Compressed Air Away Mode for Low-Energy Downtime Operation
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Solution Overview
Problem
Current compressed air systems lack an efficient method to override regular usage schedules during temporary downtime periods, such as holidays or plant shutdowns, requiring either continuous operation or complete shutdown, which is time-consuming and costly.
Innovation Solution
A control system that implements an 'away mode' allowing operators to temporarily reduce system pressure and humidity levels, minimizing energy usage and equipment wear without full shutdown, using a sensor assembly, controller, and user interface to manage compressor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the compressed air system operates according to the regular schedule during downtime, then the system remains ready for immediate operation, but energy is wasted continuously
Solution Approach 1:
The system dynamically adjusts its operational state based on the away mode status. During away mode, the controller modifies the operational parameters (pressure setpoints, compressor operation) to reduce energy consumption while maintaining the ability to quickly resume normal operation when needed.
Solution Approach 2:
The controller changes key operational parameters during away mode, specifically adjusting pressure setpoints to lower values and modifying compressor operation schedules. These parameter changes enable energy reduction while preserving system functionality for rapid restart.
2Loss of energy
If the compressed air system is completely shut down during downtime, then energy consumption is minimized, but restart becomes time-consuming and costly
Solution Approach 1:
Instead of complete shutdown, the system applies partial action by maintaining limited operation during away mode. The compressor continues to run at reduced capacity or maintains lower pressure levels, which is sufficient to prevent full shutdown but not enough to consume full operational energy. This partial operation avoids the restart time penalty while achieving significant energy reduction.
Solution Approach 2:
The system performs preliminary action by maintaining a ready state during away mode through limited compressor operation and pressure maintenance. This preliminary maintenance of operational capability prevents the need for full restart procedures, thereby reducing restart time when normal operation resumes.
3Productivity
If the controller maintains high pressure levels during away mode, then air powered devices can operate immediately upon return, but energy consumption increases
Solution Approach 1:
The controller dynamically adjusts pressure setpoints based on operational mode. During away mode, the pressure setpoint is reduced to a lower level that consumes less energy. When normal operation resumes, the controller dynamically increases the setpoint back to the original higher level, enabling quick restart capability without maintaining high pressure continuously.
Solution Approach 2:
The system implements periodic action by alternating between high pressure maintenance (during normal operation) and reduced pressure maintenance (during away mode). This periodic adjustment of pressure levels allows the system to achieve quick restart capability only when necessary, rather than continuously maintaining high pressure, thereby reducing overall energy consumption.
Data Source
AI summary
A control system for a compressed air system is configured to implement an “away mode” of operation that provides for a temporary override of the operation of the compressed air system, which can be easily enabled and disabled. During a period of down time, when the away mode of operation is enabled, the control system causes the compressed air system to operate in a limited capacity (e.g., maintaining limited system pressure, flow, higher dewpoint/humidity level, etc.) to minimize energy usage and limit unnecessary wear on system equipment without shutting down the compressed air system.