Control device of air compressor

Abstract

The utility model relates to the technical field of air compressor control, in particular to a control device of an air compressor. Comprising a signal acquisition module and a drainage and slag removal device, the signal acquisition module and the drainage and slag removal device are both connected with a DCS controller, and the signal acquisition module comprises a plurality of temperature sensors, a plurality of pressure sensors and a plurality of liquid level sensors. The temperature sensor, the pressure sensor and the liquid level sensor are used for measuring the temperature, the pressure and the liquid level of a plurality of positions of the air compressor, measured data are transmitted to the DCS controller, the air compressor is monitored and early warned, and when equipment operates or is in an abnormal working condition, the air compressor can be automatically controlled. Whether the temperature, pressure and liquid level parameters of the air compressor are abnormal or not is detected in time, further measures can be taken actively according to the detection result, faults of the air compressor are reduced, and safe operation of the air compressor is ensured.

Description

Technical Field

[0001] The utility model relates to the technical field of air compressor control, in particular to a control device for an air compressor. Background Art

[0002] Air compressors are a key component of compressed air supply in industrial production. They draw in ambient air and, through a series of processes, compress it into high-pressure gas for use in various gas-consuming equipment. Currently, most air compressors commonly used in thermal power plants are controlled by local PLC systems. All operating parameters are displayed locally, and critical protection measures, such as excessive equipment outlet pressure and temperature, and excessive motor bearing temperature, are implemented by the local PLC system. During routine operation, when parameters such as pressure and temperature deviate from normal values, centralized control personnel remain unaware. The control system only receives feedback of tripping after a protective action is triggered, shutting down the air compressor. This prevents personnel from timely monitoring of abnormal equipment operating conditions. Therefore, a monitoring system is needed to monitor all operating parameters of the air compressor in real time. This system should systematically collect detailed temperature, pressure, and liquid level data at all points within the compressor, and collect historical data over a long period of time. This system can facilitate timely and accurate action to minimize compressor failures and protect the compressor's safety. Utility Model Content

[0003] The purpose of the utility model is to provide a control device for an air compressor, which can perform real-time online monitoring of the temperature, pressure and liquid level at multiple positions of the air compressor, so as to quickly discover abnormal working conditions of the air compressor, take timely measures, reduce air compressor failures, and ensure the safe operation of the air compressor.

[0004] The utility model provides a control device for an air compressor, comprising a signal acquisition module and a water drainage and slag removal device, wherein both the signal acquisition module and the water drainage and slag removal device are connected to a DCS controller, and the signal acquisition module comprises a plurality of temperature sensors, a plurality of pressure sensors and a plurality of liquid level sensors;

[0005] Wherein a plurality of the temperature sensors are respectively installed at the exhaust port of the air compressor, the exhaust port of the low-pressure rotor, the inlet of the high-pressure rotor, the exhaust port of the high-pressure rotor, the cooling water inlet, the cooling water outlet of the low-pressure rotor, the cooling water outlet of the air compressor, the lubricating oil circuit, the U-phase winding of the motor, the V-phase winding of the motor, the W-phase winding of the motor, the drive end bearing of the motor, and the non-drive end bearing of the motor;

[0006] The plurality of pressure sensors are respectively installed at the air inlet of the air compressor, the air exhaust port of the air compressor, the compressor lubricating oil system, and the inlet or outlet of the intercooler;

[0007] The plurality of liquid level sensors are respectively mounted on the exhaust cylinder of the air compressor and the water drainage and slag removal device.

[0008] Furthermore, the DCS controller includes a configuration monitoring screen module, a graphics generation algorithm module, a string animation editing algorithm module, an animation link editing algorithm module, a numerical output algorithm module, and a numerical flashing algorithm module.

[0009] Furthermore, the drainage and slag removal device includes an electronic drainer and a slag removal tank, the air inlet of the slag removal tank is connected to the exhaust port of the air compressor, the drain outlet of the slag removal tank is connected to the water inlet of the electronic drainer through a pipe, a drain valve is provided at the water outlet of the electronic drainer, and the electronic drainer is connected to the DCS controller.

[0010] Furthermore, the deslagging tank is provided with a low liquid level sensor and a high liquid level sensor.

[0011] Furthermore, a slag removal port is provided at the bottom of the slag removal tank, and a metal filter element is provided inside the slag removal tank.

[0012] Furthermore, it also includes a control box, which is equipped with a temperature signal distributor, a pressure signal distributor and a liquid level signal distributor. The temperature signal distributor, the pressure signal distributor and the liquid level signal distributor are respectively equipped with two output ports, one of which is connected to the DCS controller, and the other is connected to the on-site PLC control system of the air compressor.

[0013] Furthermore, a terminal block and a power module are provided inside the control box.

[0014] Furthermore, the control box includes a box body, and a box cover is hinged on the box body.

[0015] Furthermore, it also includes a locking mechanism, which includes an insertion rod and an insertion block; the insertion rod is fixed to the edge of the box cover, and the insertion block is provided on the outer wall of the box body, and the insertion rod can be inserted into the insertion block.

[0016] Furthermore, a cavity is provided inside the plug block, a spring is provided in the cavity, the spring is fixed to the slide rod, a socket is provided on the slide rod, and two opposite side walls of the plug block are respectively provided with a first through hole and a second through hole corresponding to the socket, and one end of the plug rod passes through the first through hole, the socket, and the second through hole in sequence and extends out of the plug block.

[0017] In summary, compared with the prior art, the present invention has the following advantages:

[0018] The technical solution of the present invention measures the temperature, pressure and liquid level at multiple positions of the air compressor by setting up multiple temperature sensors, multiple pressure sensors and multiple liquid level sensors, and transmits the measurement data to the DCS controller to monitor and warn the air compressor. When the equipment is running or in an abnormal working condition, it can promptly detect whether the temperature, pressure and liquid level parameters of the air compressor are abnormal, and further measures can be taken actively according to the detection results to reduce the occurrence of air compressor failures and ensure the safe operation of the air compressor; multiple liquid level sensors are set to measure the liquid in the exhaust cylinder of the air compressor, and open or close the water drainage and slag removal device according to the height of the liquid level, thereby protecting the air compressor. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the specific implementation methods of the utility model or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0020] Figure 1 This is a system block diagram of the control device in Example 1 of the present utility model;

[0021] Figure 2 This is a schematic diagram of the structure inside the control box in Example 1 of the present utility model;

[0022] Figure 3 This is a schematic structural diagram of the drainage and slag removal device in Example 1 of the present utility model;

[0023] Figure 4 This is a static graphic of the air compressor monitoring parameter screen in Example 1 of the present utility model;

[0024] Figure 5 This is an interface diagram for text programming in Example 1 of the present utility model;

[0025] Figure 6 This is an interface diagram of the channel analog range of the exclusive monitoring screen in Example 1 of the present utility model;

[0026] Figure 7 This is an interface diagram for real-time sampling of temperature, pressure, and liquid level measurement parameters in Example 1 of the present utility model;

[0027] Figure 8 This is a diagram showing the real-time over-limit flashing interface of the temperature, pressure, and liquid level measurement parameters in Example 1 of the present utility model;

[0028] Figure 9 This is a schematic structural diagram of the control box in Example 2 of the present utility model;

[0029] Figure 10 It is a right sectional view of the insert in Example 2 of the present utility model;

[0030] Figure 11 This is a right sectional view of the locking mechanism in Example 2 of the present utility model.

[0031] Explanation of the reference numerals: 1-control box; 101-box body; 102-box cover; 103-insert block; 1031-first through hole; 1032-second through hole; 1033-spring; 104-slide rod; 1041-jack; 1042-limiting plate; 105-mounting plate; 106-insert rod; 2-power module; 3-temperature signal distributor; 4-pressure signal distributor; 5-liquid level signal distributor; 6-terminal block; 7-slag removal tank; 701-high liquid level sensor; 702-low liquid level sensor; 703-slag removal port; 8-electronic drainer; 801-drain valve. DETAILED DESCRIPTION

[0032] The following will clearly and completely describe the technical solutions of the present invention in conjunction with the embodiments. Obviously, the embodiments described are only a part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0033] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", etc., indicating directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore should not be understood as a limitation on the present invention.

[0034] In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the said features. In the description of the present utility model, "multiple" means two or more, unless otherwise clearly and specifically defined. In addition, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be a communication between the two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present utility model can be understood according to the specific circumstances.

[0035] Example 1

[0036] A control device for an air compressor, such as Figure 1 As shown, it includes a signal acquisition module and a water drainage and slag removal device. Both the signal acquisition module and the water drainage and slag removal device are connected to the DCS controller. The signal acquisition module includes multiple temperature sensors, multiple pressure sensors and multiple liquid level sensors.

[0037] Multiple temperature sensors are respectively installed at the exhaust port of the air compressor, the exhaust port of the low-pressure rotor, the inlet of the high-pressure rotor, the exhaust port of the high-pressure rotor, the cooling water inlet, the cooling water outlet of the low-pressure rotor, the cooling water outlet of the air compressor, the lubricating oil circuit, the U-phase winding of the motor, the V-phase winding of the motor, the W-phase winding of the motor, the drive end bearing of the motor, and the non-drive end bearing of the motor. They are used to measure the exhaust temperature of the air compressor, the exhaust temperature of the low-pressure rotor, the inlet temperature of the high-pressure rotor, the exhaust temperature of the high-pressure rotor, the cooling water inlet temperature, the cooling water outlet temperature of the low-pressure rotor, the cooling water outlet temperature, the oil temperature, the motor winding U temperature, the motor winding V temperature, the motor winding W temperature, the drive end temperature of the motor bearing, and the non-drive end temperature of the motor bearing.

[0038] Multiple pressure sensors are installed at the air compressor inlet, air compressor exhaust, compressor lubricating oil system, and the inlet or outlet of the intercooler to measure the air compressor intake pressure, exhaust pressure, oil pressure, and intercooler pressure to prevent poor cooling effect and metal friction between the rotor and cylinder body caused by quality changes of the lubricating medium.

[0039] Multiple liquid level sensors are respectively installed on the air compressor exhaust cylinder and the drainage and slag removal device. The liquid level sensor installed on the air compressor exhaust cylinder is used to measure the liquid level in the air compressor exhaust cylinder. When the liquid level is high, the electronic drainer 8 is started to drain the liquid, and when the liquid level is low, the electronic drainer 8 is automatically closed.

[0040] The drainage and slag removal device is used to discharge the impurities and water generated in the air compressor, playing a role in protecting the air compressor body. Figure 3 As shown ( Figure 3 The arrow in the figure indicates the air inlet. The drainage and deslagging device consists of an electronic drainer 8 and a deslagging tank 7. The air inlet of the deslagging tank 7 is connected to the exhaust port of the air compressor. The drain outlet of the deslagging tank 7 is connected to the water inlet of the electronic drainer 8 via a pipe. A drain valve 801 is installed at the water outlet of the electronic drainer 8. The electronic drainer 8 is connected to the DCS controller. A high liquid level sensor 701 and a low liquid level sensor 702 are installed on the deslagging tank 7. When the high liquid level sensor 701 detects a signal, the DCS controller sends a command to the electronic drainer 8 to open the drain valve 801 to drain the water. When the low liquid level sensor 702 detects a signal, the DCS controller sends a command to the electronic drainer 8 to close the drain valve 801.

[0041] A metal filter element is installed inside the slag removal tank 7 for filtering. A slag removal port 703 is provided at the bottom. The slag removal port 703 is sealed with a plug of size 6, and slag is discharged regularly.

[0042] like Figure 2 As shown, the control box 1 is equipped with a power supply module 2, a temperature signal distributor 3, a pressure signal distributor 4, and a liquid level signal distributor 5. The temperature signal distributor 3, pressure signal distributor 4, and liquid level signal distributor 5 each have two output ports, one of which is connected to the DCS controller and the other to the air compressor's local PLC control system. A 220VAC / 24V power supply module provides power to the entire system. Terminal blocks 6 for connecting wires and cables are also provided to facilitate wiring and maintenance. The input port of the liquid level signal distributor 5 is connected to the liquid level sensor, and the input port of the pressure signal distributor 4 is connected to the pressure sensor. Two temperature signal distributors 3 are provided, one of which has an input port connected to a temperature sensor mounted on the motor, and the other has an input port connected to another temperature sensor.

[0043] Control Box 1, the local control box for the air compressor's control technology, primarily houses the signal distributor, power module, and terminal block, distributing and relaying local and remote signals. The signal distributor within Control Box 1 provides two outputs: one signal is sent to the compressor's local PLC control system to display real-time values, facilitating local control mode display. The other signal is connected to the DCS controller's AI board via a shielded computer cable, enabling remote data acquisition, control, and display.

[0044] The DCS controller mainly includes the configuration monitoring screen module and the algorithm module. The algorithm module includes the graphic generation algorithm module, the string animation editing algorithm module, the animation link editing algorithm module, the numerical output algorithm module, and the numerical flashing algorithm module. The configuration monitoring screen module is configured by the DCS controller through the normal graphics to complete the static graphics of the air compressor monitoring parameter screen (such as Figure 4 As shown in the figure, the algorithm module sets the corresponding range, upper and lower limit parameters of the air compressor monitoring parameter screen, fills the screen color, describes the name of each channel, identifies the real-time sampling, transmission and display of the measurement parameters, and presents them on the RTD screen for easy monitoring by users.

[0045] The text programming of the exclusive monitoring screen (i.e. the air compressor monitoring parameter screen) is designed by the string animation editing algorithm module to complete the design of the measurement point name, domain name, and unit format, such as Figure 5 As shown. The channel analog range of the exclusive monitoring screen is filled with screen percentage by the animation link editing algorithm module, including color selection filling, minimum and maximum value filling and other designs, such as Figure 6 As shown. The real-time sampling of temperature, pressure and liquid level measurement parameters is done by the numerical output algorithm module to design the numerical unit, center alignment, format, etc. to achieve digital display, such as Figure 7 As shown. The real-time over-limit flicker of temperature, pressure and liquid level measurement parameters is designed by the numerical flicker algorithm module to select the flicker rate, the measurement point name and the domain name, so as to realize the dynamic flicker of the numerical value. Figure 8 shown.

[0046] At the same time, the DCS controller also has a data storage module for storing the collected air compressor data.

[0047] The temperature sensor in the utility model adopts a sensor with a 316L shell and a protection level of IP67. The lead is a high-temperature resistant shielded gold multi-strand soft wire. The bottom is designed with good heat conduction and customized size to ensure easy installation and disassembly in a limited space. The sensor is columnar and has a long strip structure. The bottom is connected to the various components of the air compressor and is a threaded interface. Heat is transmitted to the sensor through conduction. The working principle of the sensor is that the material resistance changes with temperature, and the potential difference generated is the temperature change. The temperature change detected by the temperature sensor indicates the current working status temperature of each part of the air compressor, and the temperature detection sensing function is realized.

[0048] The pressure sensor uses a 316L material shell with a protection level of IP67. The lead is a high-temperature resistant shielded gold multi-strand soft wire. The bottom is designed with a high-sensitivity pressure sensor with special dimensions to ensure easy installation and disassembly in limited space. The pressure sensor signal enters the control box 1, passes through the pressure signal distributor 4, and is sent to the local PLC control system for measurement and display. The other line is connected to the AI board of the DCS controller through a computer shielded cable.

[0049] The liquid level sensor uses a 316L material shell with a protection level of IP67. The lead wire is a high-temperature resistant shielded gold multi-strand soft wire. The liquid level sensing design has good liquid or soda-water mixture height detection performance. Customized size ensures easy installation and disassembly in limited space. The liquid level sensor signal enters the control box 1, passes through the liquid level signal distributor 5, and is sent to the local PLC control system for measurement and display. The other line is connected to the AI board of the DCS controller through a computer shielded cable.

[0050] The control device for an air compressor provided by the utility model collects the temperature, pressure and liquid level of various parts of the air compressor by setting a signal acquisition module, and collects and calculates the temperature, pressure and liquid level of various parts of the air compressor in the form of modules / quantities on the AI board of the DCS controller. The algorithm module of the DCS controller configures the monitoring screen, providing a real-time and visual monitoring means for monitoring personnel, avoiding the damage of the air compressor caused by changes in various physical quantities of the air compressor due to long-term operation or improper human operation, and can give an early warning of changes in temperature, pressure and liquid level values before a fault occurs, so as to make timely adjustments to avoid overall damage to the air compressor, and provide more comprehensive and detailed parameters for the maintenance of the air compressor.

[0051] The control device provided by the utility model solves the problem of single air compressor control technology, realizes dual-channel signal control of equipment measurement signals, improves measurement accuracy, and can measure and control the air compressor in real time online through the powerful data processing function and history collection function of the DCS controller.

[0052] Example 2

[0053] A control device for an air compressor, the technical solution in this embodiment is basically the same as that in embodiment 1, except that: Figure 9 As shown, in this embodiment, a locking mechanism is further provided between the box body 101 and the box cover 102 of the control box 1.

[0054] The locking mechanism in this embodiment includes an insert rod 106 and an insert block 103, and the insert rod 106 is inserted into the insert block 103. The box cover 102 is connected to one side of the box body 101 through a hinge axis. A mounting plate 105 is fixed to the edge of the side wall of the box cover 102 opposite to the hinge axis, and the insert rod 106 is fixed to the side wall of the mounting plate 105. A square insert block 103 is fixed to the outside of the side wall of the box body 101, such as Figure 10As shown, a vertical, cylindrical cavity is provided inside the insert block 103, in which a slide rod 104 is slidably connected, with the top end of the slide rod 104 extending outside the insert block 103. A socket 1041 is provided on the slide rod 104, and a first through hole 1031 and a second through hole 1032 corresponding to the socket 1041 are provided on the left and right walls of the insert block 103, respectively. A circular stop plate 1042 is fixed to the top end of the slide rod 104, and the diameter of the stop plate 1042 is larger than the diameter of the cavity. A spring 1033 is fixed to the bottom end of the cavity, and the top end of the spring 1033 is fixed to the bottom end of the slide rod 104. The diameter of the insert rod 106 is smaller than that of the socket 1041, and the diameters of the first through hole 1031, the socket 1041, and the second through hole 1032 are the same.

[0055] The initial state of the locking mechanism is: the insertion hole 1041 of the slide bar 104 is misaligned with the first through hole 1031 and the second through hole 1032 under the action of the spring 1033. When the box cover 102 needs to be locked and fixed, the slide bar 104 is pressed downward to align the insertion hole 1041 with the first through hole 1031 and the second through hole 1032. When closing the box cover 102, the insertion rod 106 is passed through the first through hole 1031, the insertion hole 1041, and the second through hole 1032 in sequence and extended to the outside of the plug block 103. The slide bar 104 is released, and the slide bar 104 moves upward under the action of the elastic force of the spring 1033, locking the insertion rod 106 (such as Figure 11 shown).

[0056] The provided locking mechanism can lock the box body 101 and the box cover 102, making operation convenient and protecting the various electronic devices inside the control box 1.

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A control device for an air compressor, characterized in that: It includes a signal acquisition module and a water drainage and slag removal device, both of which are connected to a DCS controller, and the signal acquisition module includes multiple temperature sensors, multiple pressure sensors and multiple liquid level sensors; Wherein a plurality of the temperature sensors are respectively installed at the exhaust port of the air compressor, the exhaust port of the low-pressure rotor, the inlet of the high-pressure rotor, the exhaust port of the high-pressure rotor, the cooling water inlet, the cooling water outlet of the low-pressure rotor, the cooling water outlet of the air compressor, the lubricating oil circuit, the U-phase winding of the motor, the V-phase winding of the motor, the W-phase winding of the motor, the drive end bearing of the motor, and the non-drive end bearing of the motor; The plurality of pressure sensors are respectively installed at the air inlet of the air compressor, the air exhaust port of the air compressor, the compressor lubricating oil system, and the inlet or outlet of the intercooler; The plurality of liquid level sensors are respectively mounted on the exhaust cylinder of the air compressor and the water drainage and slag removal device.

2. The control device according to claim 1, characterized in that The DCS controller includes a configuration monitoring screen module, a graphic generation algorithm module, a character string animation editing algorithm module, an animation connection editing algorithm module, a numerical value output algorithm module, and a numerical value flickering algorithm module.

3. The control device according to claim 1, characterized in that The drainage and slag removal device includes an electronic drainer and a slag removal tank. The air inlet of the slag removal tank is connected to the exhaust port of the air compressor. The drainage port of the slag removal tank is connected to the water inlet of the electronic drainer through a pipe. A drainage valve is provided at the water outlet of the electronic drainer. The electronic drainer is connected to the DCS controller.

4. The control device according to claim 3, characterized in that The deslagging tank is provided with a low liquid level sensor and a high liquid level sensor.

5. The control device according to claim 3, characterized in that A slag removal port is provided at the bottom of the slag removal tank, and a metal filter element is provided inside the slag removal tank.

6. The control device according to claim 1, characterized in that It also includes a control box, which is equipped with a temperature signal distributor, a pressure signal distributor and a liquid level signal distributor. The temperature signal distributor, the pressure signal distributor and the liquid level signal distributor are respectively equipped with two output ports, one of which is connected to the DCS controller, and the other is connected to the on-site PLC control system of the air compressor.

7. The control device according to claim 6, characterized in that The control box is also provided with a terminal block and a power module.

8. The control device according to claim 6, characterized in that The control box comprises a box body, and a box cover is hinged on the box body.

9. The control device according to claim 8, characterized in that It also includes a locking mechanism, which includes an insertion rod and an insertion block; the insertion rod is fixed to the edge of the box cover, and the outer wall of the box body is provided with an insertion block, and the insertion rod can be inserted into the insertion block.

10. The control device according to claim 9, characterized in that: A cavity is provided inside the plug block, a spring is provided in the cavity, the spring is fixed to the slide rod, a socket is provided on the slide rod, and two opposite side walls of the plug block are respectively provided with a first through hole and a second through hole corresponding to the socket, and one end of the plug rod passes through the first through hole, the socket, and the second through hole in sequence and extends out of the plug block.

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