Compressed Air Away Mode for Low-Energy Downtime Readiness
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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 shutting down the system, 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 and equipment undergoes unnecessary wear
Solution Approach 1:
The system dynamically adjusts its operational state based on the 'away mode' input, transitioning from normal operation to a reduced-capacity state. The controller modifies compressor operation, pressure maintenance levels, and humidity control based on real-time conditions and user input, allowing the system to adapt between full readiness and energy conservation modes.
Solution Approach 2:
The system changes key operational parameters when away mode is activated, including reducing pressure maintenance levels, adjusting humidity control setpoints, and modifying compressor run cycles. These parameter changes enable the system to consume less energy while maintaining sufficient functionality for eventual restart.
2Use of energy by moving object
If the compressed air system completely shuts down during downtime, then energy consumption is minimized, but manual restart is required which is time-consuming and costly
Solution Approach 1:
The system performs preliminary maintenance of critical functions during away mode, such as maintaining minimum pressure levels and periodic compressor cycling, so that when restart is needed, the system requires minimal intervention. This preliminary action prevents complete shutdown while avoiding full operational energy consumption.
Solution Approach 2:
The controller automatically manages system adjustments during away mode without requiring manual intervention. The system self-regulates compressor operation, pressure maintenance, and humidity control based on the away mode status, eliminating the need for operator involvement during the transition and restart processes.
3Reliability
If the compressed air system maintains full operational pressure and humidity control during downtime, then equipment is protected and ready for immediate use, but energy usage increases and equipment wear increases
Solution Approach 1:
Instead of maintaining full operational parameters during away mode, the system applies partial action by maintaining only the minimum necessary pressure and humidity levels required for eventual restart. This partial maintenance reduces energy consumption and equipment wear while still preserving sufficient readiness.
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.