Air compressor and vacuum pump cooperative energy saving system

Abstract

The utility model discloses an air compressor and vacuum pump collaborative energy saving system, including controller, air compressor and vacuum pump, the air inlet end of vacuum pump is connected with the vacuum demand end of production equipment through vacuum pipeline, the air inlet end of air compressor is equipped with emptying regulating valve and is connected with vacuum pipeline bypass through branch pipe, and the air outlet end of air compressor is connected with compressed air demand end, be equipped with vacuum electric regulating valve on branch pipe. The air compressor and vacuum pump collaborative energy saving system provided by the utility model replace traditional two sets of equipment independent full load operation mode, utilize air compressor air inlet end negative pressure to share vacuum pump load, reduce the actual working load of vacuum pump, and the collaborative control avoids air compressor and vacuum pump to be in high -power consumption state simultaneously, especially suitable for the production scene needing positive pressure and negative pressure simultaneously, and it is helpful to enterprise energy saving and emission reduction.

Description

Technical Field

[0001] This utility model relates to the field of workshop energy-saving technology, and in particular to an energy-saving system that combines an air compressor and a vacuum pump. Background Technology

[0002] In industrial production, compressed air is powered by positive pressure from air compressors, and a vacuum environment is created by negative pressure adsorption or extraction from vacuum pumps—these are two fundamental and critical gas power requirements. Currently, most production workshops employ a system architecture where air compressors and vacuum pumps operate independently: a separate air compressor system meets the compressed air requirement, and a separate vacuum pump system meets the vacuum requirement. The two systems lack a coordination mechanism. When production requires both compressed air and a vacuum simultaneously, both the air compressor and vacuum pump must operate at full load, resulting in very high energy consumption, which contradicts the principles of low-carbon and energy-saving practices. In fact, when the air compressor's outlet generates positive pressure, its inlet generates negative pressure. If the negative pressure generated at the air compressor's inlet could be used to share the load on the vacuum pump, energy consumption would be effectively reduced.

[0003] It is evident that existing technologies still need improvement and enhancement. Utility Model Content

[0004] In view of the shortcomings of the prior art, the purpose of this utility model is to provide an air compressor and vacuum pump co-operation energy-saving system, which aims to use the negative pressure at the air compressor inlet to share the load of the vacuum pump and reduce the actual working load of the vacuum pump.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: An energy-saving system for coordinated operation of an air compressor and a vacuum pump includes a controller, an air compressor, and a vacuum pump. The inlet of the vacuum pump is connected to the vacuum demand end of the production equipment via a vacuum pipeline. The inlet of the air compressor is equipped with a vent regulating valve and is connected to the vacuum pipeline via a branch pipe. The outlet of the air compressor is connected to the compressed air demand end. A vacuum electric regulating valve is installed on the branch pipe, and a vacuum pressure sensor is installed on the vacuum pipeline. The controller is electrically connected to the air compressor, the vacuum pump, the vacuum electric regulating valve, and the vent regulating valve, and collects system operating parameters in real time through the sensors to control the coordinated operation of each component.

[0006] As a further improvement to the above technical solution, the sensor also includes an intake pressure sensor disposed at the intake end of the air compressor and an exhaust pressure sensor disposed at the exhaust end of the air compressor.

[0007] As a further improvement to the above technical solution, an air purification device is connected in series between the venting regulating valve and the air compressor inlet.

[0008] As a further improvement to the above technical solution, the vacuum electric regulating valve and the venting regulating valve are regulating electric ball valves.

[0009] As a further improvement to the above technical solution, the controller is a DCS controller.

[0010] The beneficial effects of this utility model are as follows: The air compressor and vacuum pump coordinated energy-saving system provided by this utility model replaces the traditional mode of two sets of equipment operating independently at full load. It uses the negative pressure at the air compressor inlet to share the load of the vacuum pump, reducing the actual working load of the vacuum pump. The coordinated control avoids the air compressor and vacuum pump being in a high power consumption state at the same time. It is especially suitable for production scenarios that require both positive and negative pressure at the same time, and helps enterprises save energy and reduce emissions. Attached Figure Description

[0011] Figure 1 This utility model provides a schematic diagram of the structure of the air compressor and vacuum pump coordinated energy-saving system.

[0012] Explanation of main component symbols: 1-Air compressor, 2-Vacuum pump, 31-Vacuum demand end, 32-Compressed air demand end, 4-Vent control valve, 21-Branch pipe, 22-Vacuum pipeline, 6-Electric vacuum control valve, 81-Inlet pressure sensor, 82-Exhaust pressure sensor, 83-Vacuum pressure sensor, 9-Air purification device. Detailed Implementation

[0013] This utility model provides a coordinated energy-saving system for air compressors and vacuum pumps. To make the objectives, technical solutions, and effects of this utility model clearer and more explicit, the following detailed description, with reference to the accompanying drawings and embodiments, further illustrates this utility model. It should be understood that the specific embodiments described herein are merely illustrative of this utility model and are not intended to limit the scope of protection of this utility model.

[0014] Please see Figure 1 This utility model provides a collaborative energy-saving system for an air compressor 1 and a vacuum pump 2, including a controller, an air compressor 1, and a vacuum pump 2. The air inlet of the vacuum pump 2 is connected to the vacuum demand end 31 of the production equipment through a vacuum pipe 22. The air inlet of the air compressor 1 is equipped with a vent regulating valve 4 and is connected to the vacuum pipe 22 via a branch pipe 21. The air outlet of the air compressor 1 is connected to the compressed air demand end 32. A vacuum electric regulating valve 6 is provided on the branch pipe 21. The controller is electrically connected to the air compressor 1, the vacuum pump 2, the vacuum electric regulating valve 6, and the vent regulating valve 4, and collects system operating parameters in real time through sensors to control the collaborative operation of each component.

[0015] When the workshop only requires compressed air, air compressor 1 operates independently. The vacuum electric regulating valve 6 is closed, and the vent regulating valve 4 is fully open, allowing the air inlet of air compressor 1 to be directly connected to the atmosphere. At this time, air compressor 1 operates independently according to preset parameters, only meeting the demand for compressed air, and the negative pressure is not utilized.

[0016] When the workshop has both compressed air and vacuum negative pressure requirements, air compressor 1 and vacuum pump 2 operate synchronously. The controller adjusts the opening of vacuum electric regulating valve 6 and venting regulating valve 4 synchronously according to the vacuum level requirement in vacuum pipeline 22. If the vacuum level is insufficient, the opening of vacuum electric regulating valve 6 is increased, guiding part of the vacuum requirement of the production equipment to be borne by the negative pressure at the air compressor 1's inlet, reducing the load on vacuum pump 2. At the same time, the opening of venting regulating valve 4 is adjusted to maintain stable pressure at the air compressor 1's inlet, avoiding excessive negative pressure extraction that could affect the normal operation of air compressor 1. Vacuum pump 2 automatically adjusts its operating power according to the remaining vacuum requirement, forming a negative pressure complementarity with air compressor 1. For example, when the negative pressure generated by air compressor 1 meets 30% of the vacuum requirement, vacuum pump 2 only needs to provide the remaining 70% of the negative pressure, directly reducing its energy consumption.

[0017] When the workshop only requires vacuum negative pressure, and vacuum pump 2 is running alone, vacuum electric regulating valve 6 is closed, and vacuum pump 2 independently meets the vacuum requirements of production equipment through vacuum pipeline 22, which is suitable for working conditions where compressed air is not required.

[0018] When the air compressor 1 is running, its intake end naturally generates negative pressure. Now, through the bypass connection of the branch pipe 21 and the vacuum pipeline 22, this negative pressure can be directly applied to the vacuum demand end 31 of the production equipment. This is equivalent to utilizing the negative pressure power source that would otherwise be wasted, thereby reducing the energy consumption of the vacuum pump 2.

[0019] The air compressor 1 and vacuum pump 2 collaborative energy-saving system provided by this utility model replaces the traditional mode of two sets of equipment operating independently at full load. It uses the negative pressure at the air inlet of air compressor 1 to share the load of vacuum pump 2, reducing the actual working load of vacuum pump 2. The collaborative control avoids air compressor 1 and vacuum pump 2 being in a high power consumption state at the same time. It is especially suitable for production scenarios that require both positive and negative pressure (such as gripping and adsorption processes in automated production lines), which helps enterprises save energy and reduce emissions.

[0020] It is understandable that by linking the venting regulating valve 4 with the vacuum electric regulating valve 6, the pressure at the air inlet of the air compressor 1 is kept stable within a safe range, thus avoiding a decrease in the air intake efficiency of the air compressor 1 or damage to the equipment due to excessive negative pressure extraction.

[0021] It should be noted that the air compressor 1 and vacuum pump 2 co-energy-saving system provided here can quickly improve the original air compressor system and vacuum system. Through the design of bypass pipeline and intelligent valve, there is no need to carry out large-scale modification of the existing air compressor 1 and vacuum pump 2. Only the addition of branch pipe 21, sensor and adjustment control module is required, which reduces the system upgrade cost.

[0022] In one embodiment, pressure switches are installed on the vacuum pipeline 22 and the compressed air pipeline, with different pressure threshold ranges set. When the pressure reaches the upper limit, the pressure switch triggers a signal to control the equipment to reduce its operating power or stop operation; when the pressure drops to the lower limit, it triggers the equipment to start or increase its power. Simultaneously, a timer is used to set the equipment's start-up and shutdown times according to production schedules.

[0023] In other embodiments, the energy-saving system for the air compressor 1 and vacuum pump 2 provided by this utility model also includes a sensor assembly to collect system operating parameters in real time to control the coordinated operation of each component. The sensor assembly collects key operating parameters such as the air compressor inlet pressure, exhaust pressure, and vacuum pipeline pressure in real time, and transmits the data to the controller in real time. Based on this precise data, the controller can quickly and accurately adjust the operating status of the air compressor and vacuum pump, as well as the opening degree of the venting regulating valve and the vacuum electric regulating valve.

[0024] Specifically, the sensor assembly includes an intake pressure sensor 81 disposed at the intake end of the air compressor 1, an exhaust pressure sensor 82 disposed at the exhaust end of the air compressor 1, and a vacuum pressure sensor 83 disposed on the vacuum pipe 22.

[0025] The intake pressure sensor 81 monitors the intake pressure of the air compressor 1 in real time. Combined with the data from the vacuum pressure sensor 83 in the vacuum pipeline, the controller can accurately determine whether the negative pressure at the intake of the air compressor 1 can meet the partial vacuum requirements. When the conditions are met, the controller can dynamically reduce the operating power of the vacuum pump 2, realizing efficient collaborative work between the air compressor 1 and the vacuum pump 2, which significantly reduces overall energy consumption compared to traditional independent operation systems.

[0026] The exhaust pressure sensor 82 at the exhaust end of air compressor 1 can collect the compressed air pressure value in real time, and the controller adjusts the operating status of air compressor 1 based on this data. When the compressed air pressure is higher than the set value, the controller controls air compressor 1 to reduce the speed or reduce the output flow to avoid energy waste caused by excessive pressure, while ensuring a stable supply of compressed air, improving the stability and reliability of production equipment operation, and reducing the adverse effects of pressure fluctuations on the production process.

[0027] Pressure data collected by three types of sensors provides the controller with comprehensive system operating parameters, enabling it to perform real-time calculations and make intelligent decisions. Through precise control of each component, the system can flexibly adjust its operating status according to actual production needs, maintaining efficient and energy-saving operation under different working conditions. Compared with traditional fixed-mode systems, it has stronger environmental adaptability and energy-saving advantages.

[0028] An air purification device 9 is connected in series between the vent regulating valve 4 and the air inlet of the air compressor 1. The air purification device 9 can effectively filter dust, particles, oil, and other impurities in the air, preventing these contaminants from entering the air compressor. When the air compressor draws in clean air, its compression components can operate more smoothly, reducing frictional resistance caused by impurities, thereby reducing the air compressor's operating energy consumption, improving compression efficiency, and enabling the air compressor to operate stably with higher performance.

[0029] Of course, an air purification device can also be connected in series between the air inlet of the air compressor 1 and the branch pipe. The purified air enters the vacuum system, which can prevent impurities from damaging the vacuum pipes and the internal components of the vacuum pump.

[0030] In this embodiment, the vacuum electric regulating valve 6 and the venting regulating valve 4 are electric proportional regulating valves or electric ball valves.

[0031] If an electric proportional control valve is used, the valve opening can be precisely adjusted proportionally according to different electrical signals output by the controller, achieving fine control of the airflow and pressure at the vacuum pipeline and the air compressor 1 inlet. When the system vacuum demand changes slightly, the electric proportional control valve can respond quickly, adjusting the airflow with a very small opening to precisely control the airflow, keeping the system pressure stable near the set value and avoiding the impact of pressure fluctuations on the production process.

[0032] When using electric ball valves, their structural characteristics enable rapid opening and closing, offering significant advantages in situations requiring quick changes in airflow. When production equipment experiences sudden changes in vacuum or compressed air demand, electric ball valves can complete opening or closing actions in a very short time, ensuring rapid system response, reducing energy waste caused by slow valve action, and improving overall system efficiency. For example, in automated packaging production lines with frequent start-stop cycles, they can effectively improve the matching of production rhythms.

[0033] Preferably, the existing air compressor and vacuum systems are controlled by a DCS system. Therefore, this collaborative energy-saving system uses a DCS controller, enabling seamless integration with the existing system. Without requiring large-scale modifications to the factory's existing automation control architecture, the new collaborative energy-saving system can be quickly integrated into the overall production control system, significantly reducing the cost and difficulty of system upgrades, shortening project implementation cycles, and improving the efficiency of introducing new technologies. The DCS controller possesses powerful data acquisition, processing, and analysis capabilities, simultaneously receiving and processing multi-source data from the air compressor 1's inlet pressure sensor, exhaust pressure sensor, vacuum pipeline pressure sensor, and status feedback from the electric proportional control valve or electric ball valve. Through efficient data processing and analysis, the DCS controller can precisely regulate the operating parameters of each device, optimizing the collaborative operation of air compressor 1 and vacuum pump 2, further improving the system's energy-saving effect and operating efficiency. It should be noted that those skilled in the art are capable of reasonably arranging and debugging the DCS for automatic sensor data acquisition and automatic control of the air compressor and vacuum pump. The core invention of this technical solution lies in improving the original compressed air system and vacuum system to form an energy-saving system with synergistic effects.

[0034] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0035] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows for communication; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0036] It is understood that those skilled in the art can make equivalent substitutions or changes based on the technical solution and inventive concept of this utility model, and all such substitutions or changes should fall within the protection scope of this utility model.

Claims

1. A coordinated energy-saving system for air compressors and vacuum pumps, characterized in that, The system includes a controller, an air compressor, and a vacuum pump. The air inlet of the vacuum pump is connected to the vacuum demand end of the production equipment via a vacuum pipeline. The air inlet of the air compressor is equipped with a vent regulating valve and is connected to the vacuum pipeline via a branch pipe. The air outlet of the air compressor is connected to the compressed air demand end. A vacuum electric regulating valve is installed on the branch pipe. The controller is electrically connected to the air compressor, the vacuum pump, the vacuum electric regulating valve, and the vent regulating valve.

2. The air compressor and vacuum pump synergistic energy-saving system according to claim 1, characterized in that, It also includes sensor components that collect system operating parameters in real time to control the coordinated operation of various components.

3. The air compressor and vacuum pump synergistic energy-saving system according to claim 2, characterized in that, The sensor assembly includes an intake pressure sensor located at the air compressor intake end, an exhaust pressure sensor located at the air compressor exhaust end, and a vacuum pressure sensor located on the vacuum pipeline.

4. The air compressor and vacuum pump synergistic energy-saving system according to claim 1, characterized in that, An air purification device is connected in series between the vent regulating valve and the air inlet of the air compressor.

5. The air compressor and vacuum pump synergistic energy-saving system according to claim 1, characterized in that, The vacuum electric regulating valve and the venting regulating valve are regulating electric ball valves.

6. The air compressor and vacuum pump synergistic energy-saving system according to claim 1, characterized in that, The controller is a DCS controller.

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