Multi-brand air compressor main and auxiliary automatic switching control system

Abstract

The utility model discloses a kind of main, auxiliary automatic switching control system of multi-brand air compressor, including air compressor a, air compressor b, drying machine, process gas storage tank, instrument gas storage tank;The air compressor a is connected between air compressor b by pipeline and is arranged in parallel;Filter pipeline and buffer tank are further provided on the pipeline between the air compressor a and drying machine;Filter pipeline is provided on the pipeline between the buffer tank and drying machine;Filter pipeline is provided on the pipeline between the drying machine and process gas storage tank;Filter pipeline is further provided on the outlet pipeline of the instrument gas storage tank.The function of the utility model is that pressure trigger response time is less than 5 seconds, the continuity of production is guaranteed, main auxiliary relationship can be flexibly adjusted according to equipment state, improve system redundancy;On the basis of increasing pressure regulation, reduce transformation cost, applicable to different brand, different control mode air compressor, improve the applicability of system.

Description

Technical Field

[0001] This utility model belongs to the field of industrial compressed air supply technology, and in particular relates to a main and auxiliary automatic switching control system for multi-brand air compressors. Background Technology

[0002] An air compressor is a device that increases the pressure of compressed air by increasing the density of gas molecules. It is a power device that converts mechanical energy into gas pressure energy. It is mainly used in industrial production, energy storage and air separation units. In continuous production industries such as papermaking and chemical industry, compressed air is a key power source for pneumatic control equipment.

[0003] In the prior art, such as the air compressor control system disclosed in Chinese Patent (CN208281152U), there is a main controller. The main controller is electrically connected to a display screen and electrically bidirectionally connected to a slave controller. By adding a slave controller and using the slave controller to control two sets of air compressors, when one set of air compressors fails, it will trigger an alarm and stop running, and the other set will also start automatically according to a set time.

[0004] This approach has the following drawbacks: First, when using a single air compressor for air supply, a failure in the air compressor will directly lead to production interruption. The impact time varies depending on the type of failure, and the downtime for system repair and recovery will cause varying degrees of loss to the production workshop. Second, due to differences in communication protocols and control methods, it is difficult to achieve automatic switching when two air compressors from different brands are working together in the same system. Third, in existing compressed air supply systems, using air compressors from different brands together requires the addition of electric valves or protocol conversion modules for mutual control between the two machines, resulting in high investment and low reliability.

[0005] Therefore, this paper presents a multi-brand air compressor main and auxiliary automatic switching control system. Utility Model Content

[0006] To address the aforementioned technical issues, this utility model discloses a multi-brand air compressor main and auxiliary automatic switching control system, which reduces the pressure trigger response time to less than 5 seconds, ensuring production continuity. Simultaneously, it allows for flexible adjustment of the main and auxiliary relationship based on equipment status, enhancing system redundancy. Furthermore, it reduces modification costs while increasing pressure regulation, and is applicable to air compressors of different brands and control methods, improving the system's applicability.

[0007] To achieve the above technical effects, this utility model provides a multi-brand air compressor main and auxiliary automatic switching control system, including air compressor a, air compressor b, dryer, process air storage tank, and instrument air storage tank. Air compressor a is located to the right of air compressor a, dryer is connected to the right of air compressor a via a pipeline, process air storage tank is connected to the right front of dryer via a pipeline, and instrument air storage tank is connected above process air storage tank via a pipeline. Air compressor a, air compressor b, dryer, process air storage tank, and instrument air storage tank are all electrically connected to a production workshop controller. Air compressor a and air compressor b are connected in parallel via pipelines. A filter pipeline and a buffer tank are also installed on the pipeline between air compressor a and dryer. The buffer tank is electrically connected to the production workshop controller. A filter pipeline is installed on the pipeline between the buffer tank and dryer. A filter pipeline is installed on the pipeline between the dryer and process air storage tank. A filter pipeline is installed on the outlet pipeline of the instrument air storage tank.

[0008] Preferably, the outlet pipe of the air compressor a is also equipped with a check valve a, a manual venting test pipe a, and a shut-off valve a. The check valve a is located in front of the manual venting test pipe a, and the shut-off valve a is located on the manual venting test pipe a.

[0009] Preferably, the outlet pipe of the air compressor b is also equipped with a check valve b, a manual venting test pipe b, and a shut-off valve b. The check valve b is located in front of the manual venting test pipe b, and the shut-off valve b is located on the manual venting test pipe b.

[0010] Preferably, a bypass pipe a is provided between the parallel pipeline of air compressor a and air compressor b and the filter pipeline on the left side of the buffer tank, and a shut-off valve c is provided on the bypass pipe a.

[0011] Preferably, the filter pipeline further includes a filter valve assembly, a bypass pipeline b, and a shut-off valve d, with the bypass pipeline b located on both sides of the filter valve assembly and the shut-off valve d located on the bypass pipeline.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows: This device connects air compressors A and B in parallel, and, with the help of bypass pipe A and buffer tank adjustment switching, reduces the pressure trigger response time to less than 5 seconds, ensuring production continuity. It also allows for flexible adjustment of the main and auxiliary relationships based on equipment status, improving system redundancy. By adding a manual control shut-off valve to adjust pressure parameters with the air compressors, it increases pressure regulation while reducing modification costs. Furthermore, it is applicable to air compressors of different brands and control methods, enhancing the system's applicability. Attached Figure Description

[0013] Figure 1This is a front view of the present invention; Figure 2 This is an isometric view of the present invention; Figure 3 This is an isometric side view of the rear view of this utility model; Figure 4 This is the main and auxiliary air compressor pressure setting logic diagram of this utility model; The attached diagram lists the components represented by each number as follows: 1. Air compressor a; 2. Air compressor b; 3. Dryer; 4. Process gas storage tank; 5. Instrument gas storage tank; 6. Filter pipeline; 7. Buffer tank; 8. Check valve a; 9. Manual venting test line a; 10. Shut-off valve a; 11. Check valve b; 12. Manual venting test line b; 13. Shut-off valve b; 14. Bypass pipeline a; 15. Shut-off valve c; 16. Filter valve assembly; 17. Bypass pipeline b; 18. Shut-off valve d. Detailed Implementation

[0014] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model.

[0015] The existing technology in this embodiment has the following problems: The inventors have found the following defects in the existing technology: 1. When using a single air compressor for air supply, a failure of the air compressor will directly lead to production interruption. Different types of failures have different impact times, and the time for system shutdown and repair recovery will cause varying degrees of loss to the production workshop; 2. Due to differences in communication protocols and control methods, it is difficult to achieve automatic switching when two air compressors work together in the same system; 3. In the existing compressed air supply system, using air compressors of different brands together requires the addition of electric valves or protocol conversion modules for mutual control between the two machines, which results in large investments and low reliability. Therefore, as Figures 1 to 4As shown, the inventor provides a multi-brand air compressor main / auxiliary automatic switching control system, including air compressor a1, air compressor b2, dryer 3, process air storage tank 4, and instrument air storage tank 5. Air compressor a1 is located to the right of air compressor a1. Dryer 3 is connected to the right of air compressor a1 via a pipeline. Process air storage tank 4 is connected to the front right side of dryer 3 via a pipeline. Instrument air storage tank 5 is connected above process air storage tank 4 via a pipeline. Air compressor a1, air compressor b2, dryer 3, process air storage tank 4, and instrument air storage tank 5 are respectively... The air compressor a1 and air compressor b2 are connected in parallel via pipelines. A filter pipeline 6 and a buffer tank 7 are also installed on the pipeline between air compressor a1 and dryer 3. The buffer tank 7 is connected in telecommunications to the production workshop controller. A filter pipeline 6 is installed on the pipeline between buffer tank 7 and dryer 3. A filter pipeline 6 is installed on the pipeline between dryer 3 and process gas storage tank 4. A filter pipeline 6 is installed on the outlet pipeline of instrument gas storage tank 5.

[0016] Using the above scheme, air compressor A1 and air compressor B2 can be used as primary and secondary units respectively. When air compressor A1 starts first, air compressor B2 is used as the secondary unit, and when air compressor B2 starts first, air compressor A1 is used as the secondary unit. The switching interlock between the two air compressors requires separate setting of loading and unloading pressures. When air compressor A1 is used as the primary unit, the target pressure of air compressor B2 is set to 0.73 MPa, the unloading pressure is set to 0.7 MPa, and the load pressure is set to 0.57 MPa. When air compressor B2 is used as the primary unit, the target pressure of air compressor B2 is set to 0.7 MPa, the unloading pressure is set to 0.8 MPa, and the load pressure is set to 0.57 MPa. With a load pressure of 0.65 MPa, the auxiliary compressor will automatically start when the main unit pressure is lower than the auxiliary unit load pressure, or when the main unit fails and stops, the auxiliary unit will automatically start loading when the pressure value is lower than the load pressure value set by the auxiliary unit. When the target pressure is greater than the set pressure, the star-delta controlled air compressor will enter a sleep state, and the air compressor controlled by the frequency converter will also enter a standby sleep state. By setting two air compressors of different brands in parallel, they can cooperate with each other as the main and auxiliary units. After implementation, the pressure trigger response time can be reduced to less than 5 seconds, ensuring the continuity of production. At the same time, the relationship between the main and auxiliary units can be flexibly adjusted according to the equipment status to improve the system redundancy. In addition to setting the pressure value, the outlet pipe valves of both air compressors must be kept open during daily operation. Switching between the main and auxiliary units does not require closing the manual valve. This modification to the existing equipment, by adding a manual control shut-off valve to adjust the pressure parameters of the air compressor, reduces the modification cost while increasing pressure regulation. It is also applicable to air compressors of different brands and control methods, improving the applicability of the system. Compressed gas meeting the pressure requirements enters the buffer tank 7 through the filter pipeline 6 for buffer storage, and after being dried by the dryer 3, it is distributed to the process gas storage tank 4 and the instrument gas storage tank 5 respectively, and then discharged into different gas supply pipelines. The outlet end of the instrument gas storage tank 5 still needs to be filtered through the filter pipeline 6 before being supplied with gas.

[0017] Furthermore, the outlet pipe of the air compressor a1 is also equipped with a check valve a8, a manual venting test pipe a9, and a shut-off valve a10. The check valve a8 is located in front of the manual venting test pipe a9, and the shut-off valve a10 is located on the manual venting test pipe a9. When the two machines are running in parallel, the check valve a8 can prevent water in the pipeline from flowing back into the air compressor and causing damage to the compressor head. The manual venting test pipe a9 can be used to manually release pressure by opening the shut-off valve a10 during pressure testing.

[0018] Furthermore, the outlet pipe of the air compressor b2 is also equipped with a check valve b11, a manual venting test pipe b12, and a shut-off valve b13. The check valve b11 is located in front of the manual venting test pipe b12, and the shut-off valve b13 is located on the manual venting test pipe b12. Among them, the check valve b11 can also prevent water in the pipeline from flowing back into the air compressor and causing damage to the compressor head. The manual venting test pipe b12 can be used to manually release pressure by opening the shut-off valve b13 during pressure testing.

[0019] Furthermore, a bypass pipe a14 is provided between the parallel pipeline of air compressor a1 and air compressor b2 and the filter pipeline 6 on the left side of buffer tank 7, and a shut-off valve c15 is provided on the bypass pipe a14. Among them, the bypass pipeline a14 can open the shut-off valve c15 when the main pipeline fails and is out of service, ensuring the normal gas supply to downstream equipment.

[0020] Furthermore, the filter pipeline 6 also includes a filter valve assembly 16, a bypass pipeline b17, and a shut-off valve d18. The bypass pipeline b17 is located on both sides of the filter valve assembly 16, and the shut-off valve d18 is located on the bypass pipeline. The filter valve assembly 16 can filter impurities in compressed gas between various devices to protect the equipment. The bypass line b17 and the shut-off valve d18 can be used as bypass lines to ensure normal operation of the equipment when the filter valve assembly 16 is being maintained.

[0021] In summary, this device connects air compressors a1 and b2 in parallel, and, with the bypass pipe a14 and buffer tank 7 for adjustment and switching, reduces the pressure trigger response time to less than 5 seconds, ensuring production continuity. It also allows for flexible adjustment of the main and auxiliary relationships based on equipment status, improving system redundancy. By adding a manual control shut-off valve to adjust pressure parameters with the air compressors, it increases pressure regulation while reducing modification costs. Furthermore, it is applicable to air compressors of different brands and control methods, enhancing the system's applicability.

[0022] The working principle of this utility model: Before system optimization, the impact time varied depending on the type of fault. For general component failures, assuming spare parts were readily available, the recovery time from interruption to restart was 2 to 3 hours. Control system failures were more complex, involving internal programs, and the interruption time was generally 3 to 5 days. If spare parts for air compressor damage were insufficient, recovery would take 5 to 10 days even if the manufacturer had stock available. Based on an estimated output loss of 3.2 tons per hour, and assuming an air compressor failure lasted 10 days, the estimated output loss would be 10 (days) * 24 (hours) * 3.5 = 840 tons. During system initialization, the system defaults to setting air compressor a1 as the main unit and air compressor b2 as the backup auxiliary unit. The main and auxiliary relationship can be manually switched through the control panel of the production workshop control cabinet. The pressure sensors on the two air compressors (not shown in the figure) are connected to the PLC system of the production workshop control cabinet to transmit the pressure detection signal. Air compressor a1 is set as an Atlas Copco screw air compressor with star-delta start control, and air compressor b2 is set as an oil-injected screw air compressor, model SLV55-8A, brand Shengmitun, with frequency conversion control. When air compressor a1 is in main unit mode, if the pressure sensor on the pressure pipeline (not shown in the figure) detects that the system pressure is <0.60MPa, or if the PLC system detects that air compressor a1 has a fault shutdown signal triggering an overload, overheat, or electrical fault signal, air compressor b2, as an auxiliary unit, will start and continuously monitor the pressure to restore the compressed air pressure to the set upper limit. It is recommended to set the upper limit to 0.65MPa. After a 30-second delay, the auxiliary unit will stop. If the main unit has repaired the fault, the main unit will automatically resume stand-alone operation. When air compressor b2 is in main unit mode, when the pressure sensor on the pressure pipeline detects that the system pressure is <0.57MPa or the PLC system detects that the air compressor a1 has a fault shutdown signal that triggers an overload, overheating or electrical fault signal, the system starts the auxiliary air compressor a1 according to the same procedure until the system returns to normal. Meanwhile, during operation, the main and auxiliary machines are prohibited from starting simultaneously. A time relay (not shown in the figure) is set, the starting interval is ≥10 seconds, the fault alarm takes priority over the pressure control, and the main and backup relationship is automatically switched if the auxiliary machine runs continuously for more than 2 hours. In this operating state, the compressed gas enters the buffer tank 7 through the filter pipeline 6 and is then stored in a buffer. After being dried by the dryer 3, it is distributed to the process gas storage tank 4 and the instrument gas storage tank 5, and then discharged into different gas supply pipelines. The outlet of the instrument gas storage tank 5 still needs to be filtered through the filter pipeline 6 before being supplied with gas. The entire system continuously supplies compressed gas to the gas supply pipelines.

[0023] After the technical solution is improved, based on the existing equipment, only the addition of a manual control valve, air compressor control system parameter adjustment, and a new maintenance vent valve and vent pipeline are needed to achieve auxiliary adjustment function; it is suitable for air compressors of different brands and control methods; the pressure trigger response time is less than 5 seconds, ensuring production continuity; the system can flexibly adjust the main and auxiliary relationship according to the equipment status, improving system redundancy.

[0024] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0025] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A multi-brand air compressor main / auxiliary automatic switching control system, comprising air compressor a, air compressor b, dryer, process air storage tank, and instrument air storage tank, wherein air compressor a is located to the right of air compressor a, dryer is connected to the right of air compressor a via a pipeline, process air storage tank is connected to the right front of dryer via a pipeline, and instrument air storage tank is connected above process air storage tank via a pipeline; air compressor a, air compressor b, dryer, process air storage tank, and instrument air storage tank are respectively electrically connected to a production workshop controller, characterized in that: Air compressor a and air compressor b are connected in parallel via pipelines; a filter pipeline and a buffer tank are also installed on the pipeline between air compressor a and the dryer, and the buffer tank is electrically connected to the production workshop controller; a filter pipeline is installed on the pipeline between the buffer tank and the dryer; a filter pipeline is installed on the pipeline between the dryer and the process gas storage tank; and a filter pipeline is installed on the outlet pipeline of the instrument gas storage tank.

2. The multi-brand air compressor main and auxiliary automatic switching control system according to claim 1, characterized in that: The outlet pipe of the air compressor a is also equipped with a check valve a, a manual venting test pipe a, and a shut-off valve a. The check valve a is located in front of the manual venting test pipe a, and the shut-off valve a is located on the manual venting test pipe a.

3. The multi-brand air compressor main and auxiliary automatic switching control system according to claim 1, characterized in that: The outlet pipe of the air compressor b is also equipped with a check valve b, a manual venting test pipe b, and a shut-off valve b. The check valve b is located in front of the manual venting test pipe b, and the shut-off valve b is located on the manual venting test pipe b.

4. The multi-brand air compressor main and auxiliary automatic switching control system according to claim 1, characterized in that: A bypass pipe a is provided between the parallel pipeline of air compressor a and air compressor b and the filter pipeline on the left side of the buffer tank, and a shut-off valve c is provided on the bypass pipe a.

5. The multi-brand air compressor main and auxiliary automatic switching control system according to claim 1, characterized in that: The filter pipeline also includes a filter valve assembly, a bypass pipeline b, and a shut-off valve d. The bypass pipeline b is located on both sides of the filter valve assembly, and the shut-off valve d is located on the bypass pipeline.

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