Air compression station monitoring system

Abstract

The application discloses an air compression station monitoring system, which comprises a master station and a slave station. The master station comprises a master controller, an upper computer and a master device group. The upper computer is connected with the master controller, and the master device group is connected with the master controller. The slave station comprises a first substation, a second substation, a master frequency converter, a master electric meter and a master flowmeter. The first substation, the second substation, the master frequency converter, the master electric meter and the master flowmeter are connected respectively. The first substation comprises a first controller, a first device group, a first frequency converter, a first flowmeter and a first electric meter. The first controller is connected with the master controller. The first device group, the first frequency converter, the first flowmeter and the first electric meter are connected with the first controller respectively. The second substation comprises a second controller, a second device group, a second frequency converter, a second flowmeter and a second electric meter. The second controller is connected with the master controller. The second device group, the second frequency converter, the second flowmeter and the second electric meter are connected with the second controller respectively.

Description

Technical Field

[0001] This application relates to the field of air compressor station technology, and in particular to an air compressor station monitoring system. Background Technology

[0002] The manufacturing process of aluminum alloy cookware requires a large amount of compressed air, with air compressor stations accounting for about 30% of the total electricity consumption. Among these, sandblasting and shot blasting equipment and nitrogen generators consume more air at atmospheric pressure than other equipment. Previously, there was only one air compressor station with on-duty personnel. Based on production needs, the air compressors, freeze dryers, and other equipment were manually controlled to start and stop, resulting in high energy consumption due to the high air pressure during operation. Utility Model Content

[0003] This application aims to address at least one of the technical problems existing in the prior art. To this end, this application proposes an air compressor station monitoring system capable of intelligent pressure stabilization control and operating pressure reduction, effectively saving a significant amount of electrical energy, avoiding anomalies caused by large pressure fluctuations, and ensuring product quality.

[0004] The air compressor station monitoring system according to the embodiments of this application includes a master station and slave stations. The master station includes a master controller, a host computer, and a main equipment group. The host computer is connected to the master controller, and the main equipment group is connected to the master controller. The slave station includes a first substation, a second substation, a main frequency converter, a main power meter, and a main flow meter. The first substation, the second substation, the main frequency converter, the main power meter, and the main flow meter are respectively connected. The first substation is used to supply air to a sandblasting and shot blasting machine. The first substation includes a first controller, a first equipment group, a first frequency converter, a first flow meter, and a first power meter. The first controller is connected to the master controller, and the first equipment group, the first frequency converter, the first flow meter, and the first power meter are respectively connected to the first controller. The second substation is used to supply air to a nitrogen generator. The second substation includes a second controller, a second equipment group, a second frequency converter, a second flow meter, and a second power meter. The second controller is connected to the master controller, and the second equipment group, the second frequency converter, the second flow meter, and the second power meter are respectively connected to the second controller.

[0005] The air compressor station monitoring system described in the embodiments of this application has at least the following beneficial effects: The air compressor station monitoring system described in the embodiments of this application can realize intelligent pressure stabilization control and reduce operating pressure, effectively save a lot of power, avoid abnormalities caused by large fluctuations in air pressure, and ensure product quality.

[0006] According to the air compressor station monitoring system described in the embodiments of this application, the main equipment group includes at least one main air compressor and at least one main dryer, and the main air compressor and the main dryer are respectively connected to the main controller.

[0007] According to the air compressor station monitoring system described in the embodiments of this application, the main station further includes a main touch screen, which is connected to the main controller, the first controller, and the second controller.

[0008] According to the air compressor station monitoring system described in the embodiments of this application, the first controller is connected to the main controller via MODBUS-RTU communication, and the second controller is connected to the main controller via a wireless module.

[0009] According to the air compressor station monitoring system described in the embodiments of this application, the first equipment group includes at least one first air compressor and at least one first dryer, and the first air compressor and the first dryer are respectively connected to the first controller.

[0010] According to the air compressor station monitoring system described in the embodiments of this application, the first substation further includes a first touch screen, which is connected to the first controller.

[0011] According to the air compressor station monitoring system described in the embodiments of this application, the second equipment group includes at least one second air compressor and at least one second dryer, and the second air compressor and the second dryer are respectively connected to the second controller.

[0012] According to the air compressor station monitoring system described in the embodiments of this application, the second substation further includes a second touch screen, which is connected to the second controller.

[0013] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0014] The present application will be further described below with reference to the accompanying drawings and embodiments, wherein: Figure 1 This is a schematic diagram of the air compressor station monitoring system according to an embodiment of this application; Figure 2 This is a control principle diagram of the air compressor station monitoring system according to an embodiment of this application; Figure 3 This is a communication structure diagram of the air compressor station monitoring system according to an embodiment of this application.

[0015] Figure label: Master station 100; main controller 110; host computer 120; main equipment group 130; main touch screen 140; slave station 200; first substation 210; first controller 211; first equipment group 212; first frequency converter 213; first electricity meter 214; first flow meter 215; first touch screen 216; second substation 220; second controller 221; second equipment group 222; second frequency converter 223; second electricity meter 224; second flow meter 225; wireless module 226; second touch screen 227; main frequency converter 230; main electricity meter 240; main flow meter 250. Detailed Implementation

[0016] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0017] In the description of this application, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0018] In the description of this application, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0019] In the description of this application, unless otherwise expressly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly. Those skilled in the art can reasonably determine the specific meaning of these terms in this application based on the specific content of the technical solution. In the description of this application, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples. In the description of this specification, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0020] Reference Figures 1 to 3 This application provides an air compressor station monitoring system, including a master station 100 and slave stations 200. The master station 100 includes a master controller 110, a host computer 120, and a main equipment group 130. The host computer 120 is connected to the master controller 110, and the main equipment group 130 is connected to the master controller 110. The slave station 200 includes a first substation 210, a second substation 220, a main frequency converter 230, a main power meter 240, and a main flow meter 250. The first substation 210, the second substation 220, the main frequency converter 230, the main power meter 240, and the main flow meter 250 are respectively connected. The first substation 210 is used to supply air to a sandblasting and shot blasting machine. The first substation 210 includes a first controller 211 and a first equipment group 212. The system includes a first frequency converter 213, a first flow meter 215, and a first electricity meter 214. A first controller 211 is connected to the main controller 110. A first equipment group 212, the first frequency converter 213, the first flow meter 215, and the first electricity meter 214 are respectively connected to the first controller 211. A second substation 220 is used to supply gas to the nitrogen generator. The second substation 220 includes a second controller 221, a second equipment group 222, a second frequency converter 223, a second flow meter 225, and a second electricity meter 224. The second controller 221 is connected to the main controller 110. The second equipment group 222, the second frequency converter 223, the second flow meter 225, and the second electricity meter 224 are respectively connected to the second controller 221.

[0021] In the practical application of this application, a first substation 210 is established near the shot blasting machine, and a second substation 220 is established near the nitrogen generator. The main station 100 supplies compressed air at a pressure of 0.58 MPa to the equipment. Then, compressed air at a pressure of 0.65 MPa is supplied to the shot blasting machine through a dedicated pipeline from the first substation 210, and compressed air at a pressure of 0.73 MPa is supplied to the nitrogen generator through a dedicated pipeline from the second substation 220. This forms an automatic PID intelligent frequency conversion voltage regulation and monitoring system with the main controller 110 as its core. This system enables intelligent voltage regulation and pressure reduction, effectively saving a significant amount of energy, preventing abnormalities caused by large fluctuations in air pressure, and ensuring product quality.

[0022] It should be noted that the control methods of the main controller 110, the first controller 211, and the second controller 221 are all simple trigger control. Therefore, the control methods of the main controller 110, the first controller 211, and the second controller 221 are not within the scope of protection of this application and belong to the prior art. This application mainly protects the connection relationship between the various components.

[0023] Reference Figures 1 to 3 The host computer 120 is connected to the main controller 110, enabling it to operate, monitor, and store parameters such as electrical energy, pressure, and flow rate. The host computer 120 also generates monitoring screens, charts, and databases, providing crucial reference data for energy analysis and management. The main controller 110 communicates with the slave stations 200 (first substation 210, main inverter 230, main electricity meter 240, and main flow meter 250) via the MODBUS-RTU communication protocol. Since the second substation 220 is farther from the main controller 110, it communicates with the main controller 110 via a wireless module 226. This structure allows the main controller 110 to read operating frequency, time, current, power consumption, and flow rate parameters from the first substation 210, second substation 220, main inverter 230, main electricity meter 240, and main flow meter 250, and simultaneously issue start, stop, and operating frequency control commands to the main inverter 230.

[0024] The main equipment group 130 includes at least one main air compressor and at least one main dryer, both of which are connected to the main controller 110. Specifically, the main controller 110 performs PID control calculations and outputs signals based on the calculation results to control the start and stop of the main air compressor and main dryer. Simultaneously, it controls the frequency converter to increase or decrease the frequency speed to adjust the stable operating pressure, thereby achieving intelligent pressure stabilization control and reducing operating pressure. The start and stop sequence of the air compressors follows the principle of prioritizing energy-saving variable frequency air compressors. That is, the start sequence is: first, the variable frequency energy-saving air compressor; second, the new energy-saving air compressor; and finally, older air compressors with poor energy efficiency are used as backups. The stop sequence is the reverse of the start sequence.

[0025] It should be noted that the number of main air compressors and main dryers can be set according to the actual situation, and this application does not impose any restrictions on this.

[0026] Furthermore, the main station 100 also includes a main touch screen 140, which is connected to the main controller 110, the first controller 211, and the second controller 221. With the main touch screen 140, users can view the operating status and parameters of the main air compressor or main dryer, and perform manual operations, making operation more convenient.

[0027] Reference Figures 1 to 3 In some embodiments of this application, the first equipment group 212 includes at least one first air compressor and at least one first dryer, which are respectively connected to a first controller 211. The first controller 211 controls the start and stop of the first air compressor and the first dryer, thereby achieving intelligent pressure stabilization control of the first substation 210, effectively saving a significant amount of electrical energy, avoiding abnormalities caused by large fluctuations in air pressure, and ensuring product quality. It is conceivable that the first substation 210 also includes a first touchscreen 216, which is connected to the first controller 211. With the first touchscreen 216, the operating status, parameters, and other data of the first air compressor or the first dryer can be viewed, and manual operation can be performed through the first touchscreen 216, making operation more convenient.

[0028] Accordingly, the second equipment group 222 includes at least one second air compressor and at least one second dryer, with the second air compressor and the second dryer respectively connected to the second controller 221. The second controller 221 controls the start and stop of the second air compressor and the second dryer, thereby achieving intelligent pressure stabilization control of the second substation 220, effectively saving a significant amount of energy, avoiding abnormalities caused by large fluctuations in air pressure, and ensuring product quality. It is conceivable that the second substation 220 also includes a second touchscreen 227, which is connected to the second controller 221. This allows users to view the operating status, parameters, and other data of the second air compressor or the second dryer through the touchscreen 227, and to perform manual operations through the touchscreen 227, making operation more convenient.

[0029] The embodiments of this application have been described in detail above with reference to the accompanying drawings. However, this application is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of this application.

Claims

1. An air compressor station monitoring system, characterized in that, The system includes a master station and slave stations. The master station comprises a master controller, a host computer, and a master equipment group. The host computer is connected to the master controller, and the master equipment group is also connected to the master controller. The slave station comprises a first substation, a second substation, a main frequency converter, a main power meter, and a main flow meter. The first substation, the second substation, the main frequency converter, the main power meter, and the main flow meter are respectively connected. The first substation is used to supply air to a sandblasting and shot blasting machine. The first substation comprises a first controller, a first equipment group, a first frequency converter, a first flow meter, and a first power meter. The first controller is connected to the master controller, and the first equipment group, the first frequency converter, the first flow meter, and the first power meter are respectively connected to the first controller. The second substation is used to supply air to a nitrogen generator. The second substation comprises a second controller, a second equipment group, a second frequency converter, a second flow meter, and a second power meter. The second controller is connected to the master controller, and the second equipment group, the second frequency converter, the second flow meter, and the second power meter are respectively connected to the second controller.

2. The air compressor station monitoring system according to claim 1, characterized in that, The main equipment group includes at least one main air compressor and at least one main dryer, and the main air compressor and the main dryer are respectively connected to the main controller.

3. The air compressor station monitoring system according to claim 2, characterized in that, The main station also includes a main touch screen, which is connected to the main controller, the first controller, and the second controller.

4. The air compressor station monitoring system according to claim 1, characterized in that, The first controller is connected to the main controller via MODBUS-RTU communication, and the second controller is connected to the main controller via a wireless module.

5. The air compressor station monitoring system according to claim 4, characterized in that, The first equipment group includes at least one first air compressor and at least one first dryer, and the first air compressor and the first dryer are respectively connected to the first controller.

6. The air compressor station monitoring system according to claim 5, characterized in that, The first substation also includes a first touch screen, which is connected to the first controller.

7. The air compressor station monitoring system according to claim 4, characterized in that, The second equipment group includes at least one second air compressor and at least one second dryer, the second air compressor and the second dryer being respectively connected to the second controller.

8. The air compressor station monitoring system according to claim 7, characterized in that, The second substation also includes a second touchscreen, which is connected to the second controller.

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