Compressed Air Pressure Control for Nonlinear Piping Losses
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air pressure systems face challenges in accurately controlling air compressor discharge pressure to match varying terminal air usage rates due to nonlinear pressure losses in complex piping systems, leading to inefficiencies and potential power wastage, especially with the limitations of expensive flow rate detecting devices and response delays in pressure system volumes.
Innovation Solution
An air pressure system equipped with a compressor pressure sensor, terminal pressure sensors, and a flow rate difference calculating device that assesses the air tank capacity and piping system information to calculate deviations and control the air compressor in real-time, ensuring compressed air is supplied according to actual usage without unnecessary pressure and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressure of air discharged from the air compressor is set high to allow for maximum pressure loss, then the pressure of compressed air supplied to terminals is maintained equal to or higher than a predetermined pressure, but the air compressor consumes excessive electric power when terminal air usage is low
Solution Approach 1:
The system uses pressure detecting devices at terminals to provide feedback signals to the control apparatus. The control apparatus calculates the relationship between discharged air rate and pressure loss based on this feedback, and dynamically adjusts the air compressor's discharge pressure to match actual terminal needs, eliminating the need for constant high-pressure operation
Solution Approach 2:
The system transitions from static high-pressure setting to dynamic pressure adjustment. The control apparatus continuously modifies the air compressor's discharge pressure based on real-time terminal pressure feedback and calculated pressure loss characteristics, allowing the system to adapt to varying terminal air usage rates
2Measurement precision
If pressure detecting devices are provided near respective terminals for measured terminal pressure control, then the control accuracy is improved, but the system complexity and cost increase
Solution Approach 1:
The control apparatus performs multiple functions: it receives pressure feedback from terminals, calculates pressure loss characteristics, determines the relationship between discharged air rate and pressure loss, and controls the air compressor. This multi-functionality reduces the need for separate dedicated devices for each function
Solution Approach 2:
The control apparatus acts as an intermediary that processes terminal pressure feedback and translates it into appropriate air compressor control signals. It calculates pressure loss characteristics and determines optimal discharge pressure without requiring direct complex interactions between terminals and the air compressor
3Use of energy by moving object
If the air compressor discharge pressure is constantly adjusted to match terminal usage rates, then energy consumption is reduced, but the pressure of compressed air supplied to terminals may become unstable due to nonlinear pressure losses in complex piping systems
Solution Approach 1:
The control apparatus calculates pressure loss characteristics and determines the relationship between discharged air rate and pressure loss in advance, based on feedback from terminal pressure measurements. This preliminary characterization enables more accurate and stable pressure control when adjusting the air compressor
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 enables real-time control of the air compressor to match air usage rates, reducing power wastage and stabilizing operations by predicting volume responses, thus optimizing energy use and maintaining stable pressure delivery.
Implementation Method 1
an air compressor for compressing air drawn in from the atmosphere
Implementation Method 2
pressure detecting devices are provided near respective terminals, and a new setting value for a discharged pressure is calculated from variations in the pressure differences between the outlet of an air compressor and the respective terminals
Data Source
AI summary
There is provided an air pressure system for controlling an air compressor in real time in accordance with the actual usage of compressed air by a plurality of terminals. Furthermore, in case pressure losses change abruptly, unwanted electric power is prevented from being consumed by a stable operation free of response delays on the basis of a predicted model that assesses time lags of volume responses. There is provided an air pressure system for supplying compressed air discharged from an air compressor through an air tank and a piping system to a plurality of terminals that consume the compressed air, including a compressor pressure sensor for measuring the pressure of compressed air discharged from the air compressor, a plurality of terminal pressure sensors for measuring the pressures of compressed air supplied respectively to the terminals, a flow rate difference calculating device for calculating deviation information on the basis of a capacity of the air tank, information on the piping system, the pressure of compressed air discharged from the air compressor, and the pressures of compressed air supplied respectively to the terminals, and a control device for controlling operation of the air compressor on the basis of the deviation information.