Monitoring system for air compressor

Abstract

The utility model discloses a monitoring system for an air compressor, which is characterized in that the upper end of the air compressor is connected with an air inlet, an air filter is arranged in the air inlet, the upper end of the air compressor and the lower end of the air inlet are provided with air inlet valves, the left side of the air compressor is connected with a motor, and an input port of an oil-gas separator is connected with an output port of the air compressor; the cooler comprises an oil cooler, an aftercooler and a fan, the input end of the oil cooler is connected with the output port of the oil-gas separator, the aftercooler is connected with the upper end of the oil-gas separator, the lower end of the oil cooler is connected with the lower end of the air compressor through an oil filter, and the input port of the aftercooler is connected with the upper end of the oil-gas separator; the controller comprises a main control module, a power module, an acquisition module, a control module and a communication interface module, the main control module is electrically connected with the power module, the acquisition module and the communication interface module, and the control module is electrically connected with the motor and the fan. The power supply module supplies power to the main control module, the acquisition module, the control module and the communication interface module.

Description

TECHNICAL FIELD

[0001] The utility model belongs to air compressor technical field especially relates to the monitoring system for air compressor. BACKGROUND

[0002] Air compressor is used to compress gas volume, so as to increase gas pressure, convert mechanical energy of motor into gas pressure energy, provide gas energy power for other settings, in modern industry so developed today, air compressor has extremely extensive use in automation control, electronics, mining, agriculture, vehicle, food, aviation and other industries, the safety and stability of air compressor control system become more and more important, once air compressor fails, it will cause huge loss, and energy consumption is huge in the use process of air compressor, and waste is caused due to poor control. CONTENT OF UTILITY MODEL

[0003] The utility model provides a monitoring system for air compressor, realizes air compressor control, state display, alarm and realizes internet of things function, greatly improves the safety and energy saving in the use process of air compressor, and has good man-machine interaction performance.

[0004] To solve the above problems, the utility model discloses a scheme, including air compressor, oil-gas separator, cooler and controller, characterized by air inlet is connected to the upper end of the air compressor, the air filter is arranged in the air inlet, the air inlet lower end is provided with the air inlet valve, the left side of the air compressor is connected with motor, the oil-gas separator input is connected with the output of the air compressor, the cooler includes oil cooler, rear cooler and fan, the input of the oil cooler is connected with the output of the oil-gas separator, the rear cooler is connected with the upper end of the oil-gas separator, the lower end of the oil cooler is connected with the lower end of the air compressor through the oil filter, the rear cooler input is connected with the upper end of the oil-gas separator, the rear cooler lower end is connected with the water discharger, the controller includes main control module, power module, acquisition module, control module and communication interface module, the main control module is electrically connected with power module, acquisition module and communication interface module, the control module is electrically connected with motor and fan, and the power module provides power supply for main control module, acquisition module, control module and communication interface module.

[0005] In the above or some embodiments, the main control module includes single-chip microcomputer, clock circuit, EEPROM circuit, JATG download interface and crystal oscillator circuit.

[0006] In the above or some embodiments, the power module includes AC 220V voltage to DC 24V voltage circuit, DC 24V voltage to DC 5V voltage circuit and DC 5V voltage to DC 3.3V voltage circuit.

[0007] In the above or some embodiments, the acquisition module includes temperature acquisition circuit, pressure acquisition circuit, current acquisition circuit, voltage acquisition circuit, the acquisition module acquires signals including motor temperature, exhaust temperature, exhaust pressure, motor current voltage.

[0008] In the above or some embodiments, the control module includes motor fan control circuit, buzzer alarm circuit, flow control module, touch screen module.

[0009] In the above or some embodiments, the communication interface module includes RS485 interface and Ethernet interface.

[0010] The utility model discloses the beneficial effect has: realize the control of air compressor, state display, alarm and realize the function of internet of things, make the security and energy saving of air compressor in the use process greatly improve, and have good man-machine interactive performance. BRIEF DESCRIPTION OF DRAWINGS

[0011] Figure 1 It is the structure schematic drawing of the utility model.

[0012] Figure 2 It is the module diagram of the utility model.

[0013] Figure 3 It is the main control module circuit diagram of the utility model.

[0014] Figure 4 It is the circuit diagram of the utility model that AC 220V voltage is changed into DC 24V voltage.

[0015] Figure 5 It is the circuit diagram of the utility model that DC 24V voltage is changed into DC 5V voltage.

[0016] Figure 6 It is the circuit diagram of the utility model that DC 5V voltage is changed into DC 3.3V voltage.

[0017] Figure 7 It is the temperature acquisition circuit diagram of the utility model.

[0018] Figure 8 It is the pressure acquisition circuit diagram of the utility model.

[0019] Figure 9 It is the current acquisition circuit diagram of the utility model.

[0020] Figure 10 It is the voltage acquisition circuit diagram of the utility model.

[0021] Figure 11 It is the motor fan control circuit diagram of the utility model.

[0022] Figure 12The utility model buzzer alarm circuit diagram.

[0023] In the figure: 1, air compressor; 2, oil-gas separator; 3, cooler; 4, controller; 5, air inlet; 6, air filter; 7, inlet valve; 8, motor; 9, oil cooler; 10, rear cooler; 11, fan; 12, oil filter; 13, water drain. DETAILED DESCRIPTION

[0024] The technical solutions in the embodiments of the utility model will be apparently and completely described below with reference to the drawings in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, rather than all the embodiments. Based on the embodiments in the utility model, all the other embodiments obtained by those skilled in the art without creative labor fall within the protection scope of the utility model.

[0025] The specific embodiments of the utility model will be further described below with reference to the drawings in the description.

[0026] As shown in the figure, the monitoring system for air compressor, the air compressor 1 upper end is connected with air inlet 5, is provided with air filter 6 in air inlet 5, is used to filter dust and other sundries in air, and the filtered air enters air compressor through inlet valve 7, air compressor 1 left side is connected with motor 8, and air mixes together with the cooling and lubricating oil released in the compression work, and the output of air compressor 1 is connected with the input of oil-gas separator 2, and oil-gas mixture passes through the collision and interception of oil-gas separator 2 to filter out oil, and oil is separated out, and then does the gas and impurity filtration again in oil-gas separator 2, obtains the oil without gas, and the input end of oil cooler is connected with the output of oil-gas separator 2, and the lower end of oil cooler 9 is connected with the lower end of air compressor 1 through oil filter 12, and oil-gas separator 2 passes through pressure and makes lubricating oil pass through oil cooler 9, oil filter 12 to air compressor 1, and rear cooler 10 is connected with the upper end of oil-gas separator 2, and the separated gas enters rear cooler 10 through pressure, and the lower end of rear cooler 10 is connected with water drain 13, and residual is discharged, and the controller includes main control module, power module, acquisition module, control module and communication interface module, and main control module is electrically connected with power module, acquisition module and communication interface module, and control module is electrically connected with motor and fan, and is used to control motor and cooler work, and power module provides power supply for main control module, acquisition module, control module and communication interface module.

[0027] The master control module comprises a single-chip microcomputer, a clock circuit, an EEPROM circuit, a JATG download interface and a crystal oscillator circuit; the power module comprises an AC 220V voltage to DC 24V voltage circuit, a DC 24V voltage to DC 5V voltage circuit and a DC 5V voltage to DC 3.3V voltage circuit; the acquisition module comprises a temperature acquisition circuit, a pressure acquisition circuit, a current acquisition circuit and a voltage acquisition circuit, and the acquisition module acquires signals including motor temperature, exhaust temperature, exhaust pressure and motor current voltage; the control module comprises a motor fan control circuit, a buzzer alarm circuit, a flow control module and a touch screen module; and the communication interface module comprises an RS485 interface and an Ethernet interface.

[0028] The single-chip microcomputer can adopt STM32F103VBT6, one end of capacitors C1 and C2 is connected to the voltage of 3.3V through the pin VDDA of the single-chip microcomputer STM32, the other end of the capacitors C1 and C2 is grounded, the pins VDD_1, VDD_2, VDD_3, VDD_4 and VDD_5 of the single-chip microcomputer STM32 are connected in parallel to the voltage of 3.3V, the pins VSS_1, VSS_2, VSS_3, VSS_4 and VSS_5 of the single-chip microcomputer STM32 are grounded, the pin VBAT of the single-chip microcomputer STM32 is connected to the voltage of 3.3V, the pin NRST of the single-chip microcomputer STM32 is connected to the voltage of 3.3V through the resistor R1, and the pin BOOT0 of the single-chip microcomputer STM32 is grounded through the resistor R2.

[0029] The EEPROM circuit adopts a chip CAT24512WI-GT3, the pin SDL of the chip CAT24512WI-GT3 is connected to the pin PB11 of the single-chip microcomputer STM32 and one end of the resistor R3, the pin SCL of the chip CAT24512WI-GT3 is connected to the pin PB10 of the single-chip microcomputer STM32 and one end of the resistor R4, the other ends of the resistors R3 and R4 are connected to the voltage of 3.3V, the pin VCC of the chip CAT24512WI-GT3 is connected to the voltage of 3.3V, the anode of the capacitor C3 and one end of the capacitor C4 are connected to the voltage of 3.3V, the cathode of the capacitor C3 and the other end of the capacitor C4 are grounded, the pin WP of the clock chip DS2405ALPI is grounded through the resistor R5, and the pins A0, A1, A2 and GND of the chip CAT24512WI-GT3 are connected to one end of the resistor R5 and grounded.

[0030] The pin TD0 of the JATG download interface is connected to the power supply 3.3V through the resistor R9, the pins 2 and 1 of the chip JATG are connected to the power supply 3.3V, the pins NTRST, TDI, TMS and TCK of the chip JATG are connected to one end of the resistors R6, R7, R8 and R10 respectively, the other ends of the resistors R6, R7 and R8 are connected to the power supply 3.3V, and the other end of the resistor R10 is grounded.

[0031] The clock circuit can use a real-time clock chip DS2405ALPI, the clock chip DS2405ALPI has a crystal oscillator and a charging battery inside, the SDA pin of the clock chip DS2405ALPI is connected to the PB5 pin of the single-chip microcomputer STM32 and one end of the resistor R12, the SCL pin of the clock chip DS2405ALPI is connected to the PB6 pin of the single-chip microcomputer STM32 and one end of the resistor R13, the INI pin of the clock chip DS2405ALPI is connected to the PB7 pin of the single-chip microcomputer STM32 and one end of the resistor R11, the Vss pin of the clock chip DS2405ALPI is connected to one end of the capacitor C6 and the cathode of the capacitor C5 and grounded, the other ends of the resistors R11, R12 and R13 are connected to the power supply 3.3V, and the anode of the capacitor C5 and the other end of the capacitor C6 are connected to the power supply 3.3V.

[0032] One end of the crystal oscillator Y is connected to one end of the capacitor C8 and the OSC_IN pin of the single-chip microcomputer STM32, the other end of the crystal oscillator Y is connected to one end of the capacitor C9 and the OSC_OUT pin of the single-chip microcomputer STM32, and the other ends of the capacitors C8 and C9 are grounded.

[0033] The AC 220V voltage is converted into a DC 24V voltage circuit, the AC 220V voltage is connected to the fuse F and the resistor R14, the resistor R14 is connected to the primary coil of the transformer T1, the secondary coil of the transformer T1 is connected to the capacitor C7, the capacitor C7 is connected to the common mode inductor L1, the common mode inductor L1 is connected to the capacitor C9, the capacitor C10, the capacitor C11, the capacitor C12, the load C8, the diode D1-D4, and the diode D5, the other ends of the capacitors C9 and C10 are grounded, the diode D1-D4 is connected to the diode D5, the capacitor C11, and the capacitor C12, the other end of the diode D5 is connected to the capacitor C11, the capacitor C12, and the output DC 24V voltage, the fuse is used to protect the subsequent circuit, the capacitors C7 and C8 are used to eliminate differential mode interference in the circuit, the common mode inductor L1, the capacitors C9 and C10 are used to eliminate common mode interference, the diode D5 is used to prevent the subsequent circuit from being damaged due to short circuit, and the capacitors C11 and C12 are output filter capacitors.

[0034] The direct current 24V voltage is converted into direct current 5V voltage, the positive electrode of the direct current 24V is connected to the anode of the voltage stabilizing diode VZ1, the cathode of the voltage stabilizing diode VZ1 is connected to the anode of the capacitor C13, one end of the capacitor C14, the pin Vin of the switch voltage regulator LM2596, the pin GND of the switch voltage regulator LM2596, the cathode of the capacitor C13, the other end of the capacitor C14 is connected to the ground, the pin OUT of the switch voltage regulator LM2596 is connected to one end of the inductor L2 and the cathode of the voltage stabilizing diode VZ2, the other end of the inductor L2 is connected to the pin FeedBack of the switch voltage regulator LM2596, the anode of the capacitor C15, the anode of the capacitor C16, the anode of the capacitor C17, one end of the capacitor C18 and outputs the direct current 5V voltage, the other end of the capacitor C18, the cathode of the capacitor C15, the cathode of the capacitor C16, the cathode of the capacitor C17, the anode of the voltage stabilizing diode VZ2, the pin ON / OFF of the switch voltage regulator LM2596 is connected to the ground.

[0035] The direct current 5V voltage is converted into direct current 3.3V voltage by using the chip AMS1117, the pin IN of the chip AMS1117 is connected to the direct current 5V, the anode of the capacitor C19, the pin Vout of the chip AMS1117 is connected to the anode of the capacitor C20 and outputs the 3.3V direct current voltage, the capacitor C19, the capacitor C20, the pin GND of the chip AMS1117 is connected to the ground.

[0036] The temperature collection circuit, the direct current 3.3V voltage is connected to one end of the resistor R15 and the resistor R20, the other end of the resistor R15 is connected to the thermal resistance PT100 and one end of the resistor R16, the other end of the resistor R20 is connected to the resistor R18 and one end of the resistor R19, the thermal resistance PT100 detection device and the other end of the resistor R18 are connected and connected to the ground, the other end of the resistor R16 is connected to the resistor R17 and the ground and the same phase input end of the amplifier AR1 respectively, the other end of the resistor R19 is connected to one end of the resistor R21 and the reverse input end of the amplifier AR1, the output end of the amplifier AR1 and the other end of the resistor R21 are connected to one end of the resistor R22, the other end of the resistor R22 is connected to the same phase input end of the amplifier AR2, the reverse input end of the amplifier AR2 is connected to one end of the resistor R23 and the resistor R24, the other end of the resistor R24 is connected to the ground, the other end of the resistor R23 is connected to the output end of the amplifier AR2 and the resistor R25 and outputs the signal to the single-chip microcomputer, the circuit uses a differential bridge circuit for measurement, the resistor R15, the thermal resistance PT100, the resistor R20 and the resistor R21 constitute a differential bridge, the resistor R15, the resistor R20 and the resistor R21 are all selected to be high-precision resistors to prevent self-heating from reducing the measurement accuracy, when the temperature changes, the voltage at point a is always higher than the voltage at point b, preventing false measurement, the thermal resistance PT100 amplifies Va through the differential amplification circuit, and then amplifies Vab again through the same direction amplification circuit and outputs the signal to the single-chip microcomputer.

[0037] The pressure acquisition circuit is connected with the pin 1 of P10 through a direct current 24V series diode D6, the pin 2 of P10 is connected with the resistance R26 and the ground, one end of the resistance R27 is connected with the resistance R26 and the ground, the other end of the resistance R27 is connected with the same direction input end of the amplifier AR3, the reverse input end of the amplifier AR3 is connected with the output end of the amplifier AR3, the amplifier AR3 is connected with the voltage 3.3V, the amplifier AR3 is connected with the resistance R28 and one end of the capacitor C21, and the output signal is output to the single-chip microcomputer through the resistance R29, the other end of the resistance R28 and the capacitor C21 is connected with the ground, the diode D6 prevents the current from flowing back, the current signal generated by the pressure sensor is converted into a voltage signal through the precision resistance R26, the resistances R27 and R29 are current limiting resistances, and meanwhile, impedance matching is realized, so that sampling is more accurate, and the voltage follower circuit is used to isolate the single-chip microcomputer and the micro signal,

[0038] The current acquisition circuit is connected with the current transformer T2 which is an HWCT-20A / 20mA, the secondary output side of the current transformer T2 is connected with the two ends of the transient suppression diode D7, the two ends of the transient suppression diode D7 are connected with the pins 1 and 3 of the rectifier bridge MB6S, the pin 2 of the rectifier bridge MB6S is connected with one end of the resistance R30 and the resistance R31, the pin 4 of the rectifier bridge MB6S is connected with the other end of the resistance R30 and the ground, the other end of the resistance R31 is connected with the same direction input of the amplifier AR4, the amplifier AR4 is connected with the direct current voltage 3.3V, the reverse input end of the amplifier AR4 is connected with the output end thereof and outputs the current signal to the single-chip microcomputer through the resistance R32, the secondary output of the current transformer is connected with the transient suppression diode SMBJ6.5CA, so as to prevent the internal chip from being damaged due to external voltage mutation, the current transformer outputs an alternating current signal, but the internal ADC of the single-chip microcomputer STM32 can only detect a forward voltage, therefore, the rectifier bridge module is used to perform full-wave rectification on the alternating current, the resistance R30 is a sampling resistance, the resistances R31 and R33 are current limiting resistances, the input resistance of the operational amplifier is close to infinity, the output resistance of the operational amplifier is close to zero, and the voltage follower circuit is used to isolate the front stage and the rear stage, so that measurement is more accurate.

[0039] The voltage acquisition circuit is connected with the voltage transformer T3 which is a TV19G, the primary side of the voltage transformer T3 is connected with the resistance R33 in series, the secondary output side of the voltage transformer T3 is connected with the two ends of the transient suppression diode D12, the two ends of the transient suppression diode D12 are connected with the pins 1 and 3 of the rectifier bridge MB6S, the pin 2 of the rectifier bridge MB6S is connected with one end of the resistance R34 and the resistance R35, the pin 4 of the rectifier bridge MB6S is connected with the other end of the resistance R34 and the ground, the other end of the resistance R35 is connected with the same direction input end of the amplifier AR5, the amplifier AR5 is connected with the direct current voltage 3.3V, the reverse input end of the amplifier AR5 is connected with the output end thereof and outputs the voltage signal to the single-chip microcomputer through the resistance R36, the voltage acquisition circuit is similar to the current acquisition circuit, and the resistance R33 is a current limiting resistance.

[0040] The motor fan control circuit uses a bidirectional thyristor to control the motor start, uses a MOC3052 optical coupler to control the bidirectional thyristor to open at any phase, the DC 3.3V voltage is connected in series with the resistor R37 and the resistor R38 and the base of the triode Q2, the emitter of the triode Q2 is connected to the DC voltage 3.3V, the collector of the triode Q2 is connected to the resistor R39, the resistor R39 is connected to the pin 1 of the motor M1, the pin 2 of the motor M1 is connected to the pin 1 of the motor M2, the pin 2 of the motor M2 is connected to the ground, the pin 6 of the motor M1 is connected to the T2 pole of the thyristor Q3, one end of the load resistor R40 and one end of the voltage-dependent resistor R42, the other end of the load resistor R40 is connected to one end of the capacitor C22, the G pole of the thyristor Q3 is connected to the pin 4 of the motor M2 through the resistor R41, the pin 4 of the motor M1 and the pin 6 of the motor M2 are connected, the T1 pole of the thyristor Q3 is connected to the other end of the capacitor C22 and the voltage-dependent resistor R42, when the MCU output at point A is high level or high resistance state, the PNP triode Q1 is disconnected, the MOC3052 is disconnected, when the MCU output at point A is low level, the Q1 is turned on, the MOC3052 is turned on, at this time, when the voltage at the G pole of the thyristor is higher than the voltage at the K pole, the thyristor is turned on, when the current flowing through the thyristor is reversed, the thyristor is turned off, the R40 and the C22 form a resistance-capacitance absorption circuit to prevent the thyristor from being damaged by the voltage rising too fast, the R42 is a voltage-dependent resistor, when the voltage is too large, it is similar to a wire, which short-circuits the rear circuit to prevent the rear circuit from being damaged.

[0041] The buzzer alarm circuit, one end of the buzzer LS is connected to the DC voltage, the other end of the buzzer LS is connected to the collector of the triode Q1, the base and emitter of the triode Q1 are connected to the ground, the base of the triode Q1 is connected to the pin PC13 of the single-chip microcomputer through the resistor R5, when the detected pressure, temperature, current and voltage are abnormal, the alarm will occur, and the amount of air sucked by the air valve is controlled by the single-chip microcomputer control flow control module, and the man-machine interaction is realized through the touch screen module, the RS485 interface and the Ethernet interface, and the start and stop of the air compressor motor, the set value and the like are realized.

[0042] The utility model discloses a specific use, air compressor 1 upper end is connected with air inlet 5, is provided with air filter 6 in air inlet, is used for filtering dust and other sundries in air, and the air that filters removes enters air compressor 1 through inlet valve 7, air compressor 1 left side is connected with motor 8, and air mixes together with the cooling lubricating oil that releases further in compression work, and the output of air compressor 1 is connected with the input of oil gas separator 2, and oil gas mixture gas filters out oil through the collision and interception of oil gas separator 2, and oil is separated, and then does the gas and impurity again in oil gas separator 2 Filter removes, obtains the oil that does not contain gas, and the input of oil cooler 9 is connected with the output of oil gas separator 2, and the lower end of oil cooler 9 is connected with the lower end of air compressor 1 through oil filter 12, and oil gas separator 2 passes through pressure and lubricating oil passes through oil cooler 9, oil filter 12 to air compressor 1, and rear cooler 10 is connected with the upper end of oil gas separator 2, and the gas after separation passes through pressure and enters rear cooler 10, and the lower end of rear cooler 10 is connected with drain 13, and the residual is discharged, and power module provides power supply for main control module, acquisition module, control module and communication interface module, and main control chip STM32 passes through temperature acquisition circuit, pressure acquisition circuit, current acquisition circuit, voltage acquisition circuit in acquisition module, and gathers motor temperature, exhaust temperature, exhaust pressure, motor current voltage etc., when detecting pressure, temperature, current, voltage, all will alarm when abnormal, and through singlechip control flow control module controls the air volume of air valve suction, and realizes man-machine interaction through touch screen module, RS485 interface and ethernet interface, realizes the control of air compressor, state display, alarm and realizes the function of internet of things, makes the security and energy saving of air compressor during use greatly improve, realizes remote terminal control air compressor motor and starts and stops, sets control parameter etc.

Claims

1. A monitoring system for an air compressor comprising an air compressor (1), an oil-gas separator (2), a cooler (3) and a controller (4), characterized in that, The air compressor (1) is connected with an air inlet (5) at the upper end, the air inlet (5) is provided with an air filter (6), the air compressor (1) is provided with an air inlet valve (7) at the upper end and the lower end of the air inlet (5), the left side of the air compressor is connected with a motor (8), the oil gas separator (2) input port is connected with the output port of the air compressor (1), the cooler (3) includes an oil cooler (9), a rear cooler (10) and a fan (11), the input end of the oil cooler (9) is connected with the output port of the oil gas separator (2), the rear cooler (10) is connected with the upper end of the oil gas separator (2), the lower end of the oil cooler (9) is connected with the lower end of the air compressor (1) through an oil filter (12), the rear cooler (10) input port is connected with the upper end of the oil gas separator (2), the rear cooler (10) lower end is connected with a drain (13), the controller (4) includes a main control module, a power module, a collection module, a control module and a communication interface module, the main control module is electrically connected with the power module, the collection module and the communication interface module, the control module is electrically connected with the motor (8) and the fan (11), and the power module provides power supply for the main control module, the collection module, the control module and the communication interface module.

2. The monitoring system for an air compressor according to claim 1, wherein The main control module includes a single-chip microcomputer, a clock circuit, an EEPROM circuit, a JATG download interface and a crystal oscillator circuit.

3. The monitoring system for an air compressor according to claim 1, wherein The power module includes an AC 220V voltage to DC 24V voltage circuit, a DC 24V voltage to DC 5V voltage circuit and a DC 5V voltage to DC 3.3V voltage circuit.

4. The monitoring system for an air compressor according to claim 1, wherein The collection module includes a temperature collection circuit, a pressure collection circuit, a current collection circuit and a voltage collection circuit, and the collection module collects signals including motor temperature, exhaust temperature, exhaust pressure, motor current voltage.

5. The monitoring system for an air compressor according to claim 1, wherein The control module includes a motor fan control circuit, a buzzer alarm circuit, a flow control module and a touch screen module.

6. The monitoring system for an air compressor according to claim 1, wherein The communication interface module includes an RS485 interface and an Ethernet interface.

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