Air Compressor Drain Pipe Pressure Sensor Clogging Detection
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Solution Overview
Problem
Existing air compressor designs face reliability issues and energy inefficiencies due to the inability to accurately detect clogging in drain discharge components, leading to potential defects and continuous air leakage.
Innovation Solution
An air compressor configuration with a pressure sensor upstream of a strainer in the drain pipe, an on-off valve downstream, and a bypass system to improve detection of clogging and defects, while implementing intermittent drain discharge for energy-saving purposes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a branch circuit with always-open configuration is used for drain discharge, then the drain can be continuously discharged to the outside, but compressed air continuously flows to the outside causing energy loss
Solution Approach 1:
The drain discharge circuit operates periodically rather than continuously. The control unit opens the on-off valve at predetermined intervals to discharge accumulated drain, then closes it to prevent continuous air leakage. This periodic operation maintains drain discharge functionality while significantly reducing energy loss from compressed air escaping to the atmosphere.
2Measurement precision
If pressure detection is performed only between the strainer and orifice, then clogging of the strainer can be detected, but clogging of other parts such as orifice or pipe cannot be detected
Solution Approach 1:
The drain discharge circuit is divided into multiple segments with pressure sensors positioned at different locations. One pressure sensor is placed between the strainer and orifice to detect strainer clogging, while another pressure sensor is placed downstream of the orifice to detect orifice clogging and other downstream issues. This segmentation enables comprehensive monitoring of the entire circuit, improving overall system reliability through complete fault detection.
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
Enhances reliability by accurately detecting clogging and defects, and improves energy efficiency by reducing continuous air leakage through intermittent discharge.
Implementation Method 1
a pressure sensor is provided between the strainer and the orifice to detect a pressure between the strainer and the orifice
Implementation Method 2
the compressed air which is compressed to a predetermined pressure and heated to a high temperature by a low pressure stage side compressor body is temporarily subjected to intermediate cooling by an intermediate cooler before being sent under a pressure to a high pressure stage side compressor body, and therefore condensed water (drain) is generated here
Data Source
AI summary
Provided is an air compressor which exhibits improved reliability by resolving problems relating to drainage discharge defects, and exhibits improved energy efficiency. The air compressor comprises: a compressor body which compresses air; a compressed air flow path through which the compressed air from the compressor body flows; a heat exchanger which is provided to the compressor flow path so as to cool the compressed air from the compressor body; and a drainage pipe (62) which branches from the compressed air flow path so as to connect to the exterior, and through which drainage condensed from the compressed air cooled in the heat exchanger flows. A strainer (65) which removes foreign matter contaminating the drainage is provided to the drainage pipe (62). An on-off valve (66) at the downstream side of the strainer (65), and a pressure sensor (41) at the upstream side thereof, said sensor detecting pressure inside the drainage pipe (62), are each provided so as to resolve drainage discharge defects.