Gas Compressor Air Release Systems for Stable Control Pressure
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Solution Overview
Problem
In oil supply type air compressors, maintaining a stable control pressure within the oil separation tank is challenging during unload operations, especially when transitioning between variable and constant speed controls, leading to potential oil supply insufficiency and increased power consumption.
Innovation Solution
A gas compressor configuration that includes a compressor main body, electric motor, power conversion device, suction throttle valve, air release valve, and a controller, which detects current or pressure values to manage the unload operation by adjusting the suction throttle valve and air release valve, ensuring a variable control pressure through monitoring and feedback mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If air release amount in oil separation tank is increased to decrease load on compressor main body, then power consumption is reduced, but control pressure in oil separation tank becomes unstable and may fall below predetermined pressure
Solution Approach 1:
The patent changes the parameter of control pressure from fixed to variable by implementing multiple air release systems with different pressure thresholds. The controller dynamically selects which air release valve to operate based on the current compression load and speed control mode, allowing control pressure to vary appropriately while still ensuring sufficient oil supply to the compression mechanism.
Solution Approach 2:
The patent divides the single air release system into multiple segmented air release systems (first and second air release systems), each with its own air release valve and pressure regulating valve. This segmentation allows selective operation of different air release pathways based on operational conditions, resolving the contradiction between reducing power consumption and maintaining stable control pressure.
2Use of energy by moving object
If suction throttle valve control or air release control is performed to reduce load on compressor, then power consumption decreases, but sufficient oil supply to compression mechanism cannot be guaranteed
Solution Approach 1:
The patent implements variable control pressure management that adapts to different load conditions. By dynamically adjusting which air release valve operates and at what pressure thresholds, the system maintains adequate control pressure to ensure sufficient oil supply to the compression mechanism even during unload operations, while still achieving power consumption reduction through selective air release.
3Reliability
If constant control pressure is maintained in oil separation tank, then oil supply to compression mechanism is ensured, but air release control flexibility is reduced and power consumption cannot be optimized
Solution Approach 1:
The patent transitions from static constant pressure control to dynamic variable pressure control. The controller monitors compression load and speed control mode in real-time, dynamically selecting which air release valve to operate and adjusting control pressure thresholds accordingly. This dynamic approach ensures oil supply stability when needed while enabling power consumption optimization through flexible air release control.
Solution Approach 2:
The patent implements feedback control mechanisms where the controller continuously monitors operational parameters (compression load, discharge pressure, speed control mode) and adjusts air release valve operations accordingly. This feedback loop allows the system to maintain sufficient control pressure for reliable oil supply while optimizing power consumption by releasing air at appropriate pressure thresholds based on real-time conditions.
Data Source
AI summary
A gas compressor includes a compressor main body, an electric motor that supplies driving force to the compressor main body, a power conversion device, a plurality of air release valves disposed in a plurality of air release systems communicating with a discharge piping system to discharge the compressed gas to an atmospheric pressure environment, and a controller. The gas compressor performing an unload operation of reducing, when a discharge pressure reaches a predetermined pressure, a load on the compressor main body by opening one of the air release valves. The gas compressor including the plurality air release systems for each of which the air release value is disposed, and a plurality of pressure regulating valves provided on a downstream side of each air release valve, respectively, wherein the controller selects one of the air release valves and performs the unload operation.