Oil-Injected Air Compressor Cooling Control for Load-State Energy Saving
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Solution Overview
Problem
Oil injected air compressors face inefficiencies in energy consumption and cooling management, particularly when transitioning from heavy to empty loading states, as existing systems lack effective control mechanisms to optimize oil and air cooling processes independently.
Innovation Solution
The oil injected air compressor system incorporates a controller that manages the oil cooler and after cooler assemblies to operate in energy-saving and shutdown states respectively, based on state switching signals, ensuring efficient cooling and reduced energy consumption by independently controlling the oil and air cooling processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the oil cooler assembly and after cooler assembly operate continuously at full capacity, then the cooling effect is maximized, but energy consumption increases significantly
Solution Approach 1:
The patent applies dynamics by making the cooling system adjustable rather than fixed. The controller dynamically adjusts the operation state of the oil cooler assembly and after cooler assembly based on real-time detection of compressor loading state, oil temperature, and compressed air temperature. This allows the cooling capacity to match the actual thermal load, avoiding unnecessary energy consumption while maintaining adequate cooling effect.
Solution Approach 2:
The patent changes operational parameters (power supply state, speed) of the cooling assemblies based on detected conditions. The controller adjusts parameters such as whether to supply power to the oil cooler motor and after cooler motor, and at what speed the fans operate, according to the compressor's loading state and temperature measurements. This parameter adjustment resolves the contradiction between maintaining cooling effect and reducing energy consumption.
2Device complexity
If the cooling system is simplified to reduce device complexity, then manufacturing cost decreases, but the ability to independently optimize oil and air cooling is lost
Solution Approach 1:
The patent segments the cooling system into two independent assemblies: the oil cooler assembly (with its own motor and fan) and the after cooler assembly (with its own motor and fan). This segmentation allows each assembly to be controlled independently based on specific needs - the oil cooler can operate to maintain oil temperature within acceptable ranges, while the after cooler can be adjusted based on compressed air temperature requirements and loading state. This independent control capability enables optimized cooling performance without excessive complexity.
3Reliability
If the after cooler assembly operates at minimum speed in empty loading state, then some cooling capability is maintained, but energy consumption increases compared to shutdown
Solution Approach 1:
The patent implements feedback control where the controller continuously detects the compressor's loading state and compressed air temperature, then adjusts the after cooler assembly's operation accordingly. In empty loading state, the controller detects the low thermal load and shuts down the after cooler motor to eliminate unnecessary energy consumption. When loading state changes or temperature rises, the feedback mechanism activates the after cooler again. This feedback-based decision-making resolves the contradiction by making cooling capability available when needed while eliminating energy waste when not needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures the normal operation of the air compressor while minimizing energy usage by adjusting the cooling systems' states according to loading conditions, optimizing energy efficiency and space utilization within the compressor.
Implementation Method 1
an oil cooling heat exchanger connected to the compressor assembly and the oil separator tank and configured to exchange heat with the oil
Implementation Method 2
an oil cooling fan arranged on one side of the oil cooling heat exchanger and configured to discharge the heat generated by the oil cooling heat exchanger
Implementation Method 3
a post cooling heat exchanger connected to the oil separator tank, and configured to exchange heat with compressed air separated from the oil separator tank
Implementation Method 4
a post cooling fan arranged on one side of the post cooling heat exchanger and configured to discharge the heat generated by the post cooling heat exchanger
Data Source
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AI summary
The present disclosure provides an oil injected air compressor and a method for controlling the same, a storage medium, and an electronic device. The oil injected air compressor includes a compressor assembly (30), an oil separator tank (40), an oil cooler assembly (50), an after cooler assembly (60), and a controller (70). The oil cooler assembly (50) is connected to the compressor assembly (30) and the oil separator tank (40), and is configured to cool the oil. The after cooler assembly (60) is connected to the oil separator tank (40), and is configured to cool compressed air separated from the oil separator tank (40). The controller (70) is configued to control, based on a state switching signal, the oil cooler assembly (50) to operate in an energy-saving state, and the after cooler assembly (60) to operate in a shutdown state or in a minimum speed state.