Method and system for diagnosing health of compressed air supply facilities

Abstract

To provide a compressed air supply facility health diagnosis method that enables efficient health diagnosis of not only compressed air piping but also air compressors in one go.SOLUTION: A method of diagnosing the health of a compressed air supply facility 1 including an air compressors 2 and compressed air piping 3 is provided, the method comprising a first step of collecting operation information data including discharge air volume and power consumption of the air compressor 2, a second step of acquiring usage information data that enables identification of operating periods and idle periods of compressed air utilizing equipment, a third step of sorting the operation information data into first operation information data corresponding to the idle periods and second operation information data corresponding to the operating periods through collation with the usage information data, a fourth step of evaluating the need for maintenance of the piping 3 on the basis of the first operation information data, and a fifth step of evaluating the need for maintenance of the air compressor 2 on the basis of the second operation information data.SELECTED DRAWING: Figure 7

Description

[Technical field]

[0001] The present invention relates to a method and system for diagnosing the health of compressed air supply equipment. [Background technology]

[0002] In business establishments (factories, etc.) primarily in the manufacturing industry, compressed air generated by air compressors is used as a power source for pneumatic equipment and tools used in the process of manufacturing intermediate and finished products. Within the business establishment, a network of compressed air transport pipelines (air piping) is laid out to distribute compressed air to numerous production lines and different production areas. In addition, multiple air compressors are often installed in different locations corresponding to the production lines and production areas.

[0003] As the years go by since the establishment of a business, the pipelines become deteriorated, and compressed air leaks become more likely to occur from the pipe joints. If compressed air leaks are left unchecked for a long period of time, the air compressor will waste more electricity, which will lead to higher manufacturing costs. Furthermore, if fossil fuels are used as the primary energy source for the electricity supply, this will also lead to an increase in carbon dioxide emissions. Therefore, it is desirable to regularly diagnose the soundness of the pipelines and, if necessary, perform maintenance such as repairing or replacing the pipelines.

[0004] For example, Patent Documents 1 and 2 disclose a technology in which an inspection device equipped with a pressure sensor is connected to a compressed air transport pipeline, the change in air pressure over time is measured while equipment using the compressed air is not in operation, and the amount of air leakage and the monetary loss due to wasted electricity consumption are calculated and displayed based on the measurement results. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2001-141598 A [Patent Document 2] JP 2004-157055 A Summary of the Invention [Problem to be solved by the invention]

[0006] Incidentally, air compressors are generally equipped with filters that remove foreign matter from the air before or after compression. If the filters become too clogged, this may lead to problems such as breakdowns and malfunctions in the air compressor. For this reason, it is desirable to periodically diagnose the health of the air compressor and, if necessary, perform maintenance such as cleaning or replacing the filters.

[0007] In view of the above-mentioned demand, the present invention aims to provide a method and system for diagnosing the health of compressed air supply equipment that can efficiently and collectively diagnose the health of not only compressed air transport pipelines but also air compressors. [Means for solving the problem]

[0008] The health diagnosis method of the present invention is a method for diagnosing the health of a compressed air supply facility including an air compressor that generates compressed air and a transport pipeline used to transport the compressed air to compressed air utilization equipment, the method including: a first step of collecting operation information data including information on the discharge air volume and power consumption of the air compressor; a second step of acquiring usage information data that enables the operation periods and idle periods of the compressed air utilization equipment to be identified; a third step of sorting the operation information data by comparing it with the usage information data into first operation information data corresponding to the idle period and second operation information data corresponding to the operation period; a fourth step of evaluating the need for maintenance of the transport pipeline based on the first operation information data; and a fifth step of evaluating the need for maintenance of the air compressor based on the second operation information data.

[0009] According to this method, it is possible to efficiently and collectively diagnose the health of not only the compressed air transport pipeline but also the air compressor. Note that the "operating period" here refers to the period during which the compressed air utilization equipment operates and consumes compressed air, and the "stopping period" refers to the period during which the compressed air utilization equipment is stopped and does not consume compressed air.

[0010] More specifically, the above method may further include a sixth step of identifying a location of a compressed air leak in the transport pipeline using an inspection tool if it is evaluated in the fourth step that maintenance is necessary for the transport pipeline.

[0011] At least a portion of the transport pipeline is configured so that the compressed air flows in from each of the multiple air compressors at a different inlet position, and in the above-mentioned health diagnosis method in which steps 1 to 5 are performed for each of the multiple air compressors, if it is evaluated in step 4 for any of the air compressors that maintenance is necessary for the transport pipeline, the method may further include a sixth step of narrowing down an inspection target area based on information about the inlet position for that air compressor, and using an inspection tool to identify the location of a leak of the compressed air in the transport pipeline.

[0012] More specifically, the above method may be a method using an acoustic imaging device as the inspection tool.More specifically, the above method may be a method in which the fourth step is a process of calculating a waste power cost of the air compressor based on first operation information data, and evaluating that maintenance is necessary for the transportation pipeline when the calculated waste power cost satisfies a predetermined condition, and the fifth step is a process of calculating a specific energy of the air compressor based on second operation information data, and evaluating that maintenance is necessary for the air compressor when the calculated specific energy satisfies a predetermined condition.

[0013] Furthermore, a health diagnosis system according to the present invention is a system for diagnosing the health of a compressed air supply facility including an air compressor that generates compressed air and a transport pipeline used to transport the compressed air to a compressed air utilization device, the system comprising: a controller that controls the operation of the air compressor; and a server communicatively connected to the controller, the controller having a data storage unit that collects and stores operation information data including information on the discharge air volume and power consumption of the air compressor, and a data output unit that outputs the operation information data to the server, the server comprising: a data input unit that accepts input of usage information data that enables the operation period and idle period of the compressed air utilization device to be identified, a data storage unit in which the operation information data and the usage information data are stored, a data selection unit that compares the operation information data with the usage information data and selects the operation information data into first operation information data corresponding to the idle period and second operation information data corresponding to the operation period, a first evaluation unit that evaluates the necessity of maintenance for the transport pipeline based on the first operation information data, and a second evaluation unit that evaluates the necessity of maintenance for the air compressor based on the second operation information data. Effect of the Invention

[0014] According to the health diagnosis method of the present invention, it is possible to efficiently and collectively perform health diagnosis of not only compressed air transport pipelines but also air compressors. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 is a configuration diagram of a health diagnosis system 100 according to the present embodiment and its peripheral elements. [Diagram 2] FIG. 2 is an explanatory diagram showing a more specific example of the configuration of the health diagnostic system 100. [Diagram 3] FIG. 2 is an explanatory diagram showing a more specific configuration example of the compressed air supply facility 1. [Figure 4] FIG. 2 is an explanatory diagram showing a schematic configuration example of an air compressor 2. [Diagram 5]FIG. 2 is an explanatory diagram showing a schematic configuration example of a controller 30. [Figure 6] 1 is a flowchart of a data collection operation. [Figure 7] 13 is a flowchart relating to a health evaluation operation. [Figure 8] 13 is a flowchart showing the work process of a field engineer. [Figure 9] FIG. 2 is a block diagram showing main functional units of the controller 30 and the server 500. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] 1. Configuration of the health diagnostic system FIG. 1 shows a schematic configuration of a health diagnostic system 100 according to this embodiment and its peripheral elements.

[0017] The health diagnostic system 100 is a system having first to fourth four controllers 30a to 30d (hereinafter sometimes collectively referred to as "controllers 30") and a server 500, and is a system for diagnosing the health of a compressed air supply facility 1. The compressed air supply facility 1 is a facility having first to fourth four air compressors 2a to 2d (hereinafter sometimes collectively referred to as "air compressors 2") that generate compressed air, and a transport pipeline 3 used to transport the compressed air to compressed air-utilizing equipment 4, and is a facility that supplies compressed air to the compressed air-utilizing equipment 4. The compressed air supply facility 1 is installed in a business establishment that uses compressed air, such as an industrial facility such as a factory.

[0018] In the compressed air supply facility 1, each air compressor 2 generates compressed air and sends it out to a transport pipeline 3. The compressed air sent out from each air compressor 2 is supplied to the transport pipeline 3, and then supplied to each compressed air utilization device 4 connected to the transport pipeline 3.

[0019] In the health diagnosis system 100, in the example of this embodiment, a first controller 30a is provided corresponding to the first air compressor 2a, a second controller 30b is provided corresponding to the second air compressor 2b, a third controller 30c is provided corresponding to the third air compressor 2c, and a fourth controller 30d is provided corresponding to the fourth air compressor 2d.

[0020] Each controller 30 is capable of controlling the operation of the corresponding air compressor 2. The server 500 is capable of communicating with each controller 30. Note that in this embodiment, one controller 30 is provided corresponding to one air compressor 2, but one controller 30 may be provided corresponding to a plurality of air compressors 2. In this case, the one controller 30 is set to control the operation of each of the plurality of air compressors 2.

[0021] 2 shows a more specific example of the configuration of a communication system connecting the controller 30 and the server 500 in the health diagnosis system 100. The health diagnosis system 100 is configured to include a LAN (Local Area Network) 300 and the server 500. The LAN 300 is configured to include a mesh-type wireless network 210.

[0022] Wireless network 210 is a communication network configured using communication devices (nodes) including first to fourth communication units 200a to 200d (hereinafter sometimes collectively referred to as "communication units 200"), a repeater 201, and a master unit 202. Communication units 200 are provided in one-to-one correspondence with each of a plurality of controllers 30, and correspond to slave units in wireless network 210.

[0023] The first communication unit 200a corresponds to the first controller 30a, the second communication unit 200b corresponds to the second controller 30b, the third communication unit 200c corresponds to the third controller 30c, and the fourth communication unit 200d corresponds to the fourth controller 30d. Each controller 30 can communicate with its own corresponding communication unit 200. The wireless network 210 allows wireless communication between multiple nodes arranged in a local area of ​​the business establishment, and when radio waves cannot reach directly, mutual communication is possible through relay by a node in between.

[0024] One feature of the communication protocol of the wireless network 210 is that it has a multi-hop function that sends a packet to a target node by passing through (hopping) multiple nodes. Therefore, even if the communication unit 200 is installed in a place where radio waves are difficult to reach due to distance or other reasons, mutual communication with other nodes is possible by providing a repeater 201. Furthermore, when a new communication unit 200 is added, the burden of wiring work is small, and the communication network can be easily expanded. Furthermore, by arranging the nodes in a mesh pattern, even if a failure occurs in a node, communication can be made possible via other normal nodes.

[0025] In the LAN 300, all communication units 200 are connected to a parent device 202 via a wireless network 210, and the parent device 202 is further connected to a server 500 via the Internet 400. This allows the server 500 to communicate with each communication unit 200. Information transmitted from each communication unit 200 is sent to the server 500 via the LAN 300 and the Internet 400. If necessary, it is also possible to connect another LAN to the server 500 via the Internet 400 to expand the scale of the health diagnosis system 100.

[0026] With the above-described configuration of the health diagnosis system 100, each controller 30 can transmit the device ID and operating information data M (described in detail later) of the air compressor 2 corresponding to the controller 30 to the server 500. The device ID is information that enables the air compressor 2 to be identified from other air compressors 2.

[0027] The server 500 is capable of diagnosing the health of the compressed air supply facility 1 based on the information received from each controller 30. The device IDs of all air compressors 2 are pre-registered in the server 500, and various information can be recorded for each device ID. The operation of the health diagnosis system 100 will be described in detail later.

[0028] 2. Compressed air supply equipment configuration, etc. 3 shows a more specific configuration example of the compressed air supply facility 1. The compressed air supply facility 1 includes the first to fourth air compressors 2a to 2d and the transport pipeline 3 described above.

[0029] The transport pipeline 3 is laid out in a network-like manner within the business establishment so that each air compressor 2 can be connected to each of the multiple compressed air utilization devices 4. In this embodiment, the transport pipeline 3 has a loop-shaped main pipeline 7, four feed pipelines 8a to 8d (hereinafter, sometimes collectively referred to as "feed pipelines 8"), and three use pipelines 9a to 9c (hereinafter, sometimes collectively referred to as "use pipelines 9"). Each feed pipeline 8 and each use pipeline 9 branches off and extends from a different position of the main pipeline 7. In other words, one end of each feed pipeline 8 and each use pipeline 9 is connected to a different position of the main pipeline 7.

[0030] The connection points between each feed pipe 8 and the main pipe 7 can be seen as inflow positions β1 to β4 (hereinafter sometimes collectively referred to as "inflow positions β") at which compressed air flows from each air compressor 2 into the main pipe 7. That is, compressed air flows from the first air compressor 2a into the main pipe 7 at the first inflow position β1, compressed air flows from the second air compressor 2b into the main pipe 7 at the second inflow position β2, compressed air flows from the third air compressor 2c into the main pipe 7 at the third inflow position β3, and compressed air flows from the fourth air compressor 2d into the main pipe 7 at the fourth inflow position β4.

[0031] The other end of each use pipeline 9 is provided with a connection part 9x that can be connected to a compressed air utilization device 4. The connection part 9x may be in a form in which the compressed air utilization device 4 is fixedly connected, or in a form in which the compressed air utilization device 4 is detachably connected. The connection parts 9x of the use pipelines 9 can be installed in locations separated from each other.

[0032] Various devices that use compressed air can be applied as the compressed air utilization device 4. Specific examples of the compressed air utilization device 4 include an air gun or air spray that sprays compressed air, an air actuator such as an air cylinder that is operated by compressed air, and a blow molding machine that molds parts using compressed air. The compressed air utilization device 4 may also be a production facility that produces products using compressed air.

[0033] The first air compressor 2a is connected to a first feed pipe 8a and sends out the generated compressed air to the first feed pipe 8a. A first air dryer 19a and a first receiver tank 20a are provided in the first feed pipe 8a, in this order from the upstream side. The first air dryer 19a dehumidifies the compressed air sent out from the first air compressor 2a. The first receiver tank 20a temporarily stores the compressed air dehumidified by the first air dryer 19a.

[0034] The second air compressor 2b is connected to the second feed pipe 8b and sends out the generated compressed air to the second feed pipe 8b. In the middle of the second feed pipe 8b, a second air dryer 19b and a second receiver tank 20b are provided in this order from the upstream side. The second air dryer 19b dehumidifies the compressed air sent out from the second air compressor 2b. The second receiver tank 20b temporarily stores the compressed air dehumidified by the second air dryer 19b.

[0035] The third air compressor 2c is connected to a third feed pipe 8c and sends out the generated compressed air to the third feed pipe 8c. A third air dryer 19c and a third receiver tank 20c are provided in the third feed pipe 8c, in this order from the upstream side. The third air dryer 19c dehumidifies the compressed air sent out from the third air compressor 2c. The third receiver tank 20c temporarily stores the compressed air dehumidified by the third air dryer 19c.

[0036] The fourth air compressor 2d is connected to a fourth feed pipe 8d and sends out the generated compressed air to the fourth feed pipe 8d. A fourth air dryer 19d and a fourth receiver tank 20d are provided in the third feed pipe 8d, in this order from the upstream side. The fourth air dryer 19d dehumidifies the compressed air sent out from the fourth air compressor 2d. The fourth receiver tank 20d temporarily stores the compressed air dehumidified by the fourth air dryer 19d.

[0037] Each of the receiver tanks 20a to 20d (hereinafter sometimes collectively referred to as "receiver tanks 20") plays a role in suppressing abrupt pressure fluctuations in the compressed air delivered from each of the air compressors 2. The compressed air delivered to each of the feed pipes 8a to 8d flows into the main pipe 7. Note that an on-off valve for opening and closing the flow path of the compressed air to the main pipe 7 may be provided in all or some of the feed pipes 8a to 8d.

[0038] The compressed air that has flowed into the main pipeline 7 further flows into each use pipeline 9. As a result, the compressed air sent out from each air compressor 2 is supplied via the transport pipeline 3 to the compressed air utilization equipment 4 connected to the connection part 9x of each use pipeline 9.

[0039] 3. Air compressor configuration, etc. Fig. 4 shows a schematic configuration example of the air compressor 2. As shown in the figure, the air compressor 2 includes a compression mechanism 21, an oil separator 22, an automatic temperature control valve 23, an oil cooler 24, an oil filter 26, an inverter 27, and a suction filter 28. The compression mechanism 21 includes a compressor body 21a and an electric motor 21b.

[0040] In this embodiment, the air compressor 2 is configured as an oil-lubricated air compressor, and is capable of compressing air Aa sucked in from the outside by the compressor body 21a to produce compressed air Ab, which can be discharged to the transport pipeline 3 (corresponding feed pipeline 8) described above. The specific form of the air compressor 2 is not particularly limited, and may be configured as an oil-free air compressor, for example.

[0041] In Fig. 4, the outline arrows show the paths of the air Aa and the compressed air Ab, and the thick arrows show the lubricant oil circulation circuit X in which the lubricant oil Lu circulates. In this embodiment, the compressed air Ab discharged from the compressor body 21a passes through an oil separator 22 and is then discharged to the transport pipeline 3. An air flow sensor (not shown) is provided in the discharge line of the compressed air Ab, and detects the discharge air amount Q (in this embodiment, the unit is [m 3 / min). This detection information of the discharge air volume Q is sent to the controller 30. This enables the controller 30 to continuously collect monitor data (described in detail later) of the discharge air volume Q based on the detection information.

[0042] 4 is a path for circulating the lubricating oil Lu through predetermined locations (such as the compressor body 21a) in the compression mechanism 21 where friction reduction and cooling are performed using the lubricating oil Lu. The lubricating oil circulation circuit X has a path through which the lubricating oil Lu flows from the compressor body 21a to the compressor body 21a, passing through the oil separator 22, the automatic temperature control valve 23, the oil cooler 24, and the oil filter 26 in this order. The lubricating oil circulation circuit X also has an auxiliary path Xa that connects a position between the oil cooler 24 and the oil filter 26 to the automatic temperature control valve 23.

[0043] The compressor body 21a is driven by an electric motor 21b and operates to compress the air Aa to generate compressed air Ab. In this embodiment, a rotary (screw) compressor is used as the compressor body 21a, and the compressor body 21a uses lubricating oil Lu to reduce friction and cool the screw rotor (remove compression heat and frictional heat). The compressed air Ab generated by the compressor body 21a contains the lubricating oil Lu.

[0044] The electric motor 21b is configured to be driven to rotate by AC power (commercial power source, etc.) supplied from the outside, and drives the screw rotor of the compressor body 21a. The air compressor 2 is provided with a power sensor (not shown), which is capable of continuously detecting the power consumption L (instantaneous power, in this embodiment, the unit is [kW] as an example) of the air compressor 2. If the inverter 27 is provided with a power sensing function, this function may be used instead of the power sensor to continuously detect the power consumption L. The detection information of the power consumption L is sent to the controller 30. This enables the controller 30 to continuously collect monitor data of the power consumption L based on the detection information (described in detail later).

[0045] The oil separator 22 has an element 21 (a filter for removing oil mist) as a demister, receives compressed air Ab from the compressor body 21a, and temporarily stores the lubricating oil Lu (oil mist) contained in the compressed air Ab by separating it using the element 21. Note that the oil mist here corresponds to foreign matter mixed in the compressed air Ab. The portion of the lubricating oil circulation circuit X that runs from the compressor body 21a to the oil separator 22 is the path for the lubricating oil Lu contained in the compressed air Ab.

[0046] The automatic temperature control valve 23 is a three-way valve that adjusts the temperature of the lubricating oil Lu. The automatic temperature control valve 23 in this embodiment operates to increase the amount of lubricating oil Lu passing through the auxiliary path Xa when the temperature of the lubricating oil Lu is lower than a predetermined reference value, for example. This reduces the amount of lubricating oil Lu passing through the oil cooler 24, making it possible to suppress a drop in the temperature of the lubricating oil Lu.

[0047] The oil cooler 24 has a water-cooled oil cooler that cools the lubricating oil Lu by water cooling, and an air-cooled oil cooler that cools the lubricating oil Lu by air cooling. The water-cooled oil cooler recovers the waste heat contained in the lubricating oil Lu, and primarily cools the lubricating oil Lu by heat exchange between the lubricating oil Lu and the cooling water while warming the cooling water. The warm water generated by the water-cooled oil cooler can be used, for example, as boiler feed water within the business establishment.

[0048] The air-cooled oil cooler is configured to pass the lubricating oil Lu after passing through the water-cooled oil cooler and to perform secondary cooling of the lubricating oil Lu by heat exchange between the lubricating oil Lu and the cooling air. The oil cooler 24 may include only one of a water-cooled oil cooler and an air-cooled oil cooler. The oil filter 26 is a filter that removes impurities such as iron rust and sludge from the lubricating oil Lu.

[0049] The lubricating oil Lu circulating through the lubricating oil circulation circuit X plays a role in reducing friction in the compressor body 21a, and then flows into the oil separator 22 to be separated from the compressed air Ab. This lubricating oil Lu is temporarily stored in the oil separator 22, passes through the automatic temperature control valve 23, and is cooled when passing through the oil cooler 24. After impurities are removed from the cooled lubricating oil Lu in the oil filter 26, it flows into the compression mechanism 21 to be used for reducing friction and cooling in necessary places, and then returns to the compressor body 21a.

[0050] The inverter 27 is a device that performs power conversion of AC power supplied from the outside to the electric motor 21b. The operation of the inverter 27 can be controlled by the controller 30, which can control the drive frequency of the electric motor 21b. The higher the drive frequency, the higher the rotation speed of the electric motor 21b, and the more compressed air Ab is generated in the compressor body 21a.

[0051] The suction filter 28 is a filter that is provided in the intake path (the primary side of the intake adjustment valve) of the air Aa to the compressor body 21a and removes dust. When the air Aa passes through the suction filter 28, dust is removed from the air Aa and the air Aa is sent to the compressor body 21a.

[0052] The controller 30 controls and monitors each part of the air compressor 2 so that the air compressor 2 operates normally. As already described, the controller 30 is capable of communicating with the corresponding communication unit 200. Note that each controller 30 corresponding to each air compressor 2 may be incorporated in a control box arranged inside the housing of the air compressor 2.

[0053] The controller 30 in this embodiment monitors the pressure of the corresponding receiver tank 20, and when a pressure drop that exceeds a predetermined reference value occurs in the receiver tank 20, controls the corresponding air compressor 2 to start, and when a pressure increase that exceeds a predetermined reference value occurs in the receiver tank 20, controls the corresponding air compressor 2 to stop. Note that a pressure sensor that detects the pressure of the compressed air in the transport pipeline 3 may be disposed, and the controller 30 may control the drive frequency of the electric motor 21b according to the detection value of the pressure sensor. As a result, the lower the pressure of the compressed air in the transport pipeline 3, the higher the drive frequency is so that more compressed air is generated, and the pressure of the compressed air in the transport pipeline 3 can be maintained within an appropriate range.

[0054] 4. Controller configuration etc. 5 shows a schematic configuration example of the controller 30. As shown in the figure, the controller 30 is configured as a PLC (Programmable Logic Controller), and includes an input device 31, an output device 32, a calculation device 33, a storage device 34, and a power supply device 35.

[0055] The input device 31 is a part that accepts information input from the outside (including input of detection information from the air flow sensor and power sensor described above). The output device 32 is a part that outputs information to the outside (including output of a control signal to the air compressor 2, and output of a device ID and operation information data M to the server 500). The arithmetic device 33 is a part that is configured with a CPU and the like, and performs arithmetic processing based on a program. The storage device 34 is a part that is configured with a memory and the like, and stores various information. The power supply device 35 is a part that controls the power supply for the controller 30. A programming device can be connected to the controller 30, and the necessary programs can be stored in the storage device 34 using the programming device.

[0056] 5. Operation of the Health Diagnostic System The health diagnosis system 100 executes operations related to diagnosis of the health of the compressed air supply equipment 1. In the example of the present embodiment, the health diagnosis system 100 executes a data collection operation for causing the server 500 to collect various data, and a health evaluation operation for evaluating the health of the compressed air supply equipment 1 based on the collected data.

[0057] First, the data collection operation will be described below with reference to the flowchart shown in FIG. 6. Each controller 30 continuously collects and stores operation information data M of the corresponding air compressor 2, and transmits new operation information data M (after the data transmitted previously) together with the device ID of the air compressor 2 in question to the server 500 (step S11). The collection of operation information data M here may be limited to only those air compressors 2 that are powered on. The operation information data M includes the discharge air volume Q[m 3 / min] and power consumption L [kW].

[0058] These monitor data are all time series data (data at each time point at one-minute intervals) of values ​​detected synchronously at a predetermined period (one-minute period is used as an example in this embodiment), and all values ​​in each monitor data are accompanied by information on the date and time Ts at which the value was detected (for example, date and time in minutes such as "July 1st, 15:31"). In this way, the operation information data M includes information on both the discharge air volume Q and power consumption L at each time point at one-minute intervals. The device ID and operation information data M are transmitted from each controller 30 to the server 500 periodically (for example, at a period of 30 to 120 minutes) via the wireless network 210 described above.

[0059] Meanwhile, the server 500 waits to receive the driving information data M and the device ID from each controller 30 (step S21). Then, every time the server 500 receives the driving information data M and the device ID from any controller 30 (Yes in step S21), the server 500 records the received driving information data M as the driving information data M related to the device ID (step S22).

[0060] Furthermore, the server 500 waits for input of usage information data U (step S23). Here, the usage information data U is data that enables identification of the operation period Ta and the idle period Tb of the compressed air utilization equipment 4. The operation period Ta is a period during which at least one of the compressed air utilization equipment 4 operates and consumes compressed air, and the idle period Tb is a period during which all of the compressed air utilization equipment 4 is idle (not operating) and does not consume compressed air.

[0061] Examples of the usage information data U include operation day data representing operation days (days on which the compressed air utilization device 4 is operated) of the business establishment, holiday data representing holiday days (days on which the compressed air utilization device 4 is not operated), operation time period data representing operation time periods (time periods on which the compressed air utilization device 4 is operated) on operation days, and idle time period data representing idle time periods (time periods on which the compressed air utilization device 4 is not operated). The usage information data U may also be the setting information of a calendar timer used for ON / OFF control of the compressed air utilization device 4. The usage information data U may also be data representing only one of the operation period Ta and the idle period Tb, in which case, the period other than the one period may be regarded as the other period. For example, if the usage information data U is data representing only the operation period Ta, the period not represented by the usage information data U (i.e., the period other than the operation period Ta) may be regarded as the idle period Tb, and both the operation period Ta and the idle period Tb can be identified based on the usage information data U.

[0062] When usage information data U is input (Yes in step S23), the server 500 records the currently input information as the latest usage information data U (step S24). By performing such a series of data collection operations (steps S11 to S24), it is possible for the server 500 to collect the operation information data M and usage information data U related to each air compressor 2.

[0063] Next, the health evaluation operation will be described below with reference to the flowchart shown in Fig. 7. The health evaluation operation is periodically performed at a predetermined frequency (once a day, as an example in this embodiment). In addition, in one health evaluation operation, all air compressors 2 (device IDs) are set as processing targets once each, and a series of operations from steps S31 to S37, which will be described later, is performed on the processing targets. In other words, in one health evaluation operation, the series of operations from steps S31 to S37 are performed on each of the first to fourth air compressors 2a to 2d.

[0064] The server 500 compares the driving information data M to be processed with the latest usage information data U, and selects the first driving information data M1 corresponding to the downtime period Tb and the second driving information data M2 corresponding to the operating period Ta (step S31).

[0065] More specifically, the server 500 recognizes the downtime period Tb and the operating period Ta based on the usage information data U, and classifies, among all the monitor data in the operating information data M, the data whose date and time Ts belongs to the downtime period Tb into the first operating information data M1, and classifies the data whose date and time Ts belongs to the operating period Ta into the second operating information data M2. In this way, each of the monitor data of the discharged air volume Q and the power consumption L included in the operating information data M is divided into a part representing a value detected during the downtime period Tb and a part representing a value detected during the operating period Ta.

[0066] Next, the server 500 calculates the waste power cost C [¥] of the air compressor 2 based on the first operation information data M1 selected in the process of step S31 (step S32). More specifically, the server 500 calculates the waste power cost C per day using the collected monitor data of the power consumption L [kW] of the previous day. First, the power consumption amount P [kWh] for one day is obtained by multiplying the integrated value ΣL of each monitor data of the power consumption L by the number of collected monitor data N (corresponding to a fraction) (P=ΣL×N / 60). Then, the waste power cost C per day can be calculated by multiplying this power consumption P by the power unit price E [¥ / kWh] (Z=P×E). This power unit price E is the power unit price of the power company that supplies power to the air compressor 2, and is information that is registered in advance in the server 500. The power unit price E registered in the server 500 may be updated at any time to accommodate fluctuations.

[0067] Next, the server 500 calculates the specific energy W [kW / m 3 / min] (step S33). More specifically, the server 500 calculates the collected discharge air volume Q[m 3 The time series value of the specific energy W (specific energy W at each point in time at one-minute intervals) is calculated from the monitor data of the air consumption [kW] and the power consumption L [min]. Note that the specific energy W at each point in time can be calculated, for example, by dividing the power consumption L at the same point in time by the discharge air volume Q (W=L / Q).

[0068] Next, the server 500 determines whether the waste power cost C calculated in the current process of step S32 satisfies a predetermined reference condition Z1 (step S34). In this embodiment, the reference condition Z1 is set as a condition that is satisfied when the waste power cost C at any point in time exceeds a predetermined threshold.

[0069] During the downtime Tb when the compressed air utilization equipment 4 does not consume compressed air, the air compressor 2 should not be operating. However, if a wasteful power cost C occurs, it is revealed that a compressed air leak is progressing somewhere in the transport pipeline 3. For example, if the wasteful power cost C per day on non-working days is 2,000 yen / unit, this waste also occurs on working days, so the total wasteful power cost for the whole year is estimated to be 730,000 yen / unit. Therefore, as the predetermined threshold value for the wasteful power cost C, an amount at a level at which the total wasteful power cost for the whole year is about 50,000 yen / unit (for example, the wasteful power cost C per day is less than 150 yen / unit) is selected. If the wasteful power cost C satisfies the reference condition Z1 (Yes in step S34), the server 500 updates the transport pipeline corresponding flag F1 to ON (step S35).

[0070] That is, the server 500 stores information on the transport pipeline corresponding flag F1 (initial value is "OFF") in advance for each device ID, and the operation of step S35 updates the transport pipeline corresponding flag F1 corresponding to the current processing target to "ON." The transport pipeline corresponding flag F1 is information indicating whether or not maintenance is required for the transport pipeline 3, and when it is "ON," it indicates that maintenance is required for the transport pipeline 3, and when it is "OFF," it indicates that the necessity for said maintenance is low. When the transport pipeline corresponding flag F1 is updated to "ON" by the processing of step S35, it means that the server 500 has evaluated that maintenance is required for the transport pipeline 3.

[0071] Next, the server 500 determines whether or not the specific energy W calculated in the current process of step S33 satisfies a predetermined reference condition Z2 (step S36). In this embodiment, the reference condition Z2 is set as a condition that is satisfied when the specific energy W at any point in time exceeds a predetermined threshold value.

[0072] If the specific energy W exceeds a predetermined threshold, it is revealed that some malfunction (typically, clogging of filters such as the suction filter 28) is progressing in the air compressor 2. As the predetermined threshold for the specific energy W, for example, a numerical value obtained by multiplying the specific energy when all filters are unclogged and equivalent to a new product (for example, the specific energy on the day of commissioning of a new installation or the day of overhaul) as a base value B is selected, by a predetermined multiplication factor (for example, 1.1 to 1.3). If the specific energy W satisfies the reference condition Z2 (Yes in step S36), the server 500 updates the air compressor corresponding flag F2 to ON (step S37).

[0073] The reference condition Z2 may be set as a condition that is satisfied when the cost of replacing filters (e.g., the total of parts cost, labor cost, etc.) exceeds the excess power cost incurred by the increase in specific energy W relative to the above-mentioned base value B.

[0074] That is, the server 500 preliminarily records and holds information on the air compressor compatible flag F2 (initial value is "OFF") for each device ID, and the operation of step S37 updates the air compressor compatible flag F2 corresponding to the current processing target to "ON". The air compressor compatible flag F2 is information indicating whether or not maintenance is required for the air compressor, and when it is "ON", it indicates that maintenance is required for the air compressor, and when it is "OFF", it indicates that the necessity of said maintenance is low. When the air compressor compatible flag F2 is updated to "ON" by the processing of step S37, it means that the server 500 has evaluated that maintenance of the air compressor 2 is necessary.

[0075] The status of the transport pipeline corresponding flag F1 and the air compressor corresponding flag F2 for each device ID recorded and held in the server 500 can be confirmed by a business operator (facility management agent) contracted to perform maintenance work for the compressed air supply facility 1. This allows, for example, a field engineer performing maintenance work under the business operator to efficiently perform maintenance work for the compressed air supply facility 1 based on the status of the transport pipeline corresponding flag F1 or the air compressor corresponding flag F2. An example of a work process performed by a field engineer based on the status of these flags F1 and F2 will be described below with reference to the flowchart in FIG. 8.

[0076] The field engineer checks whether any of the transport pipeline flags F1 corresponding to all the device IDs are ON (step S41). If any of the transport pipeline flags F1 are ON (Yes in step S41), the field engineer uses an inspection tool to identify the location of the compressed air leak in the transport pipeline 3 (step S42). This step is typically achieved by the field engineer inspecting the pipe joints of the transport pipeline 3 and searching for the leak location. If all of the transport pipeline flags F1 are OFF (No in step S41), it is considered that no maintenance is required for the transport pipeline 3 at this time, so the field engineer proceeds to step S44, which will be described later.

[0077] It is preferable to use an acoustic imaging device as the inspection tool used in the process of step S42. The acoustic imaging device is generally called an ultrasonic camera, and a plurality of (for example, 64 to 128) ultrasonic microphones that collect sounds from the inspection object are arranged in a grid pattern. The acoustic imaging device is configured to calculate the magnitude of frequency components above the audible range by adding up the acoustic data collected by each of these microphones while sequentially shifting them in the time axis direction, and to measure the surface distribution of the leak sound intensity by calculating the intensity of the fluid leak sound at each angle corresponding to the difference in distance between the leak sound source and each microphone caused by this shift in the time axis direction.

[0078] Furthermore, the acoustic imaging device is configured to capture an image of the inspection target with a camera, and identify the location of the leak and the location of the reflected sound of the leak by overlaying the intensity distribution of the leak sound on the image obtained by this capture. If a device capable of calculating the amount of leakage at the location of leakage is adopted as the acoustic imaging device, the inspection work of the transport pipelines 3 that are laid out in a network in the business premises can be completed in a relatively short period of time (for example, about 1 to 3 days). In addition, there is no need to stop the compressed air utilization equipment 4 during the inspection work.

[0079] In this embodiment, the main pipeline 7, which is a part of the transport pipeline 3, is configured so that compressed air flows in from each of the multiple air compressors 2 at a different inflow position β. Furthermore, each of the multiple air compressors 2 is started and stopped by a pressure drop in the corresponding receiver tank 20, and is stopped and stopped by a pressure rise in the receiver tank 20. Therefore, when a pressure drop occurs in the main pipeline 7 due to a compressed air leak, the air compressor 2 closest to the leak location is likely to be started. This makes it possible to estimate the area where the compressed air leak occurred by identifying which air compressor 2 wasted power when started.

[0080] Therefore, in the process of step S42, the field engineer may confirm which air compressor 2 has the transportation pipeline corresponding flag F1 set to "ON", narrow down the inspection target area based on the information on the inflow position β for that air compressor 2, and then use the inspection tool to identify the location of the compressed air leak in the transportation pipeline 3. In this way, narrowing down the leakage area before the field engineer performs the inspection work can significantly shorten the inspection time.

[0081] As an example, if the transport pipeline flag F1 for the first air compressor 2a is "ON", the inspection target area can be narrowed down to the area surrounded by the dashed frame α shown in Fig. 3 (an area relatively close to the first inlet position β1) based on information on the inlet position β for the first air compressor 2a (i.e., the first inlet position β1 shown in Fig. 3). After narrowing down the inspection target area in this way, the field engineer can then use an inspection tool to identify the location of the leak in this inspection target area.

[0082] After performing the process of step S42, the field engineer performs maintenance on the transport pipeline 3 based on the information on the identified leak location (step S43). A specific example of the maintenance is repairing the transport pipeline 3 at the identified leak location so that compressed air does not leak.

[0083] Next, the field engineer checks whether any of the air compressor corresponding flags F2 corresponding to all the device IDs are ON (step S44). If any of the air compressor corresponding flags F2 are ON (Yes in step S44), the field engineer performs maintenance on the air compressor 2 (step S45).

[0084] Specific examples of such maintenance include cleaning and replacing filters such as the suction filter 28. The field engineer can check which air compressor 2 has the air compressor flag F2 set to "ON" and narrow down the targets for maintenance to those air compressors 2 with the flag F2 set to "ON." This reduces the time and cost required for maintenance work.

[0085] Through the above-described steps S41 to S45, the field engineer can appropriately perform maintenance of the compressed air supplying facility 1 by using the health diagnosis system 100. Note that for each of the flags F1, F2 that have been set to "ON," it is possible to have the health diagnosis system 100 perform the diagnosis of health again by updating the flags F1, F2 to "OFF" after performing maintenance on the compressed air supplying facility 1, for example.

[0086] 6.Other As described above, the health diagnosis method according to this embodiment is a method for diagnosing the health of a compressed air supply facility 1 including an air compressor 2 that generates compressed air and a transport pipeline 3 that is used to transport the compressed air to a compressed air utilization device 4, and includes a first step (steps S11, S21 to S22) of collecting operation information data M including information on the discharge air volume Q and power consumption L of the air compressor 2, and a second step (steps S23 to S24) of acquiring usage information data U that enables the operation period Ta and the downtime period Tb of the compressed air utilization device 4 to be specified. 4), a third step (step S31) of sorting the operation information data M into first operation information data M1 corresponding to the downtime Tb and second operation information data M2 corresponding to the operation period Ta by comparing it with the usage information data U, a fourth step (steps S32, S34 to S35) of evaluating the need for maintenance of the transport pipeline 3 based on the first operation information data M1, and a fifth step (steps S33, S36 to S37) of evaluating the need for maintenance of the air compressor 2 based on the second operation information data M2.

[0087] According to this soundness diagnosis method, by executing the first to third steps, in the fourth step it is possible to evaluate the necessity of maintenance for the transport pipeline 3, and in the fifth step it is possible to evaluate the necessity of maintenance for the air compressor 2. In this way, this soundness diagnosis method is extremely useful in the maintenance management of the compressed air supply facility 1, since it can efficiently and collectively perform soundness diagnosis not only of the compressed air transport pipeline 3 but also of the air compressor 2.

[0088] Furthermore, the soundness diagnosis method according to this embodiment further includes a sixth step (step S42) of using an inspection tool to identify the location of compressed air leakage in the transport pipeline 3 when it is evaluated in the fourth step that maintenance is necessary for the transport pipeline 3. According to this soundness diagnosis method, it is only necessary to perform the task of identifying the location of leakage when it is evaluated that maintenance is necessary for the transport pipeline 3, and therefore it is possible to reduce labor costs and the like compared to the case where the task is performed regardless of such an evaluation.

[0089] Moreover, the main pipeline 7 (part of the transport pipeline 3) is configured so that compressed air flows in from each of the multiple air compressors 2 at different inflow positions β, and the health diagnosis method according to this embodiment is a method of performing the first to fifth steps for each of the multiple air compressors 2. If it is evaluated in the fourth step for any of the air compressors 2 that maintenance is necessary for the transport pipeline 3, the health diagnosis method may further include a sixth step of narrowing down the inspection target area based on information on the inflow position β for that air compressor 2, and identifying the location of compressed air leakage in the transport pipeline 3 using an inspection tool.

[0090] The fourth step is a process of calculating the wasted power cost C of the air compressor 2 based on the first operation information data M1, and evaluating that maintenance is necessary for the transport pipeline 3 when the calculated wasted power cost C satisfies a predetermined condition. The fifth step is a process of calculating the specific energy W of the air compressor 2 based on the second operation information data M2, and evaluating that maintenance is necessary for the air compressor 2 when the calculated specific energy W satisfies a predetermined condition.

[0091] In addition, the health diagnosis system 1 of this embodiment is a system for diagnosing the health of a compressed air supply facility 1 including an air compressor 2 that generates compressed air and a transport pipeline 3 used to transport the compressed air to compressed air utilization equipment 4, and is equipped with a controller 30 that controls the operation of the air compressor 2, and a server 500 that is communicatively connected to the controller 30.

[0092] 9 is a block diagram showing main functional units of the controller 30 and the server 500 according to this embodiment. As shown in the figure, the controller 30 has a data storage unit 30p that collects and stores operation information data M including the discharge air amount Q and power consumption L of the air compressor 2, and a data output unit 30q that outputs the operation information data M to the server 500.

[0093] The server 500 also includes a data input unit 500a, a data storage unit 500b, a data selection unit 500c, a first evaluation unit 500d, and a second evaluation unit 500e. The data input unit 500a receives input of usage information data U that allows the operating period Ta and the idle period Tb of the compressed air utilization device 4 to be specified. The data storage unit 500b compares the usage information data U to the usage information data U and selects the operating information data M into the first operating information data M1 corresponding to the idle period Tb and the second operating information data M2 corresponding to the operating period Ta. The first evaluation unit 500d evaluates the necessity of maintenance for the transport pipeline 3 based on the first operating information data M1. The second evaluation unit 500e evaluates the necessity of maintenance for the air compressor 2 based on the second operating information data M2. According to the health diagnosis system 1 including such a controller 30 and the server 500, it is possible to appropriately implement the health diagnosis method according to this embodiment.

[0094] Although the embodiment of the present invention has been described above, the configuration of the present invention is not limited to the above embodiment, and various modifications can be made without departing from the spirit of the invention. In other words, the above embodiment is an example in all respects and should be considered as not restrictive. The technical scope of the present invention is indicated by the claims, not the description of the above embodiment, and should be understood to include all modifications that fall within the meaning and scope of the claims. [Explanation of symbols]

[0095] 1. Compressed air supply equipment 2. Air Compressor 2a No. 1 air compressor 2b No. 2 air compressor 2c 3rd air compressor 2d 4th air compressor 3 Transport pipeline 4. Compressed air equipment 7 Main pipeline 8 Feed Pipe 8a First feed line 8b Second feed line 8c Third feed line 8d 4th feed pipe 9, 9a~9c Use Pipeline 9x connections 19a First Air Dryer 19b Second Air Dryer 19c 3rd Air Dryer 19d No. 4 Air Dryer 20 Receiver Tank 20a 1st receiver tank 20b Second receiver tank 20c 3rd receiver tank 20d 4th receiver tank 21 Compression mechanism 21a Compressor body 21b Electric motor 22 Oil separator 23 Automatic temperature control valve 24 Oil cooler 26 Oil filter 27 Inverter 28 Suction filter 30 Controller 30a First Controller 30b Second Controller 30c 3rd Controller 30d 4th Controller 30p Data storage section 30q Data output section 100 Health diagnostic system 200 Communication Unit 200a First communication unit 200b second communication unit 200c Third communication unit 200d 4th communication unit 201 Repeater 202 Parent unit 210 Wireless Network 300 LAN 500 Servers 500a Data Entry Section 500b Data storage section 500c Data Sorting Department 500d First Evaluation Section 500e Second Evaluation Section

Claims

1. A method for diagnosing the health of a compressed air supply facility including an air compressor that generates compressed air and a transport pipeline that transports the compressed air to a compressed air utilization device, comprising: A first step of collecting operational information data including information on the discharge air volume and power consumption of the air compressor; a second step of acquiring usage information data that enables the identification of operating periods and downtime periods of the compressed air utilization device; a third step of classifying the driving information data into first driving information data corresponding to the suspension period and second driving information data corresponding to the operation period by matching the driving information data with the usage information data; A fourth step of evaluating the necessity of maintenance for the pipeline based on the first operational information data; and a fifth step of evaluating a need for maintenance on the air compressor based on the second operating information data.

2. The health diagnosis method according to claim 1, further comprising a sixth step of identifying a location of a compressed air leak in the transport pipeline using an inspection tool if the fourth step determines that maintenance is necessary for the transport pipeline.

3. At least a portion of the transport pipeline is configured so that the compressed air flows in from each of the plurality of air compressors at different inlet positions; 2. The health diagnosis method according to claim 1, further comprising the steps of: performing first to fifth steps for each of the plurality of air compressors; The health diagnosis method further includes a sixth step of, if it is evaluated in the fourth step for any of the air compressors that maintenance is necessary for the transport pipeline, narrowing down the inspection target area based on the information on the inflow position for that air compressor, and identifying the location of the compressed air leak in the transport pipeline using an inspection tool.

4. The method for diagnosing the soundness of a compressed air supply facility according to claim 2 or 3, wherein an acoustic imaging device is used as the inspection tool.

5. A fourth step is a process of calculating a wasteful power cost of the air compressor based on the first operation information data, and evaluating that maintenance is necessary for the transportation pipeline when the calculated wasteful power cost satisfies a predetermined condition, 4. The health diagnosis method according to claim 1, wherein a fifth step is a process of calculating a specific energy of the air compressor based on the second operating information data, and evaluating that maintenance is necessary for the air compressor when the calculated specific energy satisfies a predetermined condition.

6. A system for diagnosing the health of a compressed air supply facility including an air compressor that generates compressed air and a transport pipeline that transports the compressed air to a compressed air utilization device, comprising: A controller for controlling the operation of the air compressor; a server communicatively connected to the controller; The controller: A data storage unit that collects and stores operational information data including information on the discharge air volume and power consumption of the air compressor; a data output unit that outputs the driving information data to the server; The server, a data input unit that receives input of usage information data that enables the specification of an operating period and an idle period of the compressed air utilization device; a data storage unit in which the driving information data and the usage information data are stored; a data selection unit that selects the driving information data into first driving information data corresponding to the suspension period and second driving information data corresponding to the operation period by matching the driving information data with the usage information data; A first evaluation unit that evaluates the necessity of maintenance for the transportation pipeline based on first operation information data; A health diagnosis system comprising: a second evaluation unit that evaluates the necessity for maintenance of the air compressor based on second operating information data.

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