Air compressor testing device

Abstract

The utility model relates to the air compressor test field, concretely relates to an air compressor testing device, it includes pressure vessel, the air inlet pipe and the air outlet pipe are connected on pressure vessel, the air inlet pipe is connected with the air outlet of the air compressor to be tested, installs the flowmeter and the first proportional valve on the air inlet pipe, installs the second proportional valve on the air outlet pipe, and pressure vessel includes jar body, the lower side of jar body is equipped with the support frame for supporting jar body, the lower part of jar body is equipped with the bottom plate, the piston is slidably installed in jar body, the bottom hole is seted up on the bottom plate, the push rod is rotatably installed on the piston, the push rod passes through the bottom hole and extends downward, the motor for driving the piston to slide up and down is installed on the support frame, the crank is installed on the motor, one end of crank is connected with the motor output shaft, and the other end of crank is rotatably connected with the lower end of push rod. The air compressor testing device provides an adjustable load environment for the air compressor to be tested through the establishment test loop, and the control logic of air compressor and air compressor internal configuration are convenient for debugging.

Description

Technical Field

[0001] This utility model relates to the field of air compressor testing, specifically to an air compressor testing device. Background Technology

[0002] Air compressors, primarily based on air suspension and magnetic levitation, are widely used in industrial fields due to their superior performance. Their performance stability and reliability directly affect the operating efficiency of the air-consuming system. In practical applications, air compressors need to adapt to complex load changes, such as fluctuations in air consumption, adjustments in pressure requirements, and emergency shutdowns. However, traditional air compressor commissioning methods mainly rely on on-site trial runs, which are not only time-consuming but also difficult to accurately simulate the dynamic characteristics of the actual air-consuming system. This can lead to problems such as surge, unstable pressure, or insufficient air supply during the commissioning phase at the installation site.

[0003] In practical applications, air compressors have different air requirements under different operating conditions, such as fluctuations in supply air pressure and compressed air flow. Different air requirements require adjustments to the control logic and air compressor configuration to meet them. Since it is impossible to simulate real application conditions, the optimization of air compressor control logic and performance verification are limited. In practice, air compressors can often only be debugged on-site, which affects equipment installation efficiency and increases debugging costs, and needs to be improved. Utility Model Content

[0004] The purpose of this invention is to provide an air compressor testing device and method to address the above problems, thereby solving the problem in the prior art that, due to the inability to establish simulated working conditions for the air compressor, debugging and configuration can only be carried out at the equipment installation site.

[0005] To achieve the above objectives, this utility model discloses an air compressor testing device, including a pressure vessel, an inlet pipe and an outlet pipe connected to the pressure vessel, the inlet pipe being connected to the air outlet of the air compressor under test, a flow meter and a first proportional valve installed on the inlet pipe, and a second proportional valve installed on the outlet pipe.

[0006] By establishing a test loop, the compressed air output from the air compressor enters a controllable pressure vessel. The pressure vessel simulates the actual air supply network, providing an adjustable load environment for the air compressor under test. This simulates the scenario of compressed air usage demand, facilitating the debugging of the air compressor's control logic and internal configuration, timely detection of current configuration defects, and reducing the time required for on-site debugging.

[0007] A pressure transmitter is installed on the pressure vessel to monitor the internal gas pressure. A check valve is installed on the inlet pipe to prevent gas from flowing from the pressure vessel towards the air compressor under test. A silencer is installed on the outlet pipe, located at the end of the outlet pipe furthest from the pressure vessel. A vortex flow meter can be used. The first proportional valve can simulate the start-up and parallel operation of the air compressor, allowing the air compressor to operate at increased pressure. The check valve prevents high-pressure gas backflow that could cause compressor surge during shutdown. The pressure transmitter monitors the simulated required compressed air pressure. The second proportional valve controls the released compressed air flow rate, simulating the customer's air flow requirements. The silencer reduces exhaust noise and improves the testing environment.

[0008] The pressure vessel includes a tank body with a support frame on its lower side. A bottom plate is located at the bottom of the tank body. A piston is slidably mounted inside the tank body. A bottom hole is formed in the bottom plate. A push rod is rotatably mounted on the piston, extending downwards through the bottom hole. A motor is mounted on the support frame to drive the piston's up-and-down movement. A crank is mounted on the motor, with one end connected to the motor's output shaft and the other end rotatably connected to the lower end of the push rod. A stepper motor is used, which can precisely control the piston position. The piston's movement within the tank body can change the effective volume of the vessel in real time. The motor drives a crank-connecting rod mechanism, allowing the piston to move at a set speed or pattern, accurately simulating the complex and rapidly changing load fluctuations in actual gas systems.

[0009] The upper part of the base plate is provided with an annular groove, in which a sealing ring is installed. The lower part of the piston is provided with a sealing edge. When the piston slides to the lower limit position, the sealing edge presses against the upper side of the sealing ring. When the piston moves to the lower limit position, pressurized gas enters the tank. The gas pushes the piston and presses the sealing edge against the sealing ring, forming a reliable end face seal, effectively preventing high-pressure gas from leaking through the gap between the piston and the base plate.

[0010] An air compressor testing method includes the following steps: Step 1: Preparation stage. Close the first proportional valve and the second proportional valve. Connect the air outlet of the air compressor to be tested to the air inlet pipe. Select the target pressure value according to the air pressure and the target flow value according to the air flow rate. Step 2: Start-up phase. Start the air compressor under test. When the output pressure of the air compressor under test reaches the target pressure value, slowly open the first proportional valve until the first proportional valve is fully open. Step 3: During the pressurization stage, the airflow output from the air compressor under test gradually enters the pressure vessel. The internal pressure of the pressure vessel is monitored by the pressure transmitter. When the internal pressure of the pressure vessel reaches the target pressure value, the second proportional valve is opened and the opening degree of the second proportional valve is gradually increased. Step 4: During the depressurization phase, the compressed air flow rate in the intake pipe is continuously monitored using a flow meter. When the air flow rate reaches the target flow rate value, the opening of the second proportional valve remains unchanged. Step 5: Pressure Stabilization Phase. Maintain the current operating status of the air compressor under test and the experimental device, and monitor for any abnormal alarms in the internal parameters of the air compressor under test.

[0011] Before the preparation phase begins, it is necessary to collect the customer's compressed air requirements, including the customer's air pressure range, compressed air flow fluctuation range, and whether there are any emergency shutdown situations for air-using equipment. After clarifying these requirements, target pressure and target flow values ​​are determined based on the collected data. By simulating the real air usage environment, it is easier to adjust the air compressor's control logic and internal configuration, so that the air compressor's output flow and output pressure are accurately matched, reducing the time required for on-site commissioning of the air compressor.

[0012] It also includes step six: the variable operating condition test phase, where the target variable flow rate value is selected, the opening of the second proportional valve is gradually adjusted, and the compressed air flow rate in the intake pipe is continuously monitored through the flow meter; Step 7: When the airflow reaches the target variable flow value, keep the current opening of the second proportional valve unchanged; Step 8: Observe whether the air compressor under test is running smoothly and whether there is any abnormal surge condition.

[0013] Based on actual flow rate changes, the testing scope was expanded to include performance testing under dynamic varying operating conditions. Using a simulated flow rate change environment, targeted tests were conducted to determine if the air compressor exhibited any abnormalities when facing varying flow rates. This verifies the air compressor's ability to maintain target pressure or operate stably under load changes. This supplements the shortcomings of steady-state testing, more realistically reflecting the air compressor's performance under actual variable load conditions.

[0014] In step six, the opening of the second proportional valve is gradually reduced, and the compressed air flow rate in the intake pipe is continuously monitored by a flow meter. By gradually reducing the opening of the second proportional valve, the flow rate is reduced, approaching and potentially triggering surge, thus determining the lower limit of safe operation.

[0015] In step six, the opening of the second proportional valve is gradually increased, and the compressed air flow rate in the intake pipe is continuously monitored by a flow meter. The air compressor's air supply capacity and response speed are tested under sudden demand surges, its maximum output or overload capacity is evaluated, and the experimental setup is verified to quickly increase output to meet demand.

[0016] In step eight, observe whether the tested air compressor operates smoothly, whether the output pressure of the tested air compressor reaches the target pressure value, and whether any abnormal surge occurs. If abnormal surge occurs in the air compressor, adjust the air compressor control logic in a timely manner.

[0017] The internal parameters of an air compressor include input power, intake air flow rate, intake air temperature, intake air pressure, exhaust temperature, exhaust pressure, motor temperature, cabinet temperature, cabinet differential pressure, inverter temperature, cooling water temperature, inverter current, inverter voltage, inverter output frequency, air compressor speed, opening degree of internal electrically controlled valves, spindle floating parameters, and alarm information. Existing air compressors can automatically monitor these parameters and display them intuitively on a screen. When abnormal parameters occur, alarm information is displayed on the screen, facilitating testing personnel to identify deficiencies in the current air compressor configuration.

[0018] In summary, the beneficial effects of this invention are as follows: By establishing a test circuit, the compressed air output from the air compressor enters a controllable pressure vessel. The pressure vessel simulates an actual gas pipeline network. The motor can precisely control the piston position, and the piston's movement within the vessel can change the effective volume of the container in real time. The motor drives a crank-connecting rod mechanism, allowing the piston to move at a set speed or pattern, accurately simulating the complex and rapidly changing load fluctuations in an actual gas system. This provides an adjustable load environment for the tested air compressor, simulating the scenario of compressed air usage demand, facilitating the debugging of the air compressor's control logic and internal configuration, timely detection of current configuration defects, and reducing on-site debugging time. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the air compressor experimental setup; Figure 2 This is a schematic diagram of the structure when the piston is in its lower limit position. Figure 3 for Figure 2 A magnified view of the local structure at point A; Figure 4 This is a schematic diagram of the structure when the piston is in its upper limit position. Figure 5 This is a process flow diagram of the present invention; Figure 6 This is a graph showing the monitoring parameters of the air compressor screen. Figure 7 This is a map of the air compressor.

[0020] In the diagram: 1. Air compressor under test; 2. Flow meter; 3. First proportional valve; 4. Check valve; 5. Pressure transmitter; 6. Pressure vessel; 7. Second proportional valve; 8. Silencer; 9. Inlet pipe; 10. Outlet pipe; 11. Piston; 12. Bottom hole; 13. Push rod; 14. Crank; 15. Motor; 16. Sealing ring; 17. Base plate; 18. Support frame; 19. Tank body; 20. Annular groove; 21. Sealing edge. Detailed Implementation

[0021] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this utility model, but are not intended to limit its scope.

[0022] The following is a description of preferred embodiments of the present invention in conjunction with the accompanying drawings.

[0023] An air compressor testing apparatus includes a pressure vessel 6, with an inlet pipe 9 and an outlet pipe 10 connected to the pressure vessel 6. The inlet pipe 9 is connected to the air outlet of the air compressor 1 under test. A flow meter 2 and a first proportional valve 3 are installed on the inlet pipe 9, and a second proportional valve 7 is installed on the outlet pipe 10. (See attached diagram.) Figure 1 By establishing a test loop, the compressed air output by the air compressor enters the controllable pressure vessel 6. The pressure vessel 6 simulates the actual air supply network, providing an adjustable load environment for the air compressor 1 under test. This simulates the scenario of compressed air usage demand, facilitating the debugging of the air compressor's control logic and internal configuration, timely detection of current configuration defects, and reducing the time required for on-site debugging of the air compressor.

[0024] See attached document Figure 1 A pressure transmitter 5 is installed on the pressure vessel 6 to monitor the internal gas pressure. A check valve 4 is installed on the inlet pipe 9 to prevent gas from flowing from the pressure vessel 6 towards the air compressor 1 under test. A silencer 8 is installed on the outlet pipe 10, located at the end of the outlet pipe 10 away from the pressure vessel 6. A vortex flow meter 2 can be used for the flow meter 2. The first proportional valve 3 can simulate the start-up and parallel operation of the air compressor, allowing the air compressor to operate with increased pressure. The check valve 4 is used to prevent high-pressure gas backflow during shutdown, which could cause the air compressor to surge. The pressure transmitter 5 is used to monitor and simulate the required compressed air pressure. The second proportional valve 7 is used to control the released compressed air flow rate to simulate the customer's air flow rate requirement. The silencer 8 is used to silence the exhaust, reduce noise generation, and improve the test environment.

[0025] See attached document Figure 1The pressure vessel 6 includes a tank body 19. A support frame 18 is provided on the lower side of the tank body 19 to support it. A bottom plate 17 is provided at the lower part of the tank body 19. A piston 11 is slidably mounted in the tank body 19. A bottom hole 12 is provided on the bottom plate 17. A push rod 13 is rotatably mounted on the piston 11, extending downward through the bottom hole 12. A motor 15 is mounted on the support frame 18 to drive the piston 11 to slide up and down. A crank 14 is mounted on the motor 15. One end of the crank 14 is connected to the output shaft of the motor 15, and the other end is rotatably connected to the lower end of the push rod 13. The motor 15 is a stepper motor. The motor 15 can precisely control the position of the piston 11. The movement of the piston 11 within the tank body 19 can change the effective volume of the vessel in real time. The motor 15 drives the crank 14 linkage mechanism, allowing the piston 11 to move at a set speed or pattern, accurately simulating the complex and rapidly changing load fluctuations in actual gas systems. (See attached diagram.) Figure 3 The base plate 17 has an annular groove 20 on its upper part, in which a sealing ring 16 is installed. The piston 11 has a sealing edge 21 on its lower part. When the piston 11 slides to its lower limit position, the sealing edge 21 presses against the upper side of the sealing ring 16. When the piston 11 moves to its lower limit position, pressurized gas enters the tank 19. The gas pushes the piston 11 and presses the sealing edge 21 against the sealing ring 16, forming a reliable end face seal, effectively preventing high-pressure gas from leaking through the gap between the piston 11 and the base plate 17.

[0026] An air compressor testing method includes the following steps: Step 1: Preparation stage. Close the first proportional valve 3 and the second proportional valve 7. Connect the air outlet of the air compressor 1 to be tested to the air inlet pipe 9. Select the target pressure value according to the air pressure and the target flow value according to the air flow rate. Step 2: Start-up phase. Start the air compressor under test 1. When the output pressure of the air compressor under test 1 reaches the target pressure value, slowly open the first proportional valve 3 until the first proportional valve 3 is fully open. Step 3: During the pressurization stage, the airflow output from the air compressor 1 under test gradually enters the pressure vessel 6. The internal pressure of the pressure vessel 6 is monitored by the pressure transmitter 5. When the internal pressure of the pressure vessel 6 reaches the target pressure value, the second proportional valve 7 is opened and the opening degree of the second proportional valve 7 is gradually increased. Step 4: During the depressurization phase, the compressed air flow rate in the intake pipe 9 is continuously monitored by the flow meter 2. When the air flow rate reaches the target flow rate value, the opening size of the second proportional valve 7 remains unchanged. Step 5: Pressure Stabilization Stage. Maintain the current operating status of the tested air compressor 1 and the experimental device, and monitor whether there are any abnormal alarms in the internal parameters of the tested air compressor 1.

[0027] Before the preparation phase begins, it is necessary to collect the customer's compressed air requirements, including the customer's air pressure range, compressed air flow fluctuation range, and whether there are any emergency shutdown situations for air-using equipment. After clarifying these requirements, target pressure and target flow values ​​are determined based on the collected data. By simulating the real air usage environment, it is easier to adjust the air compressor's control logic and internal configuration, so that the air compressor's output flow and output pressure are accurately matched, reducing the time required for on-site commissioning of the air compressor.

[0028] It also includes step six: the variable operating condition test phase, where the target variable flow rate value is selected, the opening of the second proportional valve 7 is gradually adjusted, and the compressed air flow rate in the intake pipe 9 is continuously monitored through the flow meter 2; Step 7: When the airflow reaches the target variable flow value, keep the opening of the second proportional valve 7 unchanged; Step 8: Observe whether the air compressor 1 under test is running smoothly and whether there is any abnormal surge condition.

[0029] Based on actual flow rate changes, the testing scope was expanded to include performance testing under dynamic varying operating conditions. Using a simulated flow rate change environment, targeted tests were conducted to determine if the air compressor exhibited any abnormalities when facing varying flow rates. This verifies the air compressor's ability to maintain target pressure or operate stably under load changes. This supplements the shortcomings of steady-state testing, more realistically reflecting the air compressor's performance under actual variable load conditions.

[0030] In step six, the opening of the second proportional valve 7 is gradually reduced, and the compressed air flow rate in the intake pipe 9 is continuously monitored by the flow meter 2. By gradually reducing the opening of the second proportional valve 7, the flow rate is reduced, approaching and potentially triggering surge, thus determining the lower limit of safe operation.

[0031] In step six, the opening of the second proportional valve 7 is gradually increased, and the compressed air flow rate in the intake pipe 9 is continuously monitored by the flow meter 2. The air compressor's air supply capacity and response speed are tested when demand surges, its maximum output or overload capacity is evaluated, and the experimental device is verified to be able to quickly increase output to meet demand.

[0032] In step eight, observe whether the tested air compressor 1 operates smoothly, whether the output pressure of the tested air compressor 1 reaches the target pressure value, and whether any abnormal surge occurs. If abnormal surge occurs in the air compressor, adjust the air compressor control logic in a timely manner.

[0033] The internal parameters of the air compressor include input power, intake air flow rate, intake air temperature, intake air pressure, exhaust temperature, exhaust pressure, motor temperature, cabinet temperature, cabinet differential pressure, inverter temperature, cooling water temperature, inverter current, inverter voltage, inverter output frequency, air compressor speed, opening degree of the internal electrically controlled valves, spindle floating parameters, and alarm information. Existing air compressors can automatically monitor these parameters and display them intuitively on a screen. When abnormal parameters occur, alarm information is displayed on the screen, facilitating testing personnel to identify deficiencies in the current air compressor configuration.

[0034] Step Nine: When there is a large-scale shutdown of air-consuming equipment due to malfunction or other reasons, resulting in zero air consumption and no time to shut down the air compressor, simulate this by continuously closing the second proportional valve 7 until the valve is completely closed. At this time, allow the air compressor to adjust automatically by opening the internal electrically controlled valve of the air compressor to release pressure. During this period, observe whether the air compressor runs smoothly, whether the output pressure is stable, and whether there are large fluctuations in the intake air flow. After the second proportional valve 7 is completely closed, observe whether the air compressor runs smoothly, whether the output pressure is stable, and whether there are any severe operating conditions such as surge.

[0035] See attached document Figure 6 The map uses a coordinate system where the horizontal axis represents flow rate and the vertical axis represents pressure. There are two diagonal lines on the map: the upper one is the surge line and the lower one is the pre-surge line. Point B represents the current flow rate and pressure of the air compressor. When point B is above the surge line, the air compressor experiences surge. Therefore, it is necessary to ensure that point B is within the safe range below the pre-surge line.

[0036] The air compressor is equipped with an electric proportional valve that controls the flow and pressure of the air outlet, a solenoid valve that controls the electric proportional valve, and a vent valve that controls the internal airflow pressure. In the following embodiments, the proportional valve, solenoid valve, and vent valve all refer to the valves inside the air compressor.

[0037] Control Logic Adjustment: The control logic is adjusted by simulating air compressor operation conditions, including parallel operation, sudden supply, sudden leakage, and air supply stoppage. If abnormal conditions are observed during simulation, such as surge, continuous pressure increase, slow pressure rise after pressure drop, or unstable pressure output during stable operation, targeted optimization is performed based on the information obtained from the tests. Optimization directions include controlling the opening speed of the proportional valve inside the air compressor, controlling the speed increase and decrease of the air compressor main unit, and controlling whether the vent valve vents. Refer to the appendix for details. Figure 7 The dotted line pointed to by C is the pre-surge line. The pre-surge line and the solid line on the left are the instability area. The area to the right of the pre-surge line is the safe area, which is the safe operating area.

[0038] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and substitutions can be made without departing from the technical principles of the present utility model, and these improvements and substitutions should also be considered within the protection scope of the present utility model.

Claims

1. An air compressor testing device, comprising a pressure vessel (6), characterized in that, The pressure vessel (6) is connected to an inlet pipe (9) and an outlet pipe (10). The inlet pipe (9) is connected to the air outlet of the air compressor (1) under test. A flow meter (2) and a first proportional valve (3) are installed on the inlet pipe (9). A second proportional valve (7) is installed on the outlet pipe (10). A pressure detection device for monitoring the gas pressure inside the pressure vessel (6) is installed on the pressure vessel (6).

2. The air compressor testing apparatus as described in claim 1, characterized in that, The pressure detection device is a pressure transmitter (5).

3. The air compressor testing device as described in claim 1, characterized in that, A check valve (4) is installed on the intake pipe (9). The check valve (4) prevents the gas in the intake pipe (9) from flowing from the pressure vessel (6) towards the air compressor (1) under test.

4. The air compressor testing apparatus as described in claim 1, characterized in that, A silencer (8) is installed on the vent pipe (10), and the silencer (8) is located at the end of the vent pipe (10) away from the pressure vessel (6).

5. The air compressor testing apparatus as described in claim 1, characterized in that, The pressure vessel (6) includes a tank body (19), a support frame (18) for supporting the tank body (19) is provided on the lower side of the tank body (19), a bottom plate (17) is provided at the lower part of the tank body (19), a piston (11) is slidably installed in the tank body (19), a bottom hole (12) is opened on the bottom plate (17), a push rod (13) is rotatably installed on the piston (11), the push rod (13) extends downward through the bottom hole (12), and a motor (15) for driving the piston (11) to slide up and down is installed on the support frame (18).

6. The air compressor testing apparatus as described in claim 5, characterized in that, A crank (14) is mounted on the motor (15). One end of the crank (14) is connected to the output shaft of the motor (15), and the other end of the crank (14) is rotatably connected to the lower end of the push rod (13).

7. The air compressor testing apparatus as described in claim 6, characterized in that, The base plate (17) has an annular groove (20) on its upper part, and a sealing ring (16) is installed in the annular groove (20). The piston (11) has a sealing edge (21) on its lower part. When the piston (11) slides to the lower limit position, the sealing edge (21) presses against the upper side of the sealing ring (16).

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