High-protection internet-of-things remote start-stop and state return device for air compressor

Abstract

The utility model discloses a high-protection internet-of-things remote start-stop and state return device for an air compressor, which is characterized in that a main control module is provided with an input module and an output module, and the input module is respectively connected with a sensor group; the output module is connected with a master control system of the air compressor, the 5G signal conversion module is connected with the master control module, the 5G signal conversion module is connected with a cloud server, and the alarm module is connected with the output module of the master control module. According to the utility model, various functions of communication, alarm, remote start and stop and the like are realized mainly through a logic control function of the single-chip microcomputer and a hardware circuit. An input part and an output part both adopt an optocoupler isolation mode, so that a mode of driving large current by small signals is realized, and the safety of master control of the single-chip microcomputer is effectively protected. The optical coupler isolation chip has the advantages that the signal switching speed is high, and effective isolation and interference prevention of signals are achieved.

Description

Technical Field

[0001] This utility model relates to the field of air compressor technology, and in particular to a high-protection IoT remote start / stop and status feedback device for air compressors. Background Technology

[0002] An air compressor is a machine that uses compressed air to provide power. By compressing the volume of gas, it increases the gas pressure, converting the mechanical energy of the motor into the pressure energy of the gas, thus providing gas energy power to other devices. In today's highly developed industrial world, air compressors are ubiquitous, finding wide applications in industries such as automation control, electronics, mining, agriculture, vehicles, food, and aviation. The stable operation of an air compressor directly affects the safety and efficiency of production operations. Factors affecting stable operation mainly include over-temperature, over-pressure, and the switching of actuators. While the working process of an air compressor is not complex, its start-up and shutdown processes have strict requirements. Currently, air compressors and air compressor units are generally operated by designated workers. Start-up and shutdown are scheduled as needed for production, with workers operating the corresponding switches, valves, and main motor in a required sequence to complete the start-up and shutdown process. During operation, on-duty personnel are required to frequently monitor the unit's condition, paying attention to temperature, etc.

[0003] If the pressure or other parameters exceed the allowable values, the compressor should be shut down immediately. Therefore, the air compressor requires continuous 24-hour monitoring by workers as it operates intermittently 24 hours a day.

[0004] Currently, air compressors are controlled and started / stopped individually, with data collection limited to each individual compressor. This requires manual recording of each compressor's status, alarms, and manual start / stop procedures. Cloud-based analysis of various compressor statuses and start / stop operations is impossible, hindering power ratio analysis, early predictive maintenance, and ultimately impacting the compressor's lifespan. Utility Model Content

[0005] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a high-protection IoT remote start / stop and status feedback device for air compressors.

[0006] This utility model is achieved through the following technical solution:

[0007] A high-protection IoT remote start / stop and status feedback device for an air compressor includes a power supply module, a main control module connected to the power supply module, and a 5G signal conversion module. The main control module has an input module and an output module. The input module is connected to the following air compressor components: primary intake temperature sensor, primary exhaust temperature sensor, secondary intake temperature sensor, secondary exhaust temperature sensor, terminal exhaust temperature sensor, lubricating oil temperature sensor, front bearing temperature sensor, rear bearing temperature sensor, intake pressure sensor, secondary intake pressure sensor, secondary exhaust pressure sensor, interstage pressure sensor, terminal exhaust pressure sensor, and lubricating oil pressure sensor. The output module is connected to the air compressor's main control system. The 5G signal conversion module is connected to the main control module and a cloud server. The device also includes an alarm module connected to the output module of the main control module.

[0008] It also includes a communication module, through which the main control module interacts with the air compressor.

[0009] It also includes a gain amplification module, which is connected to the 5G signal conversion module.

[0010] Both the input and output modules use optocoupler isolation chips.

[0011] This device mainly consists of a power supply module, a main control module, an input / output module, a 5G signal conversion module, a gain amplification module, and a communication module. It enables remote start / stop control of the air compressor, while simultaneously collecting the air compressor's status, operation, and alarm information, performing power ratio analysis, and providing maintenance reminders.

[0012] The power supply module is responsible for providing power to the entire system.

[0013] The main control module is the core of the entire control system. It is controlled by a microcontroller and is responsible for core algorithms and processing such as power ratio analysis and maintenance prompts.

[0014] The input module is responsible for signal reception and data acquisition; the output module is responsible for executing remote start / stop commands for the air compressor, alarm output, data exchange, and other functions.

[0015] The 5G signal conversion module is responsible for converting data into 5G signals and inputting them into the cloud.

[0016] The gain amplifier module is responsible for amplifying the 5G signal and increasing its usability.

[0017] The communication module is responsible for communicating with the air compressor equipment.

[0018] The advantages of this utility model are:

[0019] 1. Remote monitoring and control:

[0020] This invention enables remote monitoring and control of air compressors through a 5G signal conversion module and a cloud server. Operators can view the operating status of the air compressor and perform start-up and shutdown operations via the cloud platform from anywhere with internet access, improving management flexibility and efficiency.

[0021] 2. Real-time data acquisition and analysis:

[0022] This utility model's input module connects to multiple sensors, enabling it to collect various parameters during the air compressor's operation in real time. The main control module processes and analyzes this data, allowing for the timely detection of potential faults and the implementation of proactive measures to reduce equipment downtime and maintenance costs.

[0023] 3. High protection performance:

[0024] This invention employs optocoupler isolation chips in both the input and output modules, effectively isolating electrical interference between sensor signals and the main control module circuitry, thereby improving the system's anti-interference capability and stability. This ensures reliable operation of the equipment in complex industrial environments.

[0025] 4. Alarm function provides timely warnings:

[0026] This utility model alarm module can issue an alarm in a timely manner when an abnormal situation is detected, reminding operators to take measures to prevent the fault from escalating and to ensure the safety of equipment and personnel.

[0027] 5. Signal enhancement and stable communication:

[0028] This utility model's gain amplification module amplifies 5G signals, enhancing signal strength and improving communication stability and reliability. Even in environments with weak signals, it ensures accurate data transmission and reliable remote control.

[0029] 6. Easy to maintain and manage:

[0030] This invention stores and analyzes collected data via a cloud server, allowing managers to easily view historical data and analyze equipment operating status trends, providing a basis for equipment maintenance and upkeep. Simultaneously, the remote monitoring function reduces the workload of on-site maintenance personnel and improves maintenance efficiency.

[0031] 7. This utility model enables remote start / stop of air compressors, cloud-based air compressor status analysis, power ratio analysis, and maintenance and repair prediction, reducing customer workload, saving time and labor costs, and providing a foundation for achieving Industry 4.0 and unmanned workshops. Attached Figure Description

[0032] Figure 1 This is a schematic diagram illustrating the working principle of this utility model. Detailed Implementation

[0033] like Figure 1 As shown, a high-protection IoT remote start / stop and status feedback device for an air compressor includes a power supply module 1, a main control module 2 connected to the power supply module 1, and a 5G signal conversion module 3. The main control module 2 has an input module 4 and an output module 5. The input module 4 is respectively connected to an air compressor primary intake temperature sensor 6, an air compressor primary exhaust temperature sensor 7, an air compressor secondary intake temperature sensor 8, an air compressor secondary exhaust temperature sensor 9, an air compressor terminal exhaust temperature sensor 10, an air compressor lubricating oil temperature sensor 11, an air compressor front bearing temperature sensor 12, and an air compressor... The compressor includes a rear bearing temperature sensor 13, an air compressor intake pressure sensor 14, an air compressor secondary intake pressure sensor 15, an air compressor secondary exhaust pressure sensor 16, an air compressor interstage pressure sensor 17, an air compressor terminal exhaust pressure sensor 18, and an air compressor lubricating oil pressure sensor 19. The output module 5 is connected to the main control system of the air compressor 20, the 5G signal conversion module 3 is connected to the main control module 2, the 5G signal conversion module 3 is connected to the cloud server 21, and also includes an alarm module 22, which is connected to the output module 5 of the main control module 2.

[0034] It also includes a communication module 23, through which the main control module 2 interacts with the air compressor 20.

[0035] It also includes a gain amplification module 24, which is connected to the 5G signal conversion module 3.

[0036] Both the input module 4 and the output module 5 use optocoupler isolation chips.

[0037] The working principle of this utility model is as follows:

[0038] Data collection:

[0039] Input module 4 collects various parameters during the operation of the air compressor in real time through various connected sensors (such as temperature sensors, pressure sensors, etc.), such as intake temperature, exhaust temperature, lubricating oil temperature, intake pressure, and exhaust pressure.

[0040] These sensors convert the collected physical quantities (such as temperature and pressure) into electrical signals, which are then input into the main control module 2.

[0041] Signal processing and control:

[0042] After receiving the signal from the input module 4, the main control module 2 processes and analyzes the collected data.

[0043] Based on preset control logic and thresholds, the main control module 2 determines whether the air compressor is operating normally. If certain parameters exceed the normal range, the main control module 2 will send control commands to the air compressor's main control system through the output module 5, such as starting, stopping, or adjusting operating parameters.

[0044] Remote communication and data transmission:

[0045] The 5G signal conversion module 3 uploads the data processed by the main control module 2 to the cloud server via the 5G network. The cloud server can then perform further analysis, storage, and management of this data.

[0046] Meanwhile, the cloud server can also send remote control commands to the main control module 2 through the 5G signal conversion module 3 to realize remote start and stop control of the air compressor.

[0047] Alarm function:

[0048] When the main control module 2 detects an abnormal operation of the air compressor (such as excessively high temperature or abnormal pressure), it will trigger the alarm module to issue an audible and visual alarm signal to remind the on-site operators to handle the situation in a timely manner.

[0049] Communication and gain amplification:

[0050] The communication module is used for data interaction between the main control module 2 and the air compressor, ensuring the accurate transmission of control commands and feedback signals. The communication module can also record the status of each air compressor, enabling cloud-based analysis of various air compressor states, compressor start-up and shutdown, and facilitating air compressor specific power analysis, early prediction of maintenance and repairs, and extending the service life of the air compressors.

[0051] The gain amplifier module amplifies the 5G signal, enhances the signal strength, and improves the stability and reliability of communication.

[0052] Signal isolation:

[0053] Input module 4 and output module 5 use optocoupler isolation chips to isolate the sensor signals from the main control module 2 circuit, preventing signal interference and electrical interference, and improving the stability and safety of the system.

[0054] This invention primarily utilizes the logic control function of a microcontroller to implement various communication, alarm, and remote start / stop functions through hardware circuitry. Both input and output sections employ optocoupler isolation to enable small signals to drive large currents, effectively protecting the microcontroller's main control system. The advantages of optocoupler isolation chips include fast signal switching speed and effective signal isolation to prevent interference.

Claims

1. A high-protection IoT remote start / stop and status feedback device for an air compressor, characterized in that: The system includes a power supply module, a main control module connected to the power supply module, and a 5G signal conversion module. The main control module has an input module and an output module. The input module is connected to the following sensors respectively: air compressor primary intake temperature sensor, air compressor primary exhaust temperature sensor, air compressor secondary intake temperature sensor, air compressor secondary exhaust temperature sensor, air compressor terminal exhaust temperature sensor, air compressor lubricating oil temperature sensor, air compressor front bearing temperature sensor, air compressor rear bearing temperature sensor, air compressor intake pressure sensor, air compressor secondary intake pressure sensor, air compressor secondary exhaust pressure sensor, air compressor interstage pressure sensor, air compressor terminal exhaust pressure sensor, and air compressor lubricating oil pressure sensor. The output module is connected to the air compressor's main control system. The 5G signal conversion module is connected to the main control module and a cloud server. The system also includes an alarm module, which is connected to the output module of the main control module.

2. The high-protection IoT remote start / stop and status feedback device for an air compressor according to claim 1, characterized in that: It also includes a communication module, through which the main control module interacts with the air compressor.

3. The high-protection IoT remote start / stop and status feedback device for an air compressor according to claim 1, characterized in that: It also includes a gain amplification module, which is connected to the 5G signal conversion module.

4. The high-protection IoT remote start / stop and status feedback device for an air compressor according to claim 1, characterized in that: Both the input and output modules use optocoupler isolation chips.

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