Air compressor power consumption optimization control apparatus and power consumption optimization control method using same

Abstract

The present invention relates to an air compressor power consumption optimization control apparatus and a power consumption optimization control method using same. According to the present invention, the power consumption optimization control apparatus for an air compressor for producing compressed air comprises: a data collection unit for collecting operation data of the air compressor for a predetermined period; a data calculation unit for calculating a pressure level range of compressed air actually used in a normal operation situation and a range of required power consumption corresponding thereto from the operation data collected through the data collection unit; and an optimization control unit for performing optimized power control for controlling so that power is consumed within the required power consumption range by controlling a main motor of the air compressor to produce compressed air in the pressure level range calculated through the data calculation unit.

Description

Air compressor power consumption optimization control device and power consumption optimization control method using the same

[0001] The present invention relates to an air compressor power consumption optimization control device and a power consumption optimization control method using the same. More specifically, the invention relates to an air compressor power consumption optimization control device capable of determining the required pressure and power consumption for an air compressor actually used in an industrial setting, and a power consumption optimization control method using the same, which can control the production of compressed air at the required pressure with the minimum power consumption.

[0002] While electricity demand is rapidly increasing due to the development of advanced industries such as AI, data centers, and electric vehicles, countries are facing the challenge of achieving carbon neutrality. To address these dual challenges, energy competition among nations is emerging as a major issue, often referred to as an "energy war."

[0003] Air compressors are widely used as essential equipment in domestic manufacturing plants at industrial sites.

[0004] Air compressors include reciprocating, screw, and turbo types; recently, there has been a trend toward screw-type compressors, and compressors employing inverters for energy conservation have been developed and are in use.

[0005] Because pneumatic systems are required in various production processes, air compressors are installed in almost every manufacturer and are widely used in various industrial fields. As air compressors are energy-intensive equipment, the proportion of power consumption resulting from the use of such air compressors is known to be about 10% to 40% or more of the total power consumption at industrial sites.

[0006] Generally, air compressor manufacturers ship machines with settings corresponding to the maximum production volume per horsepower. However, in industrial sites where air compressors are used, the products manufactured using compressed air vary on average over the course of a month, quarter, half-year, or season. Furthermore, when air compressors are actually used in the field, various pressure settings are inevitable depending on the installed piping size, length, and purpose of use of the compressed air. Consequently, there are cases where the maximum compressed air set by the manufacturer is not required due to various factors. Additionally, there is a problem in that significant power consumption is wasted due to the inevitable idle no-load time inherent in the nature of air compressors.

[0007] Therefore, there is a need to make efforts to reduce energy consumption for air compressors, which are energy-intensive equipment widely used in various industrial fields.

[0008] (Patent Document 1) Republic of Korea Published Patent No. 10-2023-0141337 (October 10, 2023)

[0009] Accordingly, the objective of the present invention is to provide an air compressor power consumption optimization control device capable of overcoming the aforementioned conventional problems, and a power consumption optimization control method using the same.

[0010] Another objective of the present invention is to provide an air compressor power consumption optimization control device capable of reducing power consumption by optimizing the operation of the air compressor, and a power consumption optimization control method using the same.

[0011] According to an embodiment of the present invention for achieving some of the above-mentioned technical problems, a power consumption optimization control device for an air compressor producing compressed air according to the present invention comprises: a data collection unit that collects air compressor operation data for a certain period; a data calculation unit that calculates, from the operation data collected through the data collection unit, a pressure level range of compressed air actually used in normal operation conditions and a corresponding range of required power consumption; and an optimization control unit that performs optimized power control by controlling the main motor of the air compressor so that compressed air within the pressure level range calculated through the data calculation unit is produced, thereby controlling power consumption to be within the required power consumption range.

[0012] The above data calculation unit matches the first data of the pressure or flow rate of compressed air in a normal operating situation and the second data of the current or power consumption at that time based on time from the operating data collected through the above data collection unit, derives a function representing the relationship between the first data and the second data, and can calculate the pressure level range of the compressed air actually used and the corresponding range of required power consumption through the said function.

[0013] In a state where the optimized power control for the air compressor is performed for a certain period, the system may further provide a correction unit that collects operating data through the data collection unit, calculates a new range of the pressure level of the compressed air actually used and the corresponding range of required power consumption through the data calculation unit, and compares the newly calculated range of the pressure level and the range of required power consumption with the case of the optimized power control to determine whether new optimization is required and performs a correction.

[0014] According to another embodiment of the present invention for achieving some of the technical problems described above, a power consumption optimization control device for an air compressor producing compressed air according to the present invention comprises: a data collection unit that collects air compressor operation data for a certain period; a data calculation unit that calculates the required power consumption by subtracting the average no-load power consumption value, which is calculated by extracting the current value during no-load operation in a normal operating situation from the operation data collected through the data collection unit and is averaged, from the rated power consumption value of the main motor of the air compressor, and converts the calculated required power consumption into a motor RPM value; and an optimization control unit that defines the motor RPM value calculated through the data calculation unit as the average motor rotation speed and performs optimization power control to control power consumption within the required power consumption range by performing control on the main motor based thereon.

[0015] The above data calculation unit converts the calculated required power consumption into a motor RPM value and sets an upper limit and a lower limit based on the converted motor RPM value, and the above optimization control unit can perform the above optimization power control by performing control on the air compressor so that the motor RPM is maintained within the range of the upper limit and the lower limit.

[0016] A correction unit may be further provided to correct for cases where the optimal power control is not properly performed, by determining from the operation data during the performance of the optimal power control through the above-mentioned optimization control unit whether compressed air within a preset pressure range is generated and whether the optimal power control is performed within the above-mentioned required power consumption range.

[0017] The above data output unit extracts a normal operation pattern section and a power-saving mode pattern section for power saving by collecting operation data of the air compressor, the normal operation pattern section is a pattern section in which compressed air is normally produced and used while repeating load operation and no-load operation, and the power-saving mode pattern section is a pattern section in which a long-term no-load operation section, which is relatively longer than the no-load operation section of the normal operation pattern, is repeated with a certain period, and the optimization control unit performs the optimization power control in the normal operation pattern section, and when the power-saving mode pattern section arrives, it can stop the optimization power control and control operation to be in power-saving mode.

[0018] The above air compressor comprises, as components, a motor-air end assembly providing compressed air equipped with a main motor and an air end, a controller including an inverter, an air filter for filtering foreign substances in the air, a suction valve, an oil line providing an oil path for maintaining airtightness during air compression, a separator separating air and oil, an air line serving as a path for compressed air, and a cooler including a fan to prepare for heat generated during air compression, and the detection sensor comprises a current sensor for detecting current applied to the main motor, a current sensor for detecting current applied to a fan motor for driving the fan, a temperature sensor for detecting the temperature of the main motor, a temperature sensor for detecting the temperature of the discharge port of the air end, a temperature sensor for detecting the temperature of the cooler, a pressure sensor for measuring the internal pressure of the separator, a pressure sensor for measuring the differential pressure of the separator, a pressure sensor for detecting the pressure of the air discharged from the air compressor, and a dew point sensor for detecting the air discharged from the air compressor. It includes a dew point sensor for measuring vibration of the main motor, an oil level sensor for detecting oil level in the separator, and a suction valve sensor for detecting on / off of the suction valve, and the operating data may include detection data detected through the detection sensors, including power consumption, voltage applied to the main motor, current, discharge air pressure, temperature, flow rate, and on / off information of the suction valve.

[0019] According to another embodiment of the present invention for achieving some of the above technical problems, the method for optimizing power consumption control of an air compressor producing compressed air according to the present invention comprises: a first step of calculating the required power consumption by collecting air compressor operation data over a certain period and subtracting the averaged no-load power consumption value, calculated by extracting the current value during no-load operation under normal operating conditions, from the rated power consumption value of the main motor of the air compressor; and a second step of performing optimized power control by converting the required power consumption into a motor RPM value and controlling the power consumption to be within the required power consumption range by performing control on the main motor based on the motor RPM value.

[0020] The second step above may comprise: a step of converting the required power consumption into a motor RPM value; a step of setting an upper limit and a lower limit based on the converted motor RPM value; and a step of performing the optimized power control by performing control on the main motor so that the motor RPM is maintained within the range of the upper limit and the lower limit.

[0021] The second step above may comprise: a step of converting the required power consumption into a motor RPM value; a step of setting an upper limit and a lower limit of the motor RPM value based on the converted motor RPM value; a step of deriving a motor acceleration time and a motor deceleration time based on the setting of the upper limit and the lower limit; and a step of performing the optimized power control by performing control on the air compressor based on the motor RPM, the upper limit, the lower limit, the motor acceleration time, and the motor deceleration time.

[0022] The first step further includes the step of extracting a normal operation pattern section and a power-saving mode pattern section for power saving through the collection of operation data of the air compressor, wherein the normal operation pattern section is a pattern section in which compressed air is normally produced and used while repeating load operation and no-load operation, and the power-saving mode pattern section is a pattern section in which a long-term no-load operation section, which is relatively longer than the no-load operation section of the normal operation pattern, is repeated with a certain period, and the second step may further include the step of performing the optimized power control in the normal operation pattern section, and when the power-saving mode pattern section arrives, stopping the optimized power control and controlling to operate in a power-saving mode.

[0023] After the second step above, a correction step may be further provided to correct for cases where the optimal power control is not properly performed, by determining from the operation data while the optimal power control is performed through the optimization control unit whether compressed air within a preset pressure range is generated and whether the optimal power control is performed within the required power consumption range.

[0024] According to the present invention, there is an advantage in that power consumption can be reduced by optimizing the operation of the air compressor. Furthermore, there is an advantage in that power consumption can be minimized through optimal power consumption by reflecting the usage conditions and site circumstances at the site during the operation of the air compressor. In air compressors that repeatedly alternate between load and no-load operation, unnecessary power consumption can be reduced by minimizing power consumption during no-load operation. Additionally, there is an advantage in that power consumption can be minimized as much as possible by identifying the power-saving mode pattern and controlling it, such as by automatic shutdown, during the power-saving mode section.

[0025] FIG. 1 is a schematic diagram illustrating the configuration of an air compressor, a sensing sensor, and a communication terminal applied to the present invention, and

[0026] FIG. 2 schematically shows the structural diagram of the air compressor of FIG. 1, and

[0027] FIG. 3 is a schematic block diagram of an air compressor power consumption optimization control device according to the first embodiment of the present invention.

[0028] Figure 4 shows a graph of the first pressure data and the second current data based on time in the normal operation pattern section, and

[0029] Figure 5 illustrates the process of time-synchronizing pressure and current, and

[0030] Figure 6 is a graph showing a function representing the relationship between pressure and power consumption.

[0031] FIG. 7 is a diagram for explaining an example of a first control method of the optimization control unit of FIG. 3, and

[0032] FIG. 8 is a schematic block diagram of an air compressor power consumption optimization control device according to a second embodiment of the present invention, and

[0033] Figure 9 is a graph showing the optimization process of the motor's RPM, and

[0034] Figure 10 is a graph showing the current data state before and after optimization, and

[0035] Figure 11 is a graph showing an example of a power saving mode pattern, and

[0036] FIG. 12 shows graphs illustrating the correction process through the correction unit, and

[0037] Figure 13 shows graphs illustrating expected pressure and current data during optimized power control, and

[0038] Figure 14 shows graphs representing cases where optimization was incorrect, and

[0039] Figure 15 is a graph of before / after improvement cases including before and after optimization, or before and after correction, and

[0040] Figure 16 is a flowchart showing the power consumption optimization control process of Figure 8.

[0041] In the following, preferred embodiments of the present invention will be described in detail with reference to the attached drawings, with no other intent than to provide a thorough understanding of the present invention to those skilled in the art to which the present invention pertains.

[0042] FIG. 1 is a schematic diagram illustrating the configuration of a general air compressor, a sensing sensor, and a communication terminal applied to the present invention, and FIG. 2 is a schematic diagram of the structure of the air compressor of FIG. 1.

[0043] As illustrated in FIGS. 1 and 2, a general air compressor (100) for application of the present invention comprises a motor-air end assembly (110) that provides compressed air by having a main motor and an air end, a controller (120) including an inverter (not shown) that controls the operation of the motor-air end assembly (110), an air filter (130) that filters foreign substances in the air, a suction valve (140), an oil line (150) that provides an oil path for maintaining airtightness during air compression, a separator (160) that separates air and oil, an air line (170) that is a path for compressed air, and a cooling cooler (180) including a fan (190) for preparing against heat generated during air compression. Through this, air sucked in through the air filter (130) and the intake valve (140) along with the operation of the motor-air end assembly (110) is compressed in the motor-air end assembly (110). The compressed air is separated from oil in the separator (160), and the compressed air passing through the separator (160) is supplied to the outside. Additionally, a pressure regulating valve (175) may be provided, and other components well known to a person skilled in the art may be added as needed. Since the operation and configuration of an air compressor with the structure described above are well known to a person skilled in the art, further explanation is omitted.

[0044] In addition, at least one sensing sensor (commonly denoted as 'S') may be provided for the air compressor (100), and typically at least one of a current sensor (CT), a temperature sensor (TS), and a pressure sensor (PT) may be provided. The current sensor (CT) may include a current sensor for detecting current applied to the main motor through the controller (120), a current sensor for detecting current applied to the fan motor for driving the fan (190), and a current sensor for detecting current applied to the driving unit for driving the suction valve (140); the temperature sensor (TS) may include a temperature sensor for detecting the temperature of the main motor, a temperature sensor for detecting the temperature of the discharge port of the air end, and a temperature sensor for detecting the temperature of the cooler (180); and the pressure sensor (PT) may include a pressure sensor for measuring the internal pressure of the separator (160), a pressure sensor for measuring the differential pressure of the separator (160), and a pressure sensor for detecting the pressure of air discharged from the air compressor or the cooler (180). In addition, it may further include a dew point sensor (DP) for detecting the dew point of the air discharged from the air compressor, a vibration sensor for measuring the vibration of the main motor, and an oil level sensor (OT) for detecting the oil level in the separator (160), and various other detection sensors may be added.

[0045] At least one communication terminal (200) may be provided, and it is possible to transmit the detection signal of the at least one detection sensor provided within the air compressor (100) to the outside via a wired or wireless communication network (e.g., an internet communication network). Additionally, the communication terminal (200) has a configuration capable of receiving a control signal transmitted from the outside for controlling the air compressor (100) and transmitting it to the controller (120), thereby enabling remote control of the air compressor (100).

[0046] In the above description, the air compressor (100) for application of the present invention is described using a screw-type air compressor as an example, but is not limited thereto and can be an air compressor of various configurations and structures.

[0047] This air compressor (100) produces compressed air and stores the produced compressed air in a compressed air tank. When the pressure of the stored compressed air reaches the upper limit of the preset standard pressure for use, the air compressor is switched from load operation to no-load operation. Subsequently, as the compressed air is used in industrial sites, etc., when the pressure of the stored compressed air reaches the lower limit of the standard pressure for use, it is switched back to load operation. Load operation continues until the pressure of the compressed air reaches the upper limit of the standard pressure for use again, and when it exceeds the upper limit of the standard pressure for use, it is switched to no-load operation. Subsequently, load operation and no-load operation are repeatedly performed within the upper and lower limits of the standard pressure for use. As such, as no-load operation and load operation are repeated, efforts are required to reduce the waste of electricity that is unnecessarily consumed during no-load operation. The term 'pressure' used below without special mention refers to the pressure of the compressed air, and may mean the air pressure stored in the compressed air tank. In addition, 'power consumption' may refer to the power consumed during the production of compressed air, or the power consumed due to the operation of the main motor.

[0048] FIG. 3 is a schematic block diagram of an air compressor power consumption optimization control device according to the first embodiment of the present invention.

[0049] As illustrated in FIG. 3, the air compressor power consumption optimization control device (300) according to the first embodiment of the present invention comprises a data collection unit (310), a data calculation unit (320), and an optimization control unit (330).

[0050] The data collection unit (310) collects operation data of the air compressor (100) for a certain period (e.g., approximately 2 to 4 weeks). The operation data may include all detection data information that can be detected through the detection sensor (S), including power consumption, applied voltage, applied current, compressed air pressure, temperature, vibration, dew point, flow rate, and intake valve ON / OFF information data, and all data that can be calculated therefrom.

[0051] The above data calculation unit (320) can determine whether the operation of the air compressor (100) has a normal operation pattern, a power saving mode pattern in which it operates in a power saving mode, or an exception pattern through the operation data collected through the above data collection unit (310).

[0052] The above normal operation pattern refers to an operation pattern in a normal operation situation in which the air compressor (100) normally produces and uses compressed air while repeating load operation and no-load operation, and the power saving mode pattern is a case in which a long-term no-load operation section, which is relatively longer than the no-load operation section of the above normal operation pattern, is repeated with a certain period, for example, during breakfast, lunch, dinner, or a predetermined rest time when compressed air usage is low, and is a pattern that occurs regularly and consistently at a certain period or time.

[0053] In addition, exception patterns are patterns that deviate from these normal operation patterns and power saving mode patterns, and may include patterns that occur during intermittent air loss, patterns caused by equipment operation with severe intermittent air demand pulsation, patterns caused by damage to machine suction valves, air loss patterns due to field air valve operation errors, air tank condensate removal patterns, and machine part failure patterns. These exception patterns are caused by temporary failures, malfunctions, or carelessness in use, and can be classified as temporary, intermittent, or long-term occurrences. If they occur regularly and over a long period, they may be defined as new patterns or included in the normal operation patterns or power saving mode patterns. However, exception patterns caused by temporary, intermittent, malfunctions, or carelessness in use may be classified and stored separately as exception patterns and used later as data to determine whether there is a malfunction. These exception patterns are stored separately, and when identifying exception patterns, they are based on the stored exception patterns. When accumulating data on various exception patterns, it is possible to distinguish and identify these exception patterns, and it is possible to exclude them when extracting the above normal operation pattern or the above power saving mode pattern.

[0054] In addition, the data calculation unit (320) can calculate the pressure level range of the compressed air actually used in the normal operation situation, i.e., the normal operation pattern section, and the corresponding range of required power consumption from the operation data. It is possible to match the first data of the pressure or flow rate of the compressed air in the normal operation situation with the second data of the current or power consumption at that time based on time, derive a function representing the relationship between the first data and the second data, and calculate the pressure level range of the compressed air actually used and the corresponding range of required power consumption through the said function.

[0055] Specifically, this will be explained through FIGS. 4 to 6.

[0056] Figure 4 shows a graph of the first pressure data and the second current data based on time in the normal operation pattern section, Figure 5 illustrates the process of time-synchronizing pressure and current, and Figure 6 shows a graph of a function representing the relationship between pressure and power consumption.

[0057] As illustrated in FIGS. 4 to 6, a normal operation pattern section is extracted from the operation data collected through the data collection unit (310), and it is possible to match the first data of the compressed air pressure during the normal operation situation within the normal operation pattern section with the second data of the current consumption at that time based on time, thereby enabling the derivation of a function representing the relationship between the first data and the second data. Since the air pressure and flow rate are in a proportional relationship, the current consumption and power consumption are also in a proportional relationship, and the first data and the second data are also in a proportional relationship, it is possible to use the air flow rate as the first data instead of the pressure, and the power consumption as the second data instead of the current consumption. In this embodiment, the explanation is based on pressure and current.

[0058] As shown in FIG. 4, it can be seen that in the normal operation pattern section, the air pressure of the compressed air tank has a pressure range within the lower and upper limits of 6.8 to 7.7 bar. In this case, it can be estimated that the pressure required in actual industrial sites is 6.8 bar or higher, and it can be seen that the air compressor is operating with the upper and lower limits of the pressure set to 7.7 bar and 6.8 bar. Accordingly, it can be seen that load operation is performed until the pressure reaches the upper limit, no-load operation is performed until the pressure drops to the lower limit due to the consumption of compressed air, and load operation is performed again when the pressure drops to the lower limit, thereby repeating load operation and no-load operation. For reference, when the air compressor is in no-load operation, the suction valve is in an off state (closed state), and when it is in load operation, the suction valve (140) is maintained in an on state (open state). Therefore, it is also possible to determine whether no-load or load operation is being performed through the on / off status information of the intake valve.

[0059] Looking at the current data graph at this time, it can be seen that the value is approximately 45A during load operation and 15A during no-load operation, and in this case, the current value during no-load operation corresponds to 30~40% of the rated current.

[0060] In the case of an air compressor (100), which is an energy-intensive device, as load operation and no-load operation are repeated, it becomes necessary to reduce the waste of power consumption that is wasted for an unnecessarily high upper limit pressure during load operation and the waste of power consumption that is unnecessarily consumed during no-load operation.

[0061] In order to reduce such waste of power consumption, as shown in FIG. 5, it is possible to time-synchronize and match the first data and the second data based on time, and through this, it is possible to derive a function that represents the relationship between the first data and the second data, that is, the relationship between pressure and power consumption, in the form of a quadratic function as shown in FIG. 6.

[0062] The above data calculation unit (320) can calculate the pressure level range of the compressed air actually used and the corresponding range of required power consumption through the above function. Since the power consumption efficiency range according to pressure varies depending on the performance of the engine air end manufacturer of the air compressor and the pressure settings are also diverse, it becomes necessary to calculate the range of required power consumption.

[0063] Generally, when air compressors are shipped from the manufacturer, the pressure range is typically set to 7.7 to 8.1 bar, as indicated by the red section (A) in Fig. 6, with the initial pressure setting value set to the machine's maximum pressure value. However, when actually used in the field, various pressure settings may exist depending on the installed pipe size, length, and purpose of compressed air use. Nevertheless, most industrial sites use the compressor with the default pressure range left as is, which is a cause of wasted power consumption. In this case, if the required pressure range and the required power consumption range are calculated through optimization as shown in the optimization section (B) of Fig. 6, the wasted power consumption can be reduced.

[0064] The calculation of these pressure ranges and required power consumption can be performed using a separately trained AI algorithm, or it can also be done through a separate calculation formula.

[0065] The above data calculation unit (320) can determine the pressure range based on the operating data, the usage pattern of compressed air at the actual site, the amount of compressed air used per hour, the amount of compressed air used under load, the amount of compressed air used under no load, the load operation time, the no-load operation time, etc., and can also calculate the required power consumption accordingly.

[0066] For example, through the pressure data graph of FIG. 4, the load operation time and no-load operation time can be determined, and through the operation data, data such as the amount of compressed air used and the amount of compressed air used at that time can be collected and used to calculate the required pressure level range. Once this pressure level range is calculated, the corresponding required power consumption can be calculated through the function of FIG. 6.

[0067] Alternatively, it is possible to allow the user to select the pressure level range of compressed air used in actual industrial sites and calculate the required power consumption through the function graph of Fig. 6 based on this. For example, assuming that 6.8 bar is sufficient for the pressure required in actual sites, it can be seen that in the case of the basic setting range (A) of Fig. 6, excessive power consumption of up to 40 kW is consumed in an overpressure state. In this case, if the optimal pressure range is set or calculated to 7.4 to 7.7 bar by considering the error range and various situations, and the operation of the air compressor is controlled based on this, there is an advantage in that the power consumption is 27 to 32 kW, enabling stable use of the air compressor while reducing power waste.

[0068] The optimization control unit (330) controls the main motor of the air compressor (100) so that compressed air within the pressure level range calculated through the data calculation unit (320) is produced, thereby performing optimization power control to control power consumption within the required power consumption range.

[0069] Optimized power control can be performed using a first control method in which load operation and no-load operation are repeated while the pressure range of the air compressor (100) is reduced to an optimal pressure range, and as explained through the second embodiment of the present invention described below, it is also possible to perform using a second control method in which load operation is centered while no-load operation is minimized.

[0070] Since the above second control method is explained through the second embodiment of the present invention, only the above first control method will be explained here.

[0071] Figure 7 is a diagram illustrating an example of the first control method.

[0072] As shown in FIG. 7(a), assuming that the default pressure range at the time of shipment is 6 to 8 bar, the air compressor (100) at this time will operate by performing load operation until the pressure reaches the upper limit value of 8 bar, and by performing no-load operation until the pressure drops to the lower limit value of 6 bar as compressed air is consumed, and then performing load operation again when the pressure drops to the lower limit value of 6 bar, thereby repeating load operation and no-load operation.

[0073] For an air compressor having such an operation, as shown in FIG. 7 (b), assuming that the pressure range optimized through the data calculation unit (320) is 6.5 to 7.0 bar, the air compressor (100) in the optimized power control state controlled through the optimization control unit (330) operates under load until the pressure reaches an upper limit value of 7 bar, operates under no-load until the pressure drops to a lower limit value of 6.5 bar according to the consumption of compressed air, and operates under load again when the pressure drops to the lower limit value of 6.5 bar. Since the operation of operating under load and operating under no-load is repeated in this manner, it is possible to minimize the waste of power consumption. Since a power reduction of 3 kW per hour is possible for a pressure reduction of 0.5 bar, it can be seen that a power reduction of 9 kW per hour is possible in the case of FIG. 7.

[0074] Optimized power control through the optimization control unit (330) is performed only during the normal operation pattern section, and when the power saving mode pattern section extracted through the data calculation unit (320) arrives, the optimized power control is stopped and the device is controlled to operate in power saving mode. This enables further reduction in power consumption.

[0075] The above air compressor power consumption optimization control device (300) may further include a correction unit (340).

[0076] The correction unit (340) collects operating data through the data collection unit (310) while the optimization power control for the air compressor (100) is performed for a certain period through the optimization control unit (330), and calculates a new pressure level range of the compressed air actually used and a corresponding range of required power consumption through the data calculation unit (320). Then, it is possible to determine whether new optimization is required by comparing the newly calculated pressure level range and the range of required power consumption with the case of the optimization power control.

[0077] In this case, there may be instances where the pressure level ranges or the required power consumption ranges differ; if it is determined that the result falls outside the error range, it is possible to correct the process through a new optimization to perform optimized power control using the newly calculated pressure level range and required power consumption range.

[0078] FIG. 8 is a schematic block diagram of an air compressor power consumption optimization control device according to a second embodiment of the present invention.

[0079] As illustrated in FIG. 8, the air compressor power consumption optimization control device (400) according to the second embodiment of the present invention comprises a data collection unit (410), a data calculation unit (420), and an optimization control unit (430). Additionally, a correction unit (440) may be provided.

[0080] The data collection unit (410) collects operation data of the air compressor (100) for a certain period (e.g., approximately 2 to 4 weeks). The operation data may include all detection data information that can be detected through the detection sensor (S), including power consumption, applied voltage, applied current, compressed air pressure, temperature, vibration, dew point, flow rate, and intake valve ON / OFF information data, as well as all data that can be calculated therefrom. Additionally, the main motor information of the air compressor (100), such as rated KW, HZ, RPM, voltage, torque, heating wire type, SF, and efficiency information, may also be collected as operation data or stored in advance in the data collection unit (410) or the data calculation unit (420).

[0081] The above data calculation unit (420) can determine whether the operation of the air compressor (100) has a normal operation pattern, a power saving mode pattern in which it operates in a power saving mode, or an exception pattern through the operation data collected through the above data collection unit (410).

[0082] The above normal operation pattern is an operation pattern in a normal operation situation in which the air compressor (100) repeats load operation and no-load operation as shown in FIG. 4, and refers to an operation pattern in which compressed air is actually used normally at an industrial site. The power saving mode pattern is a case in which a long-term no-load operation section, which is relatively longer than the no-load operation section of the above normal operation pattern, is repeated at a certain period, as shown in FIG. 11. For example, it may refer to a pattern that occurs regularly and consistently at a certain period or time, such as during breakfast, lunch, dinner, or a predetermined rest time when compressed air is used less.

[0083] In addition, exception patterns are patterns that deviate from these normal operation patterns and power saving mode patterns, and may include patterns that occur during intermittent air loss, patterns caused by equipment operation with severe intermittent air demand pulsation, patterns caused by damage to machine suction valves, air loss patterns caused by field air valve operation errors, air tank condensate removal patterns, and machine part failure patterns. These exception patterns are patterns that occur due to user negligence, breakdowns, or temporary failures, and can be classified as temporary, intermittent, or long-term occurrences. If they occur regularly and over a long period, they may be defined as new patterns or included in the normal operation patterns or power saving mode patterns. However, exception patterns that occur temporarily, intermittently, or due to breakdowns or user negligence may be classified and stored separately as exception patterns and used later as data to determine whether there is a breakdown. These exception patterns are stored separately, and when identifying exception patterns, they are based on the stored exception patterns. When accumulating data on various exception patterns, it is possible to distinguish and identify these exception patterns, and it is possible to exclude them when extracting the above normal operation pattern or the above power saving mode pattern.

[0084] In addition, the data calculation unit (420) can extract the current consumption value during no-load operation in a normal operation situation, i.e., a normal operation pattern section, from the operation data, and through this, it is possible to calculate the no-load power consumption value, which is the power consumption during no-load operation. It is also possible to calculate the no-load average power consumption value, which is the no-load power consumption value obtained by averaging this. At this time, if necessary, it is also possible to calculate the load average power consumption and to calculate the total power consumption.

[0085] The data calculation unit (420) calculates the optimized required power consumption by subtracting the average power consumption value during no-load operation, which is the average power consumption during no-load operation, from the rated power consumption value (motor rated KW) of the main motor of the air compressor. Here, the required power consumption may refer to the average required power consumption in a state where the power consumption during no-load operation is minimized.

[0086] Here, the method of calculating the required power consumption by subtracting it from the rated power consumption value (motor rated KW) of the main motor of the air compressor is described; however, in addition to this, the required power consumption can also be calculated by calculating the average power consumption during load operation through the extraction of the current consumption value during load operation, or by subtracting the average power consumption during no-load operation from the average power consumption during load operation and no-load operation.

[0087] The data calculation unit (420) calculates the required power consumption and converts it into a motor RPM value using the following mathematical formula, and defines the converted motor RPM value as the motor average rotation speed (AVG RPM) to optimize the motor rotation speed.

[0088] [Mathematical Formula]

[0089]

[0090] The above motor RPM value is defined as the motor average rotation speed (AVG RPM), and based on this, optimization control is possible to control the main motor in the above optimization control unit (430). However, the air compressor (100) may lose flow rate, pressure, and power consumption depending on changes in the ambient temperature during morning, afternoon, evening, and dawn. Additionally, air pulsation may occur depending on the air used, so it becomes necessary to set a margin of upper and lower limits based on the above motor RPM value.

[0091] To this end, the data calculation unit (420) can determine an upper limit (MAX RPM) and a lower limit (MIN RPM) based on the motor RPM value, and the optimization control unit (430) can perform optimized power control for the air compressor (100) or the main motor of the air compressor (100) so that the motor RPM is maintained within the range of the upper limit (MAX RPM) and the lower limit (MIN RPM).

[0092] Here, the ranges for the upper limit (MAX RPM) and lower limit (MIN RPM) can be arbitrarily determined and pre-set based on various data, or they can be calculated by considering the condition or specifications of the main motor. Additionally, they can be calculated using various methods by taking into account losses due to temperature changes and air pulsation.

[0093] FIG. 9 is a graph showing the process of optimizing the motor's RPM. As shown in FIG. 9 (a), the motor RPM value before optimization exhibits significant fluctuations and relatively high power consumption. However, as shown in FIG. 9 (b), after optimization, the motor RPM value is maintained at an optimized level, thereby reducing unnecessary power consumption. Additionally, as shown in FIG. 9 (c), when operation is performed with a margin range for optimization—specifically, an upper limit (MAX RPM) and a lower limit (MIN RPM)—it becomes possible to respond to air loss and pressure loss conditions.

[0094] Additionally, by considering the period of air pulsation, it is possible to derive the motor acceleration seconds and motor deceleration seconds based on the settings of the upper limit (MAX RPM) and lower limit (MIN RPM). That is, if the RPM of the main motor is maintained within the amplitude range of the upper limit (MAX RPM) and lower limit (MIN RPM), mechanical vibration, bearing damage, power loss, and heat generation may occur if the balance between motor acceleration and deceleration is not aligned within this amplitude range. To resolve these problems, it is possible to derive the motor acceleration seconds and motor deceleration seconds of the main motor and operate based on them. Here, motor acceleration seconds refer to the time (s) for the motor RPM to reach the upper limit (MAX RPM), and motor deceleration seconds refer to the time (s) for the motor RPM to reach the lower limit (MIN RPM). It is possible to calculate the acceleration seconds and deceleration seconds in various ways by considering the amplitude range of the upper limit (MAX RPM) and lower limit (MIN RPM), the air pulsation period, etc. The motor acceleration and deceleration seconds can be determined arbitrarily, or they can be calculated by first setting them to a certain level, operating the motor, and correcting the acceleration and deceleration seconds while checking the operating status. Additionally, the acceleration and deceleration cycles can be determined to match the aforementioned air pulsation cycle, and the acceleration and deceleration seconds can be calculated through this process.

[0095] The optimization control unit (430) performs the optimization power control by controlling the air compressor (100) based on the motor RPM value, the upper limit value (MAX RPM) and the lower limit value (MIN RPM), the motor acceleration time and the motor deceleration time.

[0096] This method corresponds to the second control method of the first embodiment of the present invention, and as previously explained in the first embodiment of the present invention, it is possible to perform optimized power control of the air compressor (100) using the second control method by additionally calculating the motor RPM value, the upper limit value (MAX RPM) and the lower limit value (MIN RPM), the motor acceleration time and the motor deceleration time, as described above in the case of the first embodiment of the present invention.

[0097] Figure 10 is a graph showing the current data state before and after optimization. As shown in Figure 10 (a), in the state before optimization, the power consumption is the sum of the load power during load operation and the no-load power during no-load operation. However, as shown in Figure 10 (b), in the optimized state, the no-load power during no-load operation is minimized, and the power consumption is consumed only with load power, thereby reducing waste of power consumption and enabling optimized power consumption.

[0098] Furthermore, the optimized power control through the optimization control unit (430) is performed only during the normal operation pattern section, and when the power saving mode pattern section (or time) extracted through the data calculation unit (420) arrives, the optimized power control is stopped and the device is controlled to operate in power saving mode. This enables further reduction in power consumption.

[0099] An example of the above power saving mode pattern is shown in FIG. 11.

[0100] As illustrated in FIG. 11, the power saving mode pattern refers to a case where a long-term no-load operation period, which is relatively longer than the short-term no-load operation period of the normal operation pattern, is repeated at a certain period. For example, it may refer to a pattern that occurs regularly and consistently at a certain period or time, such as during breakfast, lunch, dinner, or a predetermined rest period when compressed air usage is low. At this time, the suction valve remains in an OFF state.

[0101] This power saving mode pattern can be calculated through the data calculation unit (420), and when there is such a long-term no-load operation period, it is possible to calculate the interval time value for the no-load interval at that time and operate in power saving mode at the start time of the power saving mode pattern section. For example, it is possible to turn off the air compressor so that it stops automatically or to operate it with minimal power consumption.

[0102] The above air compressor power consumption optimization control device (400) may further include a correction unit (440).

[0103] The correction unit (440) can perform the optimization power control for the air compressor (100) for a certain period of time through the optimization control unit (430), collect operation data through the data collection unit (410), and determine from the operation data during the optimization power control whether compressed air within a preset pressure range is generated and whether the optimization power control is performed within the required power consumption range, thereby making corrections if the optimization power control is not performed properly.

[0104] Figure 12 shows graphs illustrating the correction process through the correction unit.

[0105] As illustrated in FIG. 12, in a state having power consumption prior to optimization as illustrated in FIG. 12 (a), optimization is performed through the second embodiment of the present invention as illustrated in FIG. 12 (b), and the above-described optimization power control is performed with the expectation that the predicted power consumption (required power consumption) will be used. However, as a result, there may be cases where exceptional situations occur where the optimization deviates from the predicted required power consumption, such as the graphs of actual power consumption 1 (when the power range is large) and actual power consumption 2 (when the power is insufficient) illustrated in FIG. 12 (c). In this case, it is possible to perform state identification, such as identifying the setting information of the motor RPM value, and to correct the operation so as shown in the corrected power consumption graph illustrated in FIG. 12 (d) by performing new optimization or correcting the motor RPM value, etc.

[0106] Here, the correction method may involve recalculating the required power consumption, motor RPM value, upper and lower limits of the motor RPM value, and motor acceleration / deceleration seconds using the operating data of the operating state of Fig. 12 (c) or the operating data of the operating state of Fig. 12 (a) before optimization, or it may be possible to perform the correction by partially correcting the already calculated motor RPM value, upper and lower limits of the motor RPM value, and motor acceleration / deceleration seconds.

[0107] Consequently, the correction unit (440) determines whether the motor settings are being performed as predicted after changing the motor settings for the predicted optimized power control, and corrects the power consumption fluctuation range if it is greater than the predicted standard or deviates from the predicted range.

[0108] Figure 13 shows graphs illustrating the expected pressure and current data during optimized power control.

[0109] When performing optimized power control through the above-mentioned optimization control unit (430), as shown in FIG. 13 (a), the optimization is performed as desired, and there may be cases where the optimized operation pattern is maintained while the target pressure is met and the target required power consumption is maintained. However, as shown in FIG. 13 (b), there may be cases where the current value is maintained at the maximum value (MAX) for a long period while the pressure does not reach the target pressure, showing a pressure under-operation pattern. As shown in FIG. 13 (c), there may be cases where the current is maintained at the minimum value (MIN) while the pressure is maintained at a surplus pressure, showing a pressure under-operation pattern. As shown in FIG. 13 (d), there may be cases where a power saving mode pattern is shown, and as shown in FIG. 13 (e), there may be cases where an exception pattern is shown.

[0110] FIG. 14 is a graph showing cases where optimization is incorrect. As illustrated in FIG. 14, there may be cases where the optimal power consumption range is deviated from, cases where motor acceleration / deceleration adjustment is required due to rapid motor operation, cases where there is a range requiring automatic stop operation in a power-saving mode pattern, and cases where the width of the pressure operation range is excessive. These cases are illustrated sequentially. Such cases can be corrected through correction via the correction unit (440), thereby enabling optimized control.

[0111] Figure 15 is a graph of improvement cases including before and after optimization, or before and after correction.

[0112] As shown in Fig. 15, the graph before improvement at the top contains a mixture of sections that operate despite being subject to automatic stop in the power saving mode pattern section, sections where power control is not optimized, sections subject to automatic stop, sections with incorrect motor acceleration / deceleration, and sections subject to automatic stop. However, the graph after improvement at the bottom confirms that it has been optimized into power saving mode sections and optimized power consumption sections. Additionally, it can be confirmed that power consumption was reduced, as 22KW of power was consumed before improvement, but it was optimized to 5KW after improvement.

[0113] The power consumption optimization control process using the air compressor power consumption optimization control device according to the second embodiment of the present invention will be briefly explained below with reference to FIG. 16.

[0114] Figure 16 is a flowchart showing the operation sequence of the power consumption optimization control process.

[0115] As illustrated in FIG. 16, in order to optimize the power consumption of the air compressor, the data collection unit (410) first collects the operation data of the air compressor (100) for a certain period (e.g., approximately 2 to 4 weeks) (S400). The operation data may include all detection data information that can be detected through the detection sensor (S), including power consumption, applied voltage, applied current, compressed air pressure, temperature, vibration, dew point, flow rate, and intake valve ON / OFF information data, and all data that can be calculated therefrom. Additionally, the main motor information of the air compressor (100), such as rated KW, HZ, RPM, voltage, torque, heating wire type, SF, and efficiency information, may also be collected as operation data or stored in advance in the data collection unit (410) or the data calculation unit (420).

[0116] Subsequently, the data calculation unit (420) can determine whether the operation of the air compressor (100) has a normal operation pattern, a power-saving mode pattern in which it operates in a power-saving mode, or an exception pattern through the operation data collected through the data collection unit (410). In addition, the optimized required power consumption in the normal operation pattern section is calculated (S410). This process has already been explained.

[0117] Afterwards, the data calculation unit (420) converts the calculated required power consumption into a motor RPM value, and defines the converted motor RPM value as the motor average rotation speed (AVG RPM) to optimize the motor rotation speed (S420).

[0118] And, it is possible to perform optimized power control by controlling the main motor based on the motor RPM value so that power is consumed within the required power consumption range, but it is possible to set an upper limit (MAX RPM) and a lower limit (MIN RPM) based on the motor RPM value (S430), and it is possible to perform optimized power control for the air compressor (100) or the main motor of the air compressor (100) so that the motor RPM is maintained within the range of the upper limit (MAX RPM) and the lower limit (MIN RPM) in the optimization control unit (430) (S440).

[0119] It has already been explained that prior to performing the above-mentioned optimized power control (S440), it is possible to derive the motor acceleration time and motor deceleration time based on the setting of the upper limit (MAX RPM) and lower limit (MIN RPM) by considering the period of air pulsation, and that optimized power control is possible by controlling the motor through this method.

[0120] Subsequently, during the process of performing optimized power control, a judgment process (S450) is performed to determine whether the optimization was properly carried out. This can be performed through the correction unit (440).

[0121] After performing optimized power control by changing the motor settings for the predicted optimized power control, the correction unit (440) determines whether it is performed as predicted (S450). If the optimization is done correctly (Yes), the optimized power control is performed as is (S460). However, if the optimization is not done correctly (No), the optimized power control process (S410~S440) is performed again starting from the previous required power consumption calculation process, or correction work is performed such as changing some motor setting values.

[0122] The power consumption optimization control device for an air compressor described through the embodiments of the present invention may be configured to control the operation of a corresponding air compressor by being included in a controller embedded in the air compressor itself or provided as a separate controller, or it may be configured to enable remote control by being embedded in a server connected to the air compressor at the site via a wired or wireless communication network or provided as a separate remote control controller.

[0123] As described above, according to the present invention, there is an advantage in that power consumption can be reduced by optimizing the operation of the air compressor. Furthermore, there is an advantage in that power consumption can be minimized through optimal power consumption by reflecting the usage conditions and site circumstances at the site during the operation of the air compressor. In air compressors that repeatedly alternate between load and no-load operation, unnecessary power consumption can be reduced by minimizing power consumption during no-load operation. Additionally, there is an advantage in that power consumption can be minimized as much as possible by identifying the power-saving mode pattern and controlling it, such as by automatic shutdown, during the power-saving mode section.

[0124] The description of the above-described embodiments is merely an example with reference to the drawings for a more thorough understanding of the present invention and should not be interpreted as limiting the present invention. Furthermore, it will be obvious to those skilled in the art that various changes and modifications are possible within the scope of the basic principles of the present invention without departing from them.

[0125] (Explanation of symbols)

[0126] 310,410: Data Collection Unit 320,420: Data Output Unit

[0127] 330,430 : Optimization control unit 340,440 : Correction unit

Claims

1. In a power consumption optimization control device for an air compressor that produces compressed air: A data collection unit that collects air compressor operation data for a certain period; A data calculation unit that calculates the required power consumption by subtracting the average no-load power consumption value, which is calculated and averaged through the extraction of current values ​​during no-load operation in normal operating conditions from the operating data collected through the data collection unit, from the rated power consumption value of the main motor of the air compressor, and converts the calculated required power consumption into a motor RPM value; An air compressor power consumption optimization control device characterized by having an optimization control unit that defines the motor RPM value calculated through the data calculation unit as the average motor rotation speed and performs optimized power control by controlling the main motor based on this to ensure that power is consumed within the required power consumption range.

2. In Claim 1, The above data calculation unit converts the calculated required power consumption into a motor RPM value, and determines an upper limit and a lower limit based on the converted motor RPM value. The power consumption optimization control device of an air compressor is characterized by the above optimization control unit performing the optimization power control by performing control of the air compressor such that the motor RPM is maintained within the range of the upper limit value and the lower limit value.

3. In Claim 2, An air compressor power consumption optimization control device characterized by further comprising a correction unit for correcting if the optimization power control is not properly performed, by determining from the operation data while performing optimization power control through the optimization control unit whether compressed air within a preset pressure range is generated and whether the optimization power control is performed within the required power consumption range.

4. In Claim 1, The above data calculation unit extracts a normal operation pattern section and a power saving mode pattern section for power saving through the collection of operation data of the air compressor, and The above normal operation pattern section is a pattern section in which compressed air is normally produced and used while repeating load operation and no-load operation, and The above power saving mode pattern section is a pattern section in which a long-term no-load operation section, which is relatively longer than the no-load operation section of the above normal operation pattern, is repeated with a certain period. The power consumption optimization control device of an air compressor is characterized by the above-mentioned optimization control unit performing the above-mentioned optimization power control during the above-mentioned normal operation pattern section, and stopping the above-mentioned optimization power control and controlling operation in power-saving mode when the above-mentioned power-saving mode pattern section arrives.

5. In Claim 1, The above air compressor comprises, as components: a motor-air end assembly having a main motor and an air end to provide compressed air; a controller including an inverter; an air filter for filtering foreign substances in the air; a suction valve; an oil line providing an oil path for maintaining airtightness during air compression; a separator for separating air and oil; an air line serving as a path for compressed air; and a cooler including a fan to prepare for heat generated during air compression. It includes a current sensor for detecting current applied to the main motor, a current sensor for detecting current applied to a fan motor for driving the fan, a temperature sensor for detecting the temperature of the main motor, a temperature sensor for detecting the temperature of the discharge port of the air end, a temperature sensor for detecting the temperature of the cooler, a pressure sensor for measuring the internal pressure of the separator, a pressure sensor for measuring the differential pressure of the separator, a pressure sensor for detecting the pressure of air discharged from the air compressor, a dew point sensor for detecting the dew point of air discharged from the air compressor, a vibration sensor for measuring the vibration of the main motor, an oil level sensor for detecting the oil level inside the separator, and a suction valve sensor for detecting the on / off of the suction valve, An air compressor power consumption optimization control device characterized by the above-mentioned operating data including power consumption, voltage applied to the main motor, current, discharge air pressure, temperature, flow rate, on / off information of the intake valve, and sensing data detected through sensors.

6. In a method for optimizing power consumption control of an air compressor that produces compressed air: A first step of calculating the required power consumption by collecting air compressor operation data over a certain period and subtracting the averaged no-load power consumption value, calculated by extracting the current value during no-load operation under normal operating conditions, from the rated power consumption value of the main motor of the air compressor; A method for optimizing power consumption of an air compressor, characterized by comprising a second step of performing optimized power control by converting the above-mentioned required power consumption into a motor RPM value and controlling the main motor based on the above-mentioned motor RPM value so that power is consumed within the above-mentioned required power consumption range.

7. In Claim 6, The above second step is, A step of converting the above required power consumption into a motor RPM value; A step of setting upper and lower limits based on the converted motor RPM value; A method for optimizing power consumption control of an air compressor, characterized by comprising the step of performing the optimized power control by controlling the main motor so that the motor RPM is maintained within the range of the upper limit value and the lower limit value.

8. In Claim 6, The above second step is, A step of converting the above required power consumption into a motor RPM value; A step of setting upper and lower limits of the motor RPM value based on the converted motor RPM value; A step of deriving motor acceleration seconds and motor deceleration seconds according to the setting of the upper limit value and the lower limit value; A method for optimizing power consumption control of an air compressor, characterized by comprising the step of performing the optimized power control by performing control on the air compressor based on the motor RPM, the upper limit value, the lower limit value, the motor acceleration time, and the motor deceleration time.

9. In Claim 6, The above first step further includes the step of extracting a normal operation pattern section and a power saving mode pattern section for power saving through the collection of operation data of the air compressor, and The above normal operation pattern section is a pattern section in which compressed air is normally produced and used while repeating load operation and no-load operation, and the above power saving mode pattern section is a pattern section in which a long-term no-load operation section, which is relatively longer than the no-load operation section of the above normal operation pattern, is repeated with a certain period. A method for optimizing power consumption control of an air compressor, characterized in that the second step further includes the step of performing the optimization power control during the normal operation pattern section, and when the power saving mode pattern section arrives, stopping the optimization power control and controlling to operate in power saving mode.

10. In Claim 6, After the above second step, A method for optimizing power consumption control of an air compressor, characterized by further comprising a correction step for correcting if the optimizing power control is not properly performed, by determining from the operating data during the performance of the optimizing power control whether compressed air within a preset pressure range is generated and whether the optimizing power control is performed within the required power consumption range.

Images