Compressed Air Dew Point Estimation for Pneumatic Device Protection
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Solution Overview
Problem
Existing systems fail to effectively determine whether compressed air supplied to pneumatic devices is sufficiently dried, leading to potential failures due to insufficient dryer capacity or failure, as they rely on measurements at the supply source rather than the pneumatic device side.
Innovation Solution
A process quantity measurement device installed in the supply pipe includes a pressure measuring element, thermo-hygrometer, and dew point estimation unit to estimate the dew point of compressed gas, allowing for real-time determination of drying efficiency and displaying the results on a user interface, enabling early detection of dryer failures or insufficient capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dew point measurement is performed at the supply source, then the measurement system is simple, but it cannot determine whether compressed air is sufficiently dried at the pneumatic device side
Solution Approach 1:
A dew point estimation unit acts as an intermediary, calculating the dew point at the supply source based on temperature, humidity, and pressure measurements, then transmitting this estimated value to the pneumatic device side for comparison with the actual dew point measurement, enabling indirect determination of drying sufficiency
Solution Approach 2:
The patent replaces direct physical dew point measurement at the supply source with a calculation-based estimation system that uses temperature, humidity, and pressure sensors combined with dew point calculation algorithms, avoiding the need for complex direct measurement equipment at the supply source
2Reliability
If dryer capacity is increased to ensure sufficient drying, then drying reliability improves, but device cost and size increase
Solution Approach 1:
The system implements feedback by continuously monitoring temperature, humidity, and pressure at the supply source, calculating the dew point, and comparing it with the pneumatic device side dew point measurement to determine whether the dryer is functioning properly, enabling real-time adjustment and early warning without requiring oversized dryer capacity
Solution Approach 2:
The system performs preliminary detection by monitoring drying sufficiency at the supply source and providing early warnings before pneumatic device failures occur, allowing preventive maintenance or adjustments before actual problems manifest at the pneumatic devices
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
Enables accurate determination of dew point estimation on the pneumatic device side, preventing failures by ensuring sufficient drying of compressed air and allowing for timely intervention in case of dryer issues.
Implementation Method 1
a pressure measuring element that generates a pressure signal corresponding to a pressure of the compressed gas passing through a pipe connected to the supply pipe
Implementation Method 2
a thermo-hygrometer that measures a temperature and a humidity of the compressed gas passing through the pipe
Implementation Method 3
a dew point estimation unit that estimates a dew point in the supply source based on the pressure signal generated by the pressure measuring element, the temperature and the humidity measured by thermo-hygrometer, and the pressure of the compressed gas in the supply source received via the reception unit
Implementation Method 4
The dryer installed in the supply source is generally of a cooling type, and dew condensation is caused by lowering a temperature of the compressed air to a dew point under a set pressure to remove moisture in the compressed air
Implementation Method 5
water condenses and accumulates in the pneumatic device when a pressure drops in the pneumatic device and the temperature of the air decreases due to adiabatic expansion
Data Source
AI summary
A failure of a pneumatic device is prevented in advance by making it possible to determine whether or not compressed air supplied to the pneumatic device is sufficiently dried on the pneumatic device side. A process quantity measurement device includes: a pressure sensor generating a pressure signal corresponding to a pressure of a compressed gas passing through a pipe; a thermo-hygrometer measuring a temperature and a humidity of the compressed gas passing through the pipe; a user interface receiving an input of a pressure of the compressed gas in the supply source; and a dew point estimation unit that estimates a dew point in the supply source based on the pressure signal generated by the pressure measuring element, the temperature and the humidity measured by the thermo-hygrometer, and the pressure of the compressed gas in the supply source received via the user interface.