Compressor Anomaly Cause Identification via Sensor Segmentation
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Solution Overview
Problem
Multi-stage compressors face challenges in identifying the cause of anomalies in sensor readings, leading to difficulties in troubleshooting and maintenance.
Innovation Solution
Incorporating a controller with multiple temperature and pressure sensors that estimate the cause of anomalies by analyzing sensor data and providing specific notifications for issues like leakage, coolant temperature changes, and compressor speed adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple temperature and pressure sensors are installed to monitor compressor operation, then anomaly detection capability is improved, but the ability to specify the cause of anomalies deteriorates
Solution Approach 1:
The monitoring system segments the anomaly detection function by sensor type and location. Temperature sensors monitor discharge temperature, intercooler inlet temperature, and intercooler outlet temperature separately, while pressure sensors monitor discharge pressure and inlet pressure separately. The controller segments the analysis by evaluating each sensor's data independently and then integrating the results to identify specific anomaly causes such as leakage, cooling issues, or performance degradation.
2Measurement precision
If additional sensors are added to specify anomaly causes, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The existing temperature and pressure sensors serve multiple functions. The same sensors used for general operation monitoring are also used for specific anomaly cause identification. The controller universally applies anomaly determination logic across all sensor data, enabling the system to identify various anomaly types (leakage, cooling problems, performance degradation) without requiring additional specialized sensors for each specific anomaly type.
Solution Approach 2:
The controller acts as an intermediary that processes and interprets sensor data. Instead of adding more sensors, the controller introduces intelligent analysis logic that correlates temperature and pressure readings from existing sensors to infer anomaly causes. The controller mediates between raw sensor data and anomaly identification by applying determination logic that translates sensor readings into specific diagnostic information.
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 precise identification of anomaly causes, reducing maintenance time and costs by providing clear notifications without the need for additional sensors.
Implementation Method 1
a first temperature sensor that senses a temperature of the compressed gas on a discharge side of the low-pressure-stage compressor body and on an upstream side of the intercooler
Implementation Method 2
a first pressure sensor that senses a pressure of the compressed gas on the discharge side of the low-pressure-stage compressor body
Implementation Method 3
a second temperature sensor that senses a temperature of the compressed gas on an intake side of the high-pressure-stage compressor body and on a downstream side of the intercooler
Implementation Method 4
a third temperature sensor that senses a temperature of the compressed gas on a discharge side of the high-pressure-stage compressor body
Implementation Method 5
an intercooler that uses a cooling medium to cool the compressed gas discharged from the low-pressure-stage compressor body
Implementation Method 6
a low-pressure-stage compressor body that compresses a gas
Implementation Method 7
a high-pressure-stage compressor body that further compresses the compressed gas having been cooled by the intercooler
Data Source
AI summary
Provided are a compressor and a monitoring system that can specify a cause of an anomaly of a sensed value of a sensor. A compressor (1) includes: a temperature sensor (11A) that senses a temperature of a compressed air on a discharge side of a low-pressure-stage compressor body (3) and on an upstream side of an intercooler (5); a pressure sensor (12A) that senses a pressure of the compressed air on the discharge side of the low-pressure-stage compressor body (3); a temperature sensor (11B) that senses a temperature of the compressed air on an intake side of a high-pressure-stage compressor body (6) and on a downstream side of the intercooler (5); a temperature sensor (11C) that senses a temperature of the compressed air on a discharge side of the high-pressure-stage compressor body (6); a controller (8) that decides whether or not an anomaly has occurred in sensed values of the sensors (11A), (11B), (11C), and (12A), and estimates a cause of the anomaly; and a display device (9) that displays the cause of the anomaly estimated by the controller (8).