Compressor Maintenance Calculation Using Dynamic Temperature Weighting
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Solution Overview
Problem
Existing compressor maintenance schedules are not accurately adjusted based on actual usage conditions such as pressure and temperature, leading to insufficient maintenance time, which can result in premature failure.
Innovation Solution
A compressor system that calculates maintenance time by adjusting temperature weighting in relation to fluid pressure and compressor operating rate, using sensors and correction maps to account for internal temperature and operational conditions, ensuring accurate maintenance timing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If maintenance time is set based on predetermined operating time or pressure specification, then the maintenance schedule is simple to implement, but the maintenance time does not accurately reflect actual component degradation conditions
Solution Approach 1:
The patent applies parameter changes by modifying the maintenance time calculation based on operating parameters (pressure and temperature). Instead of using fixed predetermined time intervals, the system dynamically adjusts maintenance time by integrating operating time with correction coefficients that depend on detected pressure and temperature values, thereby reflecting actual component degradation conditions
Solution Approach 2:
The patent implements feedback by using sensors to continuously detect pressure and temperature during compressor operation, then feeding this information back to the maintenance calculation unit. This closed-loop system allows the maintenance schedule to be continuously adjusted based on actual operating conditions, improving accuracy while managing complexity through systematic data collection and processing
2Measurement precision
If ambient temperature is used to calculate maintenance time, then the calculation is simple, but it does not accurately represent the internal temperature that actually affects component life
Solution Approach 1:
The patent uses ambient temperature as an intermediary parameter to estimate internal temperature. Since directly measuring internal temperature is difficult, the system detects ambient temperature and uses correction coefficients based on pressure and ambient temperature to calculate the effect of internal temperature on component degradation, thereby indirectly representing the actual thermal conditions
Solution Approach 2:
The system changes parameters by using pressure and ambient temperature as measurable parameters to derive information about internal temperature. Through correction maps that relate these parameters, the system transforms easily measurable external parameters into meaningful indicators of internal component stress conditions
3Reliability
If maintenance time is extended for low-load operation, then customer benefits increase, but failure prevention may be compromised if not properly calculated
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting maintenance intervals based on operating parameters. During low-load operation with lower pressure and temperature, the correction coefficients result in extended maintenance intervals, reducing unnecessary maintenance. During high-load operation, the coefficients automatically shorten intervals to prevent failure, thereby optimizing both reliability and time loss
Data Source
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AI summary
Provided is a compressor capable of calculating the correct time remaining before maintenance. The compressor is provided with: a compressor body that compresses fluid; a motor that drives the compressor body; a temperature sensor that detects the temperature of the compressor; a pressure sensor that detects the pressure of the compressed fluid outputted from the compressor body; and a calculation unit that calculates the time remaining before maintenance for the compressor body, using the temperature of the compressor and the pressure of the compressed fluid assigned with respective predetermined weights. The calculation unit changes the weighting of the temperature according to the pressure of the compressed fluid or the operation rate of the compressor body.