Oil-Injected Air Compressor Cooling Control for Empty-Load Energy Saving
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Solution Overview
Problem
Oil injected air compressors face inefficiencies in energy consumption and cooling management, particularly when transitioning from heavy to empty loading states, as existing systems lack effective control mechanisms to optimize energy usage and maintain normal operation without providing compressed air.
Innovation Solution
The oil injected air compressor system includes a controller that switches the oil cooler assembly to an energy-saving state and the after cooler assembly to a shutdown or minimum speed state based on a state switching signal, ensuring efficient operation and reduced energy consumption by independently managing oil and air cooling paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the oil cooler assembly and after cooler assembly continue to operate at full capacity during empty loading state, then the cooling effect is maintained, but energy consumption increases significantly
Solution Approach 1:
The patent applies dynamics by making the cooling system adjustable rather than fixed. The controller dynamically adjusts the operation state of the oil cooler assembly and after cooler assembly based on the loading state signals. During empty loading state, the system transitions from full-capacity operation to reduced-capacity or shutdown states, optimizing energy consumption while maintaining necessary cooling functions when required.
Solution Approach 2:
The patent changes operational parameters (operation state) of the cooling assemblies based on loading conditions. The controller receives loading state signals and adjusts parameters such as fan speed, motor power, or operational mode of the oil cooler assembly and after cooler assembly, switching between different operation states to match the actual cooling demand and reduce energy waste during empty loading periods.
2Use of energy by moving object
If the cooling assemblies are shutdown during empty loading state, then energy consumption is reduced, but the oil and compressed air may overheat
Solution Approach 1:
The patent implements feedback control where the controller continuously monitors the loading state and adjusts the cooling assemblies accordingly. The controller receives signals about the loading state and uses this feedback to determine whether to maintain, reduce, or shutdown cooling functions. This closed-loop control ensures that cooling is provided only when necessary, preventing overheating while avoiding unnecessary energy consumption during empty loading states.
Solution Approach 2:
The system dynamically adjusts cooling capacity based on real-time operational conditions. Rather than maintaining fixed cooling capacity or completely shutting down, the system can transition between multiple operation states (full capacity, reduced capacity, shutdown) to match the actual thermal load, ensuring temperature control is optimized according to actual compressor loading conditions.
3Device complexity
If a unified cooling control system is used for both oil cooler and after cooler, then the control structure is simple, but energy optimization during empty loading state is insufficient
Solution Approach 1:
The patent segments the cooling control system into independent controllable units: the oil cooler assembly and the after cooler assembly. Each assembly can be controlled independently based on its specific cooling requirements and the overall loading state. This segmentation allows the controller to optimize energy consumption by selectively adjusting or shutting down specific cooling functions during empty loading state, rather than controlling all cooling components uniformly.
Solution Approach 2:
The controller serves multiple functions: it monitors the loading state, determines the appropriate operation state for each cooling assembly, and executes the control decisions. This multi-functional controller manages both the oil cooler assembly and after cooler assembly, coordinating their operation to achieve overall energy optimization while maintaining necessary cooling functions, thereby resolving the contradiction between control simplicity and energy optimization.
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 ensures the normal operation of the air compressor while minimizing energy consumption by optimizing the cooling processes, allowing the compressor to operate efficiently even in empty loading states with reduced energy usage.
Implementation Method 1
The oil cooler assembly is connected to the compressor assembly and the oil separator tank, and is configured to cool the oil
Implementation Method 2
The after cooler assembly is connected to the oil separator tank, and is configured to cool compressed air separated from the oil separator tank
Data Source
AI summary
The present disclosure provides an oil injected air compressor and a method for controlling the same, a storage medium, and an electronic device. The oil injected air compressor includes a compressor assembly, an oil separator tank, an oil cooler assembly, an after cooler assembly, and a controller. The oil cooler assembly is connected to the compressor assembly and the oil separator tank, and is configured to cool the oil. The after cooler assembly is connected to the oil separator tank, and is configured to cool compressed air separated from the oil separator tank. The controller is configued to control, based on a state switching signal, the oil cooler assembly to operate in an energy-saving state, and the after cooler assembly to operate in a shutdown state or in a minimum speed state.