Compressor Load Control via Electrical Quantity Monitoring
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Solution Overview
Problem
Existing compressor systems require costly pressure sensors and regular maintenance to determine when to switch between load and unload modes, which are prone to malfunctions.
Innovation Solution
A method that monitors the operating state of a compressor system by tracking electrical quantities such as mechanical power or torque at a constant rotational speed, allowing for the identification of pressure limits and subsequent mode switching without pressure sensors, using an identification phase to store values and an operational phase to detect pressure limits through interpolation functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensors are used to determine when to switch between load and unload modes, then the compressor system can accurately detect pressure limits, but the system cost increases and maintenance requirements increase
Solution Approach 1:
The patent uses electrical quantity (power consumption) as an intermediary parameter to indirectly detect pressure limits. Instead of directly measuring pressure with sensors, the system monitors the electrical power consumed by the compressor motor, which changes characteristically when pressure limits are approached. This intermediary measurement approach eliminates the need for expensive pressure sensors while maintaining detection capability.
Solution Approach 2:
The patent replaces the mechanical/physical pressure sensing system with an electrical measurement system. By substituting pressure sensors with electrical quantity monitoring, the system achieves the same control function (detecting when to switch modes) without the complexity and cost of mechanical sensing components.
2Reliability
If pressure sensors are installed in the compressor system, then pressure monitoring is enabled, but the sensors are prone to malfunctions and require regular maintenance
Solution Approach 1:
The compressor system performs self-monitoring by using its own electrical consumption data to detect pressure conditions. The system serves itself by leveraging existing operational parameters (power consumption) rather than requiring external sensing components that need maintenance. This self-service approach eliminates sensors entirely, removing the maintenance burden.
Solution Approach 2:
The patent extracts the pressure monitoring function from the physical sensing domain and relocates it to the electrical measurement domain. By taking out the pressure sensor component entirely and using electrical quantity as the monitoring basis, the system eliminates the reliability issues and maintenance requirements associated with physical sensors.
3Loss of energy
If the compressor operates at constant speed with load/unload modes, then energy consumption is reduced, but the ability to respond to varying pressure demands is limited
Solution Approach 1:
The patent implements a feedback control mechanism where the electrical quantity measurement provides continuous information about the pressure state. This feedback loop allows the system to automatically switch between load and unload modes based on real-time conditions, enabling the compressor to respond adaptively to pressure demands while maintaining energy efficiency through constant speed operation.
Solution Approach 2:
The system uses periodic switching between load and unload modes based on detected pressure conditions. By alternating between these two operational states in response to feedback from electrical quantity measurements, the compressor achieves both energy efficiency and adaptability to varying pressure demands over time.
Data Source
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AI summary
The present disclosure describes a load/unload control method for a compressor system with a rotating compressor connected to a pressure vessel. In the method, the present operating state can be monitored on the basis of a monitored/estimated electrical quantity of the compressor system. The method comprises an identification phase and an operational phase. In the identification phase, the compressor is operated at a constant rotational speed to generate two known pressures to the pressure vessel. At least one electrical quantity is monitored, and values of the electrical quantity corresponding to the pressure limits are stored. In the operational phase, reaching of a pressure limit may then be detected by comparing the present value of the monitored electrical quantity to the stored values.