 isolator 2.

[0024] The RS-232 isolator 2 can be used to isolate and protect the RS-232 signal to prevent the communication quality from being affected by electrical interference and potential ground loop problems around the air compressor.

[0025] In one embodiment, an RS-232 serial cable (also known as a serial cable or a DB9 cable) is used to connect the RS-232 serial port of the RS-232 isolator 2 to the RS-232 serial port of the communication protocol converter 3. The two ends of this serial cable are respectively inserted into the RS-232 interfaces of the RS-232 isolator 2 and the communication protocol converter 3.

[0026] The communication protocol converter 3 is used to convert the communication protocol of the air compressor controller 1 into a communication protocol adapted to the DCS system 5 for the DCS system 5 to read, so that the air compressor controller 1 and the DCS system 5 can communicate with each other. In one embodiment, the communication serial port of the air compressor controller 1 is defined as non-standard, in a 7-bit no-parity format, while the general single-chip microcomputer serial port is 8-bit. It is necessary to use conventional I / O to simulate a 7-bit serial port. The communication message is in a non-standard format. After being read by the single-chip microcomputer, it needs to be converted into 8-bit standard communication data according to the definition and sent to the Modbus communication interface buffer for the DCS system 5 to read.

[0027] In one embodiment, the communication protocol converter 3 is connected to the RS-485 interface of the RS-485 isolator 4 through a suitable RS-485 serial cable (also known as an RS-485 bus cable). The RS-485 bus cable generally includes a wire A and a wire B. Connect the wire A on the RS-485 interface of the communication protocol converter 3 to the wire A of the RS-485 interface of the RS-485 isolator 4, and connect the wire B on the RS-485 interface of the communication protocol converter 3 to the wire B of the RS-485 interface of the RS-485 isolator 4. At the same time, the ground wire also needs to be connected to ensure stable and reliable communication.

[0028] The RS-485 isolator 4 is used to isolate and protect the RS-485 bus to ensure the communication quality and stability during long-distance data transmission between the communication protocol converter 3 and the RS-485 isolator 4.

[0029] In one embodiment, the RS-485 isolator 4 has two groups of RS-485 interfaces, one for input and the other for output. Select a suitable RS-485 bus cable (usually a twisted pair), connect the wire A of the output interface of the RS-485 isolator 4 to the wire A of the RS-485 interface of the DCS system 5, and connect the wire B of the output interface of the RS-485 isolator 4 to the wire B of the RS-485 interface of the DCS system 5. The ground wire also needs to be connected to ensure the signal stability and transmission quality.

[0030] In one embodiment, the DCS system 5 provides an intuitive and user-friendly human-machine interaction interface, enabling remote real-time monitoring and control of various parameters in the industrial process of air compressors, recording and storing a large amount of process data. At the same time, it also has a fault detection and diagnosis function, capable of quickly responding to equipment failures or abnormal situations and taking corresponding measures, such as alarming, automatic switching, equipment protection, etc., to minimize the possibility of production interruption and damage to the air compressor.

[0031] In one embodiment, the data reception counter 8 is used to record and monitor the number of events or commands received by the air compressor controller 1, helping to monitor, maintain, and optimize the operating state and performance of the air compressor.

[0032] In one embodiment, the operating status indicator 9 is used to indicate the current working status of the air compressor, including running, stopped, and faulty.

[0033] In one embodiment, the exhaust pressure gauge 10 is used to measure the pressure in the exhaust pipeline of the air compressor, transmit the real-time measured exhaust pressure data to the air compressor controller 1, monitor and adjust the exhaust pressure of the air compressor to ensure operation within a safe range.

[0034] In one embodiment, the oil pressure gauge 11 is used to measure the oil pressure in the lubricating oil circuit of the air compressor, transmit the real-time measured oil pressure data to the air compressor controller 1, monitor and adjust the lubrication system of the air compressor to ensure the oil circuit pressure and oil condition during operation.

[0035] In one embodiment, the exhaust temperature gauge 12 is used to measure the temperature in the exhaust pipeline of the air compressor, transmit the real-time measured exhaust temperature data to the air compressor controller, monitor and control the exhaust temperature of the air compressor to prevent overheating or abnormal temperature conditions.

[0036] In one embodiment, the internal temperature gauge 13 is used to measure the temperature inside the air compressor, transmit the real-time measured internal temperature data of the air compressor to the air compressor controller, monitor the working environment temperature of the air compressor, and promptly detect and prevent problems of excessive temperature.

[0037] In one embodiment, the motor ammeter 14 is used to measure the current during the operation of the air compressor motor, transmit the real-time measured motor current data to the air compressor controller 1, monitor the operating state and load condition of the motor, and ensure that the motor operates within a safe and effective current range.

[0038] Embodiment:

[0039] Such as Figure 1As shown, connect the air compressor controller 1, RS-232 isolator 2, communication protocol converter 3, RS-485 isolator 4, and DCS system 5. Also connect the air compressor controller 1 to the data receiving counter 8, operating status indicator 9, exhaust pressure gauge 10, oil pressure gauge 11, exhaust temperature gauge 12, internal temperature gauge 13, and motor ammeter 14 respectively. The specific equipment models and required power supplies are selected according to the actual application situation.

[0040] There are two communication processes between the air compressor controller 1 and the DCS system 5. The first is that the air compressor controller 1 collects data from devices such as the data receiving counter 8, operating status indicator 9, exhaust pressure gauge 10, oil pressure gauge 11, exhaust temperature gauge 12, internal temperature gauge 13, and motor ammeter 14. When the air compressor controller 1 receives the data collection response instruction sent by the communication protocol converter 3, the air compressor controller 1 starts to store the data in the location specified by the communication protocol converter 3. The communication protocol converter 3 organizes the data, converts it into a protocol and format that the DCS system 5 can parse, and stores it in the Modbus buffer. When the DCS system 5 issues a Modbus communication instruction, the communication protocol converter 3 receives the Modbus communication command and performs corresponding operations according to the instruction. The DCS system 5 parses and processes the received data, such as converting the collected temperature unit from Fahrenheit to Celsius, the pressure unit from pounds to kilopascals, and the data range from non-percentage to percentage, etc. It will also perform corresponding control actions based on the received data and status information. For example, it will issue an alarm when detecting an abnormal situation, automatically adjust the operating parameters of the air compressor controller 1, or issue a remote command to start or stop the equipment. Finally, the processed data is displayed on the human-machine interface of the DCS system 5. The second is that the DCS system 5 writes control commands into Modbus. The communication protocol converter 3 receives the Modbus communication instruction, which may include operations such as requesting the current status, data collection, and setting parameters. The communication protocol converter 3 converts the data into a protocol and format that the air compressor controller 1 can parse and then sends it. After receiving the instruction, the air compressor controller performs corresponding operations according to the instruction. For example, reading sensor data, querying the equipment status, and adjusting working parameters. Thus, remote monitoring of the air compressor system with non-standard communication and non-standard message formats and the DCS can be achieved.

[0041] References to "each embodiment", "some embodiments", "an embodiment", or "embodiments", etc. in this document refer to a particular feature, structure, or property described in connection with the embodiment being included in at least one embodiment. Thus, the appearances of phrases such as "in each embodiment", "in some embodiments", "in an embodiment", or "in embodiments", etc. throughout this document are not necessarily referring to the same embodiment. In addition, a particular feature, structure, or property may be combined in any suitable manner in one or more embodiments. Therefore, a particular feature, structure, or property shown or described in connection with one embodiment may be combined with the features, structures, or properties of one or more other embodiments, either wholly or partially, without limitation, as long as the combination is not illogical or non - working.

[0042] Some exemplary embodiments of the present utility model have been described above. It can be understood that the above - mentioned embodiments are only used to explain the present utility model and do not constitute a limitation on the protection scope of the present utility model. The features in these embodiments can be recombined in a suitable manner, and the solutions obtained thereby are still within the protection scope required by the present utility model. Based on the above - mentioned embodiments, all other embodiments obtained by those skilled in the art without creative efforts, that is, all modifications, equivalent replacements, and improvements, etc. made within the spirit and principle of this application, fall within the protection scope required by the present utility model.

Claims

1. An air compressor system with remote monitoring function, characterized in that, Including: An air compressor, an air compressor controller (1), an RS-232 isolator (2), a communication protocol converter (3), an RS-485 isolator (4), a DCS system (5), a data receiving counter (8), an operating status indicator (9) for indicating the operating status of the air compressor, an exhaust pressure gauge (10) for measuring the pressure in the exhaust pipeline of the air compressor, an oil pressure gauge (11) for measuring the oil pressure in the lubricating oil pipeline of the air compressor, an exhaust temperature gauge (12) for measuring the temperature in the exhaust pipeline of the air compressor, an internal temperature gauge (13) for measuring the internal temperature of the air compressor, and a motor ammeter (14) for measuring the current when the air compressor motor is running. The air compressor is connected to the air compressor controller (1), the air compressor controller (1) is connected to the RS-232 isolator (2) through a cable, the RS-232 isolator (2) is connected to the communication protocol converter (3) through a cable, the communication protocol converter (3) is connected to the RS-485 isolator (4) through a cable, the RS-485 isolator (4) is connected to the DCS system (5) through a cable, and the air compressor controller (1) is respectively connected to the data receiving counter (8), the operating status indicator (9), the exhaust pressure gauge (10), the oil pressure gauge (11), the exhaust temperature gauge (12), the internal temperature gauge (13), and the motor ammeter (14).

2. The air compressor system with remote monitoring function according to claim 1, wherein, The exhaust pressure gauge (10), the oil pressure gauge (11), the exhaust temperature gauge (12), and the motor ammeter (14) are connected to the RS-232 interface of the air compressor controller (1).

3. The air compressor system with remote monitoring function according to claim 1, wherein, The air compressor controller (1) is connected to the RS-232 isolator (2) through an RS-232 serial connection cable. One end of the RS-232 serial connection cable is connected to the RS-232 serial port of the air compressor controller (1), and the other end is connected to the RS-232 serial port of the RS-232 isolator (2).

4. The air compressor system with remote monitoring function according to claim 1, wherein, Use an RS-232 serial cable to connect the RS-232 serial port of the RS-232 isolator (2) to the RS-232 serial port of the communication protocol converter (3).

5. The air compressor system with remote monitoring function according to claim 1, wherein, Connect the RS-485 interface of the communication protocol converter (3) to the RS-485 interface of the RS-485 isolator (4) through an RS-485 serial cable.

6. The air compressor system with remote monitoring function according to claim 5, wherein, The RS-485 serial cable includes line A and line B. Connect line A of the RS-485 interface of the communication protocol converter (3) to line A of the RS-485 interface of the RS-485 isolator (4), connect line B of the RS-485 interface of the communication protocol converter (3) to line B of the RS-485 interface of the RS-485 isolator (4), and connect the ground wire at the same time.

7. The air compressor system with remote monitoring function according to claim 1, wherein, The RS-485 isolator (4) has two sets of RS-485 interfaces, one set is the input interface and the other set is the output interface.

8. The air compressor system with remote monitoring function according to claim 1, wherein, Connect the A wire of the output interface of the RS-485 isolator (4) to the A wire of the RS-485 interface of the DCS system (5) through an RS-485 serial port cable, connect the B wire of the output interface of the RS-485 isolator (4) to the B wire of the RS-485 interface of the DCS system (5), and connect the ground wire at the same time.

9. The air compressor system with remote monitoring function according to claim 1, wherein, The DCS system (5) has a human-machine interface.

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