Air compressor energy-saving system based on hydraulic energy recovery

Abstract

The utility model discloses an air compressor energy-saving system based on hydraulic energy recovery and an operation method of the air compressor energy-saving system, and relates to the technical field of air compressor energy saving. According to the system, under the unloading or low-load state of the air compressor, residual mechanical energy is converted into hydraulic energy through the hydraulic pump linked with the air compressor, and the hydraulic energy is stored in the hydraulic energy accumulator. And when the system load rises or the air compressor needs to be quickly started, the stored hydraulic energy is released through the hydraulic motor, and the air compressor is assisted to be accelerated to a rated state. The system adopts closed-loop PID control, feedforward control and a self-adaptive adjustment algorithm, ensures that the energy recovery and release process is stable and efficient, has a multi-stage safety protection function, and achieves the purposes of saving energy, reducing consumption, shortening starting response and prolonging the service life of equipment.

Description

TECHNICAL FIELD

[0001] The utility model relates to air compressor energy saving technical field especially, it relates to a kind of air compressor energy saving system and its operating method based on hydraulic energy recovery, the utility model under the condition of air compressor unloading or low load, through hydraulic energy recovery device capture residual mechanical energy, and using hydraulic energy storage module stores and releases energy to assist air compressor start or accelerate energy saving. BACKGROUND

[0002] Air compressor sucks external air into compression cavity through the reciprocating / rotating motion of internal piston, screw or impeller, and increases pressure by reducing gas volume. The compressed high-pressure air is stored in gas storage tank for subsequent equipment use.

[0003] Piston air compressor: compresses gas through piston reciprocating motion, simple structure, suitable for low-pressure scenarios (such as auto repair, paint spraying).

[0004] Screw air compressor: uses male and female screws to compress gas, high efficiency, low noise, suitable for continuous high-load operation (such as factories, mines).

[0005] Centrifugal air compressor: generates centrifugal force to compress gas through high-speed rotation of impeller, suitable for high-flow, low-pressure scenarios (such as power plants).

[0006] Portable air compressor: small size, easy to move, commonly used for outdoor work or small repairs (such as inflating, pneumatic tools).

[0007] Currently, industrial air compressors often generate a large amount of residual mechanical energy that is not utilized due to frequent unloading or low-load conditions. This part of energy is usually wasted through heat dissipation, vibration or other forms, and is not used by the system. Although there are waste heat recovery schemes in existing technology, there is no mature scheme for directly capturing mechanical energy during air compressor unloading and converting it into hydraulic energy for storage, and then releasing it to assist compression when the system needs it. Therefore, how to realize hydraulic energy recovery and intelligent control to balance energy capture and release is a key technical problem for air compressor overall energy saving and improving system response speed. INVENTION CONTENTS

[0008] The utility model aims to make up for the defects of existing technology and provide an air compressor energy saving system based on hydraulic energy recovery and its operating method.

[0009] The utility model is realized by the following technical solutions:

[0010] An air compressor energy saving system based on hydraulic energy recovery includes:

[0011] Air compressor;

[0012] The sensor monitoring module monitors the parameters of the air compressor in real time.

[0013] The hydraulic energy recovery device converts the residual mechanical energy of the air compressor into hydraulic energy under the unloaded or low load state of the air compressor through the linkage mechanism.

[0014] The hydraulic energy storage module is used to store the hydraulic energy converted by the hydraulic energy recovery device.

[0015] The intelligent control module collects the operating parameters of the air compressor and the hydraulic energy storage module in real time, and controls the recovery and release of hydraulic energy through a closed-loop feedback control algorithm.

[0016] The auxiliary execution module feeds back the energy released by the hydraulic energy storage module to the auxiliary drive system of the air compressor to realize auxiliary starting or acceleration.

[0017] The hydraulic energy recovery device includes a hydraulic pump linked with the air compressor, which converts the residual mechanical energy of the air compressor into hydraulic energy under the low load state of the air compressor.

[0018] The hydraulic energy storage module is a hydraulic accumulator or a hydraulic cylinder, and the hydraulic energy storage module is provided with a pressure sensor and a safety valve.

[0019] The auxiliary execution module is a hydraulic motor.

[0020] The sensor monitoring module monitors the pressure, flow rate, rotational speed, and temperature parameters of the air compressor in real time.

[0021] The intelligent control module uses an embedded controller or an industrial-grade PLC, and uses a closed-loop PID controller control combined with a feedforward control module and an adaptive adjustment algorithm to accurately control the operating parameters of the hydraulic energy storage module and the auxiliary execution module.

[0022] An air compressor energy-saving operation method based on hydraulic energy recovery, specifically comprising the following steps:

[0023] (1) The sensor monitoring module monitors the operating state of the air compressor to determine whether the air compressor is in an unloaded or low load state.

[0024] (2) When it is determined to be an unloaded state, the hydraulic energy recovery device is started to convert the residual mechanical energy of the air compressor into hydraulic energy, which is then transmitted to the hydraulic energy storage module for storage.

[0025] (3) The pressure in the hydraulic energy storage module and the operating parameters of the air compressor are monitored in real time, and the required auxiliary energy is calculated using a closed-loop feedback control algorithm.

[0026] (4) When the load rises or the air compressor starts to demand, the control hydraulic energy storage module releases energy through the auxiliary execution module to supply energy to the air compressor auxiliary drive system;

[0027] (5) In the process of energy recovery and release, the control parameters are adjusted in real time, and the safety protection mechanism is started.

[0028] The intelligent control module uses the preset PID algorithm and historical data to adaptively determine when the air compressor is in the low load interval. When the intelligent control module detects that the air compressor exhaust pressure is lower than the set value and the flow is insufficient, the hydraulic energy recovery device is started. The PID controller is used to adjust the speed of the hydraulic energy recovery device, so that the hydraulic oil is uniformly delivered to the hydraulic energy storage module.

[0029] When the load suddenly rises or the air compressor starts to demand, the intelligent control module quickly calculates the required released hydraulic energy, and controls the auxiliary execution module to start the auxiliary air compressor acceleration. The feedforward control module adjusts the output of the auxiliary execution module in advance according to historical data.

[0030] The intelligent control module continuously collects sensor data, adjusts the working parameters of the hydraulic energy recovery device and the hydraulic energy storage module in real time, ensures that the energy conversion process is smooth and efficient, and starts the safety protection program to monitor abnormal conditions. Once the abnormality occurs, the machine is stopped immediately and the emergency power-off device is started to ensure that the system automatically switches to a safe state in abnormal conditions.

[0031] The air compressor can be a screw type or a reciprocating type air compressor with conventional air supply function.

[0032] The hydraulic energy recovery device converts the remaining mechanical energy into hydraulic energy through the hydraulic pump and transmission mechanism linked with the air compressor under unloaded or low load conditions of the air compressor. The hydraulic pump can be controlled by variable speed to adapt to different working conditions, so that the energy conversion is efficient and smooth.

[0033] The hydraulic energy storage module includes a hydraulic oil cylinder or a hydraulic accumulator for storing hydraulic energy converted by the hydraulic pump. The hydraulic energy storage module is provided with a pressure sensor and a safety valve to ensure stable energy storage process and overpressure protection.

[0034] The intelligent control module uses an embedded controller or an industrial-grade PLC to collect air compressor operation data (such as exhaust pressure, flow, speed, vibration, etc.) and hydraulic energy storage module status in real time, and uses closed-loop feedback control algorithm (combined with PID control, feedforward control and adaptive adjustment) to accurately control the start of the hydraulic pump, hydraulic energy recovery and release.

[0035] Auxiliary Execution Module When the system detects a load increase or the air compressor needs to quickly reach the rated state, the auxiliary execution module (such as a hydraulic motor) releases the energy in the hydraulic energy storage module to the air compressor drive system, providing auxiliary power, shortening the startup time and smoothing the load fluctuations.

[0036] The specific working principle is as follows:

[0037] State Monitoring and Triggering

[0038] Intelligent Control Module Real-time monitoring of air compressor operating conditions. When the air compressor is in an unloaded or low-load state (e.g., exhaust pressure is below the set threshold and flow is insufficient), the system enters the energy recovery state, triggering the hydraulic energy recovery device.

[0039] Hydraulic Energy Recovery Process:

[0040] 1. Trigger Condition Judgment

[0041] Using the pre-set PID algorithm and historical data, the system adaptively determines when the air compressor is in a low-load interval, thereby starting the hydraulic pump.

[0042] 2. Energy Conversion and Storage

[0043] The hydraulic pump, under the action of the linkage mechanism, converts the remaining mechanical energy of the air compressor into hydraulic oil energy, which is transported through the pipeline to the hydraulic energy storage module. The control module continuously monitors the pressure in the energy storage module and adjusts the output rate of the hydraulic pump to ensure efficient and safe recovery.

[0044] Hydraulic Energy Release and Auxiliary Operation:

[0045] 1. Release Trigger

[0046] When the system detects a load increase or the air compressor needs to accelerate quickly, the intelligent control module calculates the required hydraulic energy release based on the Model Predictive Control (MPC) or improved PID+feedforward control algorithm.

[0047] 2. Auxiliary Energy Release

[0048] The energy storage module releases energy to the auxiliary drive system of the air compressor through the auxiliary execution module (hydraulic motor), thereby providing additional power support to assist the air compressor in quickly reaching the rated operating state.

[0049] Closed-loop Feedback and Adaptive Control:

[0050] Throughout the process, the control module compares the actual parameters collected in real time with the target parameters and automatically adjusts the control parameters of the hydraulic pump and auxiliary execution module to ensure the stability, response speed, and energy-saving effect of the energy recovery and release process.

[0051] Safety Protection Mechanism:

[0052] The system sets multiple levels of safety protection measures:

[0053] The hydraulic energy storage module has overpressure and overcurrent protection functions;

[0054] The control module monitors temperature, pressure and vibration, and stops immediately and starts the emergency power-off device once abnormal;

[0055] The hydraulic system adopts double insurance design to ensure automatic switching to a safe state in case of failure.

[0056] The utility model has the advantages that: the utility model discloses a system, through the unloading or low load state of air compressor, utilize the hydraulic pump that links to air compressor with the remaining mechanical energy conversion hydraulic energy, and store the hydraulic energy in hydraulic accumulator.When the system load rises or air compressor needs to start quickly, the stored hydraulic energy releases through the hydraulic motor, and air compressor accelerates to the rated state. The system adopts closed loop PID control, feedforward control and adaptive adjustment algorithm, ensures that the energy recovery and release process is stable and efficient, and has multiple levels of safety protection functions, realizes the goal of energy saving, shortens the starting response and prolongs the service life of equipment.

[0057] The core innovation of the utility model is that the remaining mechanical energy during the unloading of the air compressor is captured and stored through the hydraulic energy conversion device, and the hydraulic energy storage module is used to assist the air compressor operation at the critical moment, which overcomes the limitations of simple waste heat recovery or simple energy efficiency monitoring in the prior art, and has significant advantages in overall system energy saving, starting acceleration and equipment protection. The utility model has high novelty and creativity, and is suitable for large-scale industrial air compression system popularization and application. BRIEF DESCRIPTION OF DRAWINGS

[0058] Figure 1 It is the whole system structure schematic diagram;

[0059] Figure 2 It is the hydraulic energy recovery and release flow chart;

[0060] Figure 3 It is the internal control flow chart of intelligent control module;

[0061] Figure 4 It is the utility model system connection diagram. DETAILED DESCRIPTION

[0062] As shown in Figure 1 A kind of air compressor energy-saving system based on hydraulic energy recovery, comprising:

[0063] Air compressor 1;

[0064] Sensor monitoring module 2, real-time monitoring is carried out to air compressor parameter;

[0065] Hydraulic energy recovery device 3, driven by linkage mechanism in air compressor unloading or low load state, converts the remaining mechanical energy of air compressor into hydraulic energy;

[0066] Hydraulic energy storage module 4, used for storing hydraulic energy converted by hydraulic energy recovery device;

[0067] Intelligent control module 5, real-time acquisition of air compressor and hydraulic energy storage module operation parameters, through closed loop feedback control algorithm to regulate and control the recovery and release of hydraulic energy;

[0068] Auxiliary execution module 6, feedback energy released by hydraulic energy storage module to air compressor auxiliary drive system, realizes auxiliary start or acceleration.

[0069] The hydraulic energy recovery device 3 includes a hydraulic pump connected with the air compressor 1, so that the hydraulic pump converts the remaining mechanical energy of the air compressor 1 into hydraulic energy in the low load state of the air compressor 1.

[0070] The hydraulic energy storage module 4 is a hydraulic accumulator or a hydraulic cylinder, and the hydraulic energy storage module 4 is provided with a pressure sensor and a safety valve.

[0071] The auxiliary execution module 6 is a hydraulic motor.

[0072] The sensor monitoring module 2 monitors the pressure, flow, speed and temperature parameters of the air compressor 1 in real time.

[0073] The intelligent control module 5 adopts an embedded controller or an industrial grade PLC, adopts a closed loop PID controller control combined with a feedforward control module and an adaptive adjustment algorithm, and realizes accurate control of working parameters of the hydraulic energy storage module 4 and the auxiliary execution module 6.

[0074] As shown in Figure 4 The automatic clutch A connects the air compressor 1 and the hydraulic pump, and engages in low load state to transfer part of the mechanical energy to the hydraulic pump.

[0075] The hydraulic pump converts the received mechanical energy into hydraulic energy.

[0076] The hydraulic accumulator stores hydraulic energy, and is provided with a pressure sensor and a safety valve to ensure the safety of energy storage process.

[0077] The automatic clutch B connects the hydraulic motor and the air compressor auxiliary drive system, and engages in high load or start state.

[0078] The hydraulic motor converts the stored hydraulic energy into mechanical energy to assist the air compressor to start or accelerate.

[0079] As shown in Figure 2 , 3As shown, an air compressor 1 energy-saving operation method based on hydraulic energy recovery specifically includes the following steps:

[0080] (1) The sensor monitoring module 2 monitors the running state of the air compressor 1, and judges whether the air compressor 1 is in an unloaded or low-load state;

[0081] (2) When it is judged as an empty state, the hydraulic energy recovery device 3 is started, the residual mechanical energy of the air compressor 1 is converted into hydraulic energy, and is transported to the hydraulic energy storage module 4 for storage;

[0082] (3) The pressure in the hydraulic energy storage module 4 and the running parameters of the air compressor 1 are monitored in real time, and the required auxiliary energy is calculated by using a closed-loop feedback control algorithm;

[0083] (4) When the load rises or the air compressor 1 startup demand is detected, the hydraulic energy storage module 4 releases the stored energy through the auxiliary execution module 6 to supply energy to the air compressor 1 auxiliary drive system;

[0084] (5) In the energy recovery and release process, the control parameters are adjusted in real time, and a safety protection mechanism is started.

[0085] The intelligent control module 5 uses a preset PID algorithm and historical data to adaptively judge when the air compressor 1 is in a low-load interval, and when the intelligent control module 5 detects that the air compressor 1 exhaust pressure is lower than the set value and the flow is insufficient, the hydraulic energy recovery device 3 is started; the speed of the hydraulic energy recovery device 3 is adjusted by using a PID controller, so that the hydraulic oil is uniformly transported to the hydraulic energy storage module 4.

[0086] When the load suddenly rises or the air compressor 1 startup instruction is issued, the intelligent control module 5 quickly calculates the required released hydraulic energy, and controls the auxiliary execution module 6 to start assisting the air compressor 1 to accelerate; the feedforward control module adjusts the output of the auxiliary execution module 6 in advance according to historical data.

[0087] The intelligent control module 5 continuously collects sensor data, adjusts the working parameters of the hydraulic energy recovery device 3 and the hydraulic energy storage module 4 in real time, ensures that the energy conversion process is stable and efficient, and starts a safety protection program to monitor abnormal conditions, and once the abnormality occurs, the machine is stopped immediately and the emergency power-off device is started, so that the safety state is automatically switched in the abnormal condition.

[0088] The air compressor 1 provided by the utility model provides compressed air.

[0089] The sensor monitoring module 2: real-time monitoring of the pressure, flow, speed, temperature and other parameters of the air compressor 1.

[0090] Intelligent control module 5: collect sensor data, and after PID, feedforward and adaptive regulation, issue instructions in two directions:

[0091] On the one hand, the hydraulic pump is controlled to start, and the remaining mechanical energy at low load is converted into hydraulic energy;

[0092] On the other hand, when the system load rises, an auxiliary command is issued to start the auxiliary execution module 6.

[0093] Hydraulic energy recovery device 3: through the hydraulic pump and linkage mechanism, the unused energy of the air compressor 1 is converted into hydraulic energy.

[0094] Hydraulic energy storage module 4: the hydraulic accumulator stores the converted hydraulic energy, and the built-in sensor feedbacks the energy storage state in real time.

[0095] Auxiliary execution module 6: the stored hydraulic energy is released by the hydraulic motor to assist the air compressor 1 to start quickly or accelerate.

[0096] Air compressor 1 auxiliary drive system: auxiliary energy is input to the air compressor 1 system to help the device to reach the normal working state.

[0097] When the air compressor 1 is in a stable running state, the sensor continuously monitors the key parameters.

[0098] Once it is detected that the air compressor 1 is in a low load or unloaded state, the system automatically starts the hydraulic energy recovery, and the hydraulic pump converts the remaining energy of the air compressor 1 into hydraulic energy and stores it in the accumulator.

[0099] The energy storage state is monitored in real time, and when the system needs (such as load rise or start request), the auxiliary execution module 6 quickly releases the stored hydraulic energy to help the air compressor 1 to start quickly or improve the running efficiency.

[0100] Data acquisition: the sensor collects the running data of the air compressor 1 in real time.

[0101] State judgment: the intelligent control module 5 judges the current load state according to the collected data, whether it is low load (suitable for energy recovery) or high load (needs auxiliary start).

[0102] Control decision:

[0103] When the load is low, the hydraulic energy recovery mode is started, and the hydraulic pump starts to work to convert the remaining energy into hydraulic energy and store it;

[0104] When the load is high or the start demand is needed, the system calculates the optimal release parameters and instructs the auxiliary execution module 6 to start the hydraulic motor to release the stored hydraulic energy to the air compressor 1.

[0105] Closed loop feedback: the whole process forms a closed loop, and the system continuously feedbacks the actual running data to adaptively adjust the control parameters to ensure that the energy conversion process is smooth and efficient. Example 1

[0106] Take a screw air compressor 1 as an example:

[0107] 1. Hardware configuration

[0108] During the unloading of the air compressor 1, the hydraulic pump is driven by the linkage mechanism to work, and the excess energy of the air compressor 1 is converted into hydraulic energy.

[0109] The output end of the hydraulic pump is connected to the hydraulic accumulator, which is equipped with a high-precision pressure sensor and a safety valve.

[0110] The industrial PLC is used as an intelligent control module 5, which is interconnected with the hydraulic pump, the hydraulic accumulator and the air compressor 1 sensor data through RS485.

[0111] When the load rise signal is monitored, the PLC instructs the hydraulic accumulator to supply energy to the air compressor 1 auxiliary drive system through the hydraulic motor.

[0112] 2. Control process

[0113] Energy recovery stage: when the PLC detects that the exhaust pressure of the air compressor 1 is lower than the set value and the flow is insufficient, start the hydraulic pump; the PID controller adjusts the hydraulic pump speed to make the hydraulic oil uniformly delivered to the hydraulic accumulator.

[0114] Energy release stage: when the system load suddenly rises or the air compressor 1 starts to issue instructions, the PLC quickly calculates the required hydraulic energy to be released, and controls the hydraulic motor to start the auxiliary air compressor 1 to accelerate; the feedforward control module adjusts the output of the hydraulic motor in advance according to historical data to ensure that the system responds quickly.

[0115] Closed loop feedback: throughout the process, the PLC continuously collects sensor data, adjusts the working parameters of the hydraulic pump and hydraulic motor in real time, ensures that the energy conversion process is smooth and efficient, and starts the safety protection program to monitor abnormal conditions. Example 2

[0116] For another configuration, a similar hydraulic energy recovery scheme can be used on a reciprocating air compressor, and the system structure and control algorithm are basically the same. The key is to match and adjust the linkage mechanism and the hydraulic system to adapt to different mechanical structures of the air compressor. Example 3

[0117] The required auxiliary energy is calculated by using the closed loop feedback control algorithm, and the specific process is as follows:

[0118] Set parameters:

[0119] - Hydraulic pump displacement: 10 mL / rev;

[0120] - Low load state speed of air compressor: 1500 rpm;

[0121] - Hydraulic system working pressure: 10 MPa;

[0122] - Hydraulic pump efficiency: 80%.

[0123] Calculation process:

[0124] 1. Energy conversion per revolution:

[0125] E_rev = ΔP × V_p

[0126] = 10×10^6 Pa × 10×10^-6 m^3

[0127] = 100 J

[0128] 2. Theoretical conversion energy per minute:

[0129] E_min = 1500 rev / min × 100 J / rev = 150,000 J / min

[0130] 3. Actual conversion energy after considering efficiency:

[0131] E_actual = 150,000 J / min × 0.8 = 120,000 J / min

[0132] 4. Auxiliary start-up requirement: Assuming 100,000 J is needed,

[0133] Considering the 80% efficiency of the hydraulic motor, the required energy storage of the hydraulic accumulator is:

[0134] E_required = 100,000 J / 0.8 ≈ 125,000 J

[0135] When the energy storage of the hydraulic accumulator reaches or exceeds 125,000 J, the system can achieve auxiliary start-up through the automatic clutch B and hydraulic motor, shorten the start-up time of the air compressor, and improve the operating efficiency.

Claims

1. An air compressor energy saving system based on hydraulic energy recovery, characterized in that, The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device.

2. The energy-saving system for air compressor based on hydraulic energy recovery according to claim 1, characterized in that, The application relates to an air compressor and a hydraulic energy recovery device.

3. The energy saving system for air compressor based on hydraulic energy recovery according to claim 1, characterized in that, The application relates to an air compressor and a hydraulic energy recovery device.

4. The energy-saving system for air compressor based on hydraulic energy recovery according to claim 1, characterized in that, The application relates to an air compressor and a hydraulic energy recovery device.

5. The energy saving system for air compressor based on hydraulic energy recovery according to claim 1, characterized in that, The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and a hydraulic energy recovery device. The application relates to an air compressor and

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