Stepless air volume adjusting system of compressor

Abstract

The utility model discloses a compressor stepless air flow regulation system, which relates to the compressor field, and comprises a cabinet module, a central control module and an explosion-proof area, the cabinet module comprises an electronic control unit ECU, a setting module, a DC driving power supply and an interface adapter IA, and the explosion-proof area comprises a stepless air flow regulation execution mechanism and a hydraulic energy HPU. The central control module is electrically connected with the ECU based on a 4-20 mA load control signal, the ECU is electrically connected with the interface adapter IA through a first TDC signal line, the interface adapter IA is electrically connected with the stepless gas flow regulation executing mechanism through a second TDC signal line, and the ECU is electrically connected with the stepless gas flow regulation executing mechanism through BUS communication. According to the stepless air flow adjusting system of the compressor, the power consumption during working of the compressor can be effectively reduced, the overall working energy consumption can be reduced, meanwhile, replacement and maintenance of spare parts of the compressor can be reduced, the service life of the compressor can be effectively prolonged, and the working time of the compressor can be effectively prolonged.

Description

Technical Field

[0001] This utility model relates to the field of compressors, and in particular to a stepless air volume regulation system for compressors. Background Technology

[0002] A compressor is a driven fluid machine that elevates low-pressure gas to high-pressure gas; it is the heart of a refrigeration system. Compressors are classified into reciprocating compressors, screw compressors, centrifugal compressors, and linear compressors, among others. A reciprocating compressor generally consists of a housing, electric motor, cylinder, piston, control equipment, and a cooling system. Cooling methods include oil cooling, air cooling, and natural cooling. A linear compressor has no shaft, cylinder, seals, or heat dissipation structures. It uses the principle of magnetic levitation and a spiral ring fluid dynamics structure to compress gas and provide power for refrigeration. The compressor draws in low-temperature, low-pressure refrigerant gas through the suction pipe, compresses it using the piston driven by the motor, and then discharges high-temperature, high-pressure refrigerant gas through the exhaust pipe, providing power for the refrigeration cycle and thus realizing the refrigeration cycle of compression → condensation (heat release) → expansion → evaporation (heat absorption).

[0003] The DW-59.1 / (27.1-35.6)-X type circulating hydrogen compressor, tag number 01C1102A / B / C, and the MW-184.7 / (4.6-9.6)-X type recoverable hydrogen compressor, tag number 01C0601A-F, use reflux valves to regulate gas flow during actual operation, resulting in significant energy waste. The DW-59.1 / (27.1-35.6)-X type circulating hydrogen compressor has a 40% reflux rate, and the MW-184.7 / (4.6-9.6)-X type recoverable hydrogen compressor has a 28% reflux rate, wasting a large portion of their energy consumption.

[0004] Therefore, it is necessary to propose a compressor stepless gas volume regulation system to solve the above problems. Utility Model Content

[0005] The main objective of this invention is to provide a compressor stepless air volume regulation system, which can effectively solve the problems in the background art.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0007] A compressor stepless air volume regulation system includes a cabinet module, a central control module, and an explosion-proof zone. The cabinet module includes an electronic control unit (ECU), a setting module, a DC drive power supply, and an interface adapter (IA). The explosion-proof zone includes a stepless air volume regulation actuator and a hydraulic power unit (HPU).

[0008] Preferably, the central control module is electrically connected to the electronic control unit (ECU) based on a 4-20mA load control signal. The ECU is electrically connected to the interface adapter (IA) via a first TDC signal line. The interface adapter (IA) is electrically connected to the continuously variable air volume (CVV) actuator via a second TDC signal line. The ECU is also electrically connected to the CVV actuator via a BUS bus. The DC drive power supply is electrically connected to the CVV actuator via a drive power supply line. The hydraulic power unit (HPU) is connected to the CVV actuator via a hydraulic circuit.

[0009] Preferably, the electronic control unit (ECU) is used for high-speed data transmission with the continuously variable air volume (CVV) actuator, the central control module, the setting module, and the interface adapter (IA). It is also responsible for receiving load signals sent by the central control module and generating precise control commands based on these signals. The ECU is used to monitor the operating status of the CVT actuator.

[0010] Preferably, the continuously variable air volume regulating actuator is connected to the compressor's air valve via an unloader for controlling the opening and closing of the air valve. The hydraulic energy source (HPU) provides hydraulic oil to the continuously variable air volume regulating actuator, which converts hydraulic energy into mechanical energy to achieve precise control of the air valve. The continuously variable air volume regulating actuator employs a valve plate hydraulic double buffer device to prevent impact damage caused by delayed valve plate closure.

[0011] Preferably, the hydraulic energy source (HPU) is used to provide high oil pressure for the continuously variable air volume (CVV) actuator, and the specifications of the HPU are selected according to the number of CVV ​​actuators, their working pressure, and flow requirements.

[0012] Preferably, the electronic control unit (ECU) adopts a PID control algorithm to achieve precise control of the stepless gas volume regulating actuator. By collecting feedback signals from the stepless gas volume regulating actuator in real time, the control quantity is calculated, and the opening degree of the solenoid valve is adjusted, thereby precisely controlling the opening and closing time of the gas valve.

[0013] The central control module is used to collect and store the operating data of the compressor's stepless air volume regulation system in real time, including historical air volume, actuator action records, and changes in hydraulic oil station parameters.

[0014] Compared with the prior art, the present invention has the following beneficial effects:

[0015] The compressor's stepless air volume regulation system can effectively reduce the power consumption of the compressor during operation, thereby reducing the overall energy consumption and minimizing the need for replacement and maintenance of spare parts, thus effectively increasing the compressor's service life and operating time. Attached Figure Description

[0016] Figure 1 This is a system block diagram of this utility model;

[0017] Figure 2 This is a diagram showing the reciprocating motion of the piston in the compressor cylinder of this utility model.

[0018] In the diagram: 1. Cabinet module; 2. Central control module; 3. Explosion-proof area; 4. Electronic control unit (ECU); 5. Setting module; 6. DC drive power supply; 7. Interface adapter (IA); 8. Stepless air volume regulating actuator; 9. Hydraulic power supply (HPU). Detailed Implementation

[0019] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the present utility model will be further described below in conjunction with specific embodiments.

[0020] like Figure 1-2As shown, a compressor stepless air volume regulation system includes a cabinet module 1, a central control module 2, and an explosion-proof zone 3. The cabinet module 1 includes an electronic control unit (ECU) 4, a setting module 5, a DC drive power supply 6, and an interface adapter IA 7. The explosion-proof zone 3 includes a stepless air volume regulation actuator 8 and a hydraulic power supply (HPU) 9. The central control module 2 is electrically connected to the ECU 4 based on a 4-20mA load control signal. The ECU 4 is electrically connected to the interface adapter IA via a first TDC signal line. The interface adapter IA is electrically connected to the stepless air volume regulation actuator 8 via a second TDC signal line. The ECU 4 is also electrically connected to the stepless air volume regulation actuator 8 via a BUS bus communication. The DC drive power supply 6... The power supply line is electrically connected to the continuously variable air volume (CVV) actuator 8. The hydraulic power unit (HPU) 9 is connected to the CCV actuator 8 via a hydraulic circuit. The electronic control unit (ECU) 4 is used for high-speed data transmission with the CCV actuator 8, the central control module 2, the setting module 5, and the interface adapter IA. It also receives load signals from the central control module 2 and generates precise control commands based on these signals. The ECU 4 monitors the operating status of the CCV actuator 8. When the central control module 2 issues a command to increase the air volume, the ECU 4, through calculation and logical judgment, sends corresponding control signals to the CCV actuator 8 to adjust the opening and closing positions of the intake valve, thereby controlling the compressor. Precise control of exhaust volume is achieved, while the electronic control unit (ECU4) monitors the operating status of the continuously variable air volume (CVV) actuator 8 in real time, including valve position, operating frequency, and temperature. Upon detecting any abnormality, an alarm signal is immediately issued, and corresponding protective measures are taken to ensure the safe and stable operation of the system. The CVT actuator 8 is connected to the compressor's air valve via an unloader to control the opening and closing of the air valve. The hydraulic power unit (HPU9) provides hydraulic oil to the CVT actuator 8, which converts hydraulic energy into mechanical energy to achieve precise control of the air valve. The CVT actuator 8 employs a valve plate hydraulic double buffer device to prevent impact damage caused by delayed valve plate closure. During the closing process, the hydraulic buffer device first decelerates the hydraulic valve plate and then smoothly lowers it into place, extending the service life of the hydraulic valve plate. The continuously variable air volume regulating actuator 8 is equipped with a high-precision intake valve temperature detection sensor to monitor the temperature change of the intake valve in real time. When the temperature exceeds the set threshold, the sensor transmits a signal to the electronic control unit ECU4, which immediately takes cooling measures to ensure safe and reliable operation in harsh industrial environments. When the electronic control unit ECU4 issues a control signal, the continuously variable air volume regulating actuator 8 controls the flow and pressure of the hydraulic oil, thereby driving the unloader to operate and achieve delayed or normal closure of the air valve. The hydraulic power unit HPU9 provides high oil pressure to the continuously variable air volume regulating actuator 8.The specifications of the hydraulic power unit (HPU9) are selected based on the number, working pressure, and flow requirements of the continuously variable air volume (CVV) actuators (8). When multiple CVV actuators (8) operate simultaneously, and each CVV actuator (8) has a high demand for high-pressure oil, a hydraulic power unit (HPU9) with a higher flow rate and pressure is selected. The HPU9 is installed close to the CVV actuators (8) to reduce the length of the hydraulic oil pipes and lower pressure loss. The electronic control unit (ECU4) uses a PID control algorithm to achieve precise control of the CVV actuators (8). By collecting feedback signals from the CVV actuators (8) in real time, the ECU calculates the control quantity and adjusts the opening degree of the solenoid valve, thereby precisely controlling the opening and closing time of the air valve. When receiving data from the central control module (2), the ECU4 verifies and unpacks the received data, extracts valid information, and processes it accordingly. The central control module (2) is used to collect and store the operating data of the compressor's CVV control system in real time, including historical discharge volume, actuator action records, and changes in hydraulic oil station parameters.

[0021] It should be noted that this utility model is a stepless gas volume regulation system for a compressor. During use, at the beginning of each working cycle of the compressor cylinder, the high-pressure gas remaining in the clearance volume is in an expanded state. Figure 2 In the AB curve, at this point, both the compressor intake valve and exhaust valve are tightly closed to prevent gas leakage. As the piston moves, the high-pressure gas in the clearance volume gradually expands and the pressure decreases, creating conditions for the subsequent intake process.

[0022] When the piston moves to a certain position and the pressure inside the cylinder is lower than the pressure in the intake line, the intake valve opens under the action of the pressure difference, and gas begins to enter the cylinder. Figure 2 In the BC curve, gas continuously flows in until the piston moves to point C, completing an intake volume equivalent to 100% of the cylinder's volumetric flow rate. Then the intake valve closes to ensure that the amount of gas entering the cylinder reaches the theoretical maximum value.

[0023] Conventional compression: Under normal circumstances, after the intake valve is closed, the piston continues to move, and the gas in the cylinder is compressed along the CD curve, and the pressure continues to rise until it reaches the exhaust pressure.

[0024] Stepless volume regulation compression: In stepless volume regulation mode, after the intake process reaches point C, the stepless volume regulation actuator 8 forcibly keeps the intake valve open. At this time, some gas flows back to the intake pipe through the open intake valve and does not participate in compression. When the piston moves to a specific position Cr, the stepless volume regulation actuator 8 removes the external force, the intake valve closes, and the remaining gas in the cylinder begins to be compressed. The compression process is carried out along the Cr-Dr curve. By controlling the opening time of the intake valve and the position of the piston reaching point Cr, the amount of gas participating in compression can be precisely adjusted, thereby achieving stepless regulation of the gas volume.

[0025] After the gas is compressed to the rated exhaust pressure, the exhaust valve opens, and the exhaust process begins. Figure 2 The DA curve shows that the compressed gas is discharged from the cylinder through the exhaust valve and enters the next stage of compression or is transported to subsequent process steps.

[0026] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A stepless gas volume regulating system of a compressor, comprising a cabinet module (1), a central control module (2) and an explosion-proof area (3), characterized in that: The cabinet module (1) comprises an electronic control unit ECU (4), a setting module (5), a DC driving power supply (6) and an interface adapter IA (7), and the explosion-proof area (3) comprises a stepless gas volume adjusting actuator (8) and a hydraulic power unit HPU (9); The central control module (2) is electrically connected with the electronic control unit ECU (4) based on a 4-20mA load control signal, the electronic control unit ECU (4) is electrically connected with the interface adapter IA (7) through a first TDC signal line, the interface adapter IA (7) is electrically connected with the stepless gas volume adjusting actuator (8) through a second TDC signal line, the electronic control unit ECU (4) is electrically connected with the stepless gas volume adjusting actuator (8) through BUS bus communication, the DC driving power supply (6) is electrically connected with the stepless gas volume adjusting actuator (8) through a driving power supply line, and the hydraulic power unit HPU (9) is connected with the stepless gas volume adjusting actuator (8) through a hydraulic oil circuit. The electronic control unit ECU (4) is used for high-speed data transmission with the stepless gas volume adjusting actuator (8), the central control module (2), the setting module (5) and the interface adapter IA (7), is responsible for receiving a load signal sent by the central control module (2), and generates accurate control instructions according to the signals, and is used for monitoring the running state of the stepless gas volume adjusting actuator (8). The stepless gas volume adjusting actuator (8) is connected with a gas valve of a compressor through a unloader and is used for controlling opening and closing of the gas valve, the hydraulic power unit HPU (9) is used for providing hydraulic oil for the stepless gas volume adjusting actuator (8), the stepless gas volume adjusting actuator (8) is used for converting hydraulic energy into mechanical energy to realize accurate control of the gas valve, and the stepless gas volume adjusting actuator (8) adopts a valve plate hydraulic double-buffering device to avoid impact damage caused by delayed closing of a valve plate of the gas valve. The hydraulic power unit HPU (9) is used for providing high oil pressure for the stepless gas volume adjusting actuator (8), and the specification of the hydraulic power unit HPU (9) is selected according to the number, working pressure and flow demand of the stepless gas volume adjusting actuator (8). The electronic control unit ECU (4) adopts a PID control algorithm to realize accurate control of the stepless gas volume adjusting actuator (8), calculates a control amount by collecting feedback signals of the stepless gas volume adjusting actuator (8) in real time, adjusts the opening degree of an electromagnetic valve, and thus accurately controls the opening and closing time of the gas valve, and the central control module (2) is used for collecting and storing running data of the stepless gas volume adjusting system of the compressor in real time, including historical exhaust volume, actuator action record and hydraulic oil station parameter change.

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