Automatic switching control device of air compressor

Abstract

The utility model relates to an automatic switching control device for air compressors, which comprises two groups of air compressors and an air storage tank, and further comprises a pressure sensor, a PLC (programmable logic controller) and a pressure gauge, the two groups of air compressors are respectively connected with the air storage tank through pipelines, and an electric valve and the pressure sensor are arranged on each pipeline. The PLC is respectively connected with the two groups of air compressor controllers through the RS-485 communication interface, the air compressor controllers respectively control the start and stop of respective air compressors, the PLC is also connected with the pressure gauge through the RS-485 communication interface, and pressure signals collected by the pressure sensor are transmitted to the pressure gauge and are processed and controlled by the PLC. Intelligent switching and linkage control between the two air compressors can be achieved, the system stability is improved, when a host breaks down or the system pressure is insufficient, the standby air compressor is automatically started, air source interruption is avoided, and the management efficiency is improved through remote control and state display of the upper computer.

Description

Technical Field

[0001] This utility model relates to the field of industrial automation control technology, and in particular to an automatic switching control device for an air compressor. Background Technology

[0002] Air compressors are widely used in current industrial production to provide compressed air to equipment. To ensure continuous air supply and reduce equipment wear, multiple air compressors are usually set up to operate in coordination. However, in actual use, when the main air compressor fails or the system pressure falls below the set value, manual switching of the backup air compressor is often required. This process suffers from problems such as untimely response, cumbersome operation, and delayed equipment failure handling, which can easily lead to insufficient system pressure, causing pneumatic equipment to malfunction, affecting normal production, and even causing system shutdown. Therefore, there is an urgent need for a control device that can automatically identify pressure status and control the automatic switching of air compressors to improve the stability and intelligence of the air supply system. Utility Model Content

[0003] The purpose of this utility model is to provide an automatic switching control device for air compressors that can realize automatic start-up and intelligent switching of air compressors through PLC control, pressure sensor acquisition, RS-485 communication and host computer monitoring.

[0004] To achieve the above objectives, the present invention provides the following technical solution.

[0005] An automatic switching control device for an air compressor includes an air compressor and an air tank. The device also includes a pressure sensor, a PLC controller, and a pressure gauge.

[0006] The air compressor is provided in two sets, which are connected to the air storage tank through pipelines, and each pipeline is equipped with an electric valve and a pressure sensor.

[0007] The PLC is connected to two sets of air compressor controllers via an RS-485 communication interface, and the air compressor controllers control the start and stop of their respective air compressors.

[0008] The PLC is also connected to the pressure gauge via an RS-485 communication interface. The pressure signal collected by the pressure sensor is transmitted to the pressure gauge and processed and controlled by the PLC.

[0009] Preferably, the input terminals IN0 to IN11 of the PLC are connected to the following control or status signals respectively: local manual, local automatic, and remote / automatic control signals of the first air compressor; local manual, local automatic, and remote / automatic control signals of the second air compressor; emergency stop switch, valve opening limit switch, and valve closing limit switch of the first air compressor; and valve opening limit switch, valve closing limit switch, and emergency stop switch of the second air compressor.

[0010] Preferably, the output terminals OUT0 to OUT11 of the PLC are used to output the following control signals: first air compressor valve open, valve closed, second air compressor valve open, valve closed, first air compressor start, second air compressor start, first air compressor alarm, second air compressor alarm, first air compressor operation indication, stop indication, second air compressor operation indication and stop indication, which are used to control the corresponding switches, alarm lights or indicator lights.

[0011] Preferably, the two sets of electric valves are equipped with a first switch, a second switch, a third switch, and a fourth switch, respectively.

[0012] Preferably, the air compressor controller is equipped with a fifth switch and a sixth switch for controlling the start and stop of the air compressor.

[0013] Preferably, the PLC is also connected to a network via a communication interface, an Ethernet interface, or a wireless communication interface for remote monitoring and data interaction.

[0014] Technical advantages:

[0015] It enables intelligent switching and linkage control between two air compressors, improving system stability. When the main unit fails or the system pressure is insufficient, the backup air compressor is automatically started to avoid air supply interruption. Remote control and status display via a host computer improve management efficiency. The air compressor is equipped with local manual / automatic and remote control / automatic modes for flexible control. The electric valve is linked to the start and stop of the air compressor, and the manual valve facilitates maintenance. The operation, shutdown, and alarm status of the entire system can be clearly displayed through indicator lights, improving equipment operating efficiency, reducing maintenance costs, and ensuring production continuity. Attached Figure Description

[0016] Figure 1 This is a block diagram of the overall structure of this embodiment.

[0017] Figure 2 This is a schematic diagram of the electric valve in this embodiment. Detailed Implementation

[0018] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0019] Please see Figure 1-2 This embodiment provides an automatic switching control device for an air compressor, which includes an air compressor and an air tank. The device also includes a pressure sensor, a PLC controller, and a pressure gauge.

[0020] The air compressor is provided in two sets, which are connected to the air storage tank through pipelines, and each pipeline is equipped with an electric valve and a pressure sensor.

[0021] The PLC is connected to two sets of air compressor controllers via an RS-485 communication interface, and the air compressor controllers control the start and stop of their respective air compressors.

[0022] The PLC is also connected to the pressure gauge via an RS-485 communication interface. The pressure signal collected by the pressure sensor is transmitted to the pressure gauge and processed and controlled by the PLC.

[0023] Preferably, the input terminals IN0 to IN11 of the PLC are connected to the following control or status signals respectively: local manual, local automatic, and remote / automatic control signals of the first air compressor; local manual, local automatic, and remote / automatic control signals of the second air compressor; emergency stop switch, valve opening limit switch, and valve closing limit switch of the first air compressor; and valve opening limit switch, valve closing limit switch, and emergency stop switch of the second air compressor.

[0024] Preferably, the output terminals OUT0 to OUT11 of the PLC are used to output the following control signals: first air compressor valve open, valve closed, second air compressor valve open, valve closed, first air compressor start, second air compressor start, first air compressor alarm, second air compressor alarm, first air compressor operation indication, stop indication, second air compressor operation indication and stop indication, which are used to control the corresponding switches, alarm lights or indicator lights.

[0025] Preferably, the two sets of electric valves are equipped with a first switch, a second switch, a third switch, and a fourth switch, respectively.

[0026] Preferably, the air compressor controller is equipped with a fifth switch and a sixth switch for controlling the start and stop of the air compressor.

[0027] Preferably, the PLC is also connected to a network via a communication interface, an Ethernet interface, or a wireless communication interface for remote monitoring and data interaction.

[0028] In this embodiment, the automatic air compressor switching control device includes two sets of air compressors (air compressor A and air compressor B) and an air tank. The air outlet of each air compressor is connected to the air tank through an electric valve, and pressure sensors S1 and S2 are installed on the pipeline to collect pressure data.

[0029] The PLC receives pressure sensor signals and pressure gauge feedback data, and communicates with the air compressor controller via an RS-485 communication interface. When the PLC receives a current pressure value that is less than a set threshold, it determines whether the main air compressor is operating normally. If a fault occurs or there is no response, it sends a start signal to the standby air compressor controller and controls the electric valve to open, thus achieving automatic switching.

[0030] The PLC input ports IN0-IN11 receive field control signals, such as mode selection (manual / automatic), valve status, emergency stop signals, etc.; the output ports OUT0-OUT11 control the opening and closing of electric valves, the start and stop of air compressors, alarm lights and status indicator lights.

[0031] Control methods supported: local manual control, local automatic control, and remote manual and automatic control via host computer.

[0032] The system features a host computer interface that displays the air tank pressure, air compressor operating status, switching records, etc., enabling system monitoring and remote operation.

[0033] The working principle is as follows:

[0034] Initial state:

[0035] Main air compressor: The default setting is "Air Compressor A" (the main / auxiliary role can be changed via the host computer or parameter settings).

[0036] Auxiliary air compressor: Default is "Air Compressor B"

[0037] System pressure ≥ Set low pressure threshold (P_low): Neither air compressor starts.

[0038] Normal operating logic:

[0039] 1. The PLC reads the pressure sensor value P.

[0040] 2. Judgment conditions:

[0041] If P <P_low:

[0042] Check if the main air compressor is in the "manual" or "automatic" start-up enabled state.

[0043] If the main air compressor is not started, a signal to start the main air compressor (OUT5) will be sent, and the main air compressor electric valve (OUT0 or OUT2) will be opened at the same time.

[0044] 3. Delayed detection of pressure changes:

[0045] After starting the main air compressor, set a delay of T1 seconds and read the new pressure value P1.

[0046] If P1 is still lower than P_low or the host reports a "fault":

[0047] Determine if the auxiliary air compressor is in a state where it is allowed to start.

[0048] Start the auxiliary air compressor (OUT6) and open its electric valve (OUT1 or OUT3).

[0049] Alarm signal: Main air compressor malfunction (OUT7)

[0050] Switching logic:

[0051] If an emergency stop signal is received during the operation of the main air compressor or if the PLC receives a fault feedback from the host machine:

[0052] Immediately stop the main air compressor

[0053] Start the auxiliary air compressor

[0054] Automatically switch control authority to auxiliary machine

[0055] Shutdown logic:

[0056] When the system pressure is ≥ the set high-pressure threshold (P_high):

[0057] Stop the currently running air compressor

[0058] Close the corresponding electric valve.

[0059] Record running time and number of switches

[0060] Priority between host computer and local control:

[0061] Emergency stop button signal > Local control > Host computer control;

[0062] When switching modes, the PLC automatically clears the invalid command cache to avoid accidental triggering.

[0063] The above is a detailed description of the present invention in conjunction with specific embodiments, and it should not be construed that the specific embodiments of the present invention are limited to these descriptions. For those skilled in the art, any equivalent substitutions or obvious modifications made without departing from the concept of the present invention, and which have the same performance or use, should be considered as falling within the patent protection scope defined by the submitted claims.

Claims

1. An automatic switching control device for an air compressor, comprising an air compressor and an air tank, characterized by: The device also includes a pressure sensor, a PLC controller, and a pressure gauge; The air compressor is provided in two sets, which are connected to the air storage tank through pipelines, and each pipeline is equipped with an electric valve and a pressure sensor. The PLC is connected to two sets of air compressor controllers via an RS-485 communication interface, and the air compressor controllers control the start and stop of their respective air compressors. The PLC is also connected to the pressure gauge via an RS-485 communication interface. The pressure signal collected by the pressure sensor is transmitted to the pressure gauge and processed and controlled by the PLC.

2. The automatic switching control device for an air compressor according to claim 1, characterized by: The input terminals IN0 to IN11 of the PLC are connected to the following control or status signals respectively: local manual, local automatic, and remote / automatic control signals of the first air compressor; local manual, local automatic, and remote / automatic control signals of the second air compressor; emergency stop switch, valve opening limit switch, and valve closing limit switch of the first air compressor; and valve opening limit switch, valve closing limit switch, and emergency stop switch of the second air compressor.

3. The automatic switching control device for an air compressor according to claim 2, characterized by: The output terminals OUT0 to OUT11 of the PLC are used to output the following control signals: first air compressor valve open, valve closed, second air compressor valve open, valve closed, first air compressor start, second air compressor start, first air compressor alarm, second air compressor alarm, first air compressor running indicator, stop indicator, second air compressor running indicator and stop indicator, which are used to control the corresponding switches, alarm lights or indicator lights.

4. The automatic switching control device for an air compressor according to claim 3, wherein: The two sets of electric valves are respectively equipped with a first switch, a second switch, a third switch, and a fourth switch.

5. The automatic switching control device for an air compressor as set forth in claim 4, wherein: The air compressor controller is equipped with a fifth switch and a sixth switch for controlling the start and stop of the air compressor.

6. The automatic switching control device for an air compressor as set forth in claim 4, wherein: The PLC is also connected to a network via a communication interface, Ethernet interface, or wireless communication interface for remote monitoring and data interaction.

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