Compressor No-Load Speed Control for Fast Pressure Recovery
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Solution Overview
Problem
Current compressor systems face challenges in reducing fuel cost and power consumption while maintaining operational efficiency, particularly during transitions from no-load to full-load running, which can lead to pressure drops affecting pneumatic tools and increasing fuel costs.
Innovation Solution
A method for compressor operation control that adjusts the no-load rotation speed and implements a target speed change process, allowing the compressor to start at a standard no-load speed and then reduce to a low-speed no-load speed after a predetermined time, along with purging during no-load running to minimize fuel consumption and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the compressor maintains high rotation speed during no-load running to quickly respond to full-load demand, then the response time to full-load is reduced, but fuel consumption and noise increase
Solution Approach 1:
The patent applies dynamics by making the rotation speed adjustable and time-dependent. The control unit dynamically changes the rotation speed from a first no-load rotation speed (higher) to a second no-load rotation speed (lower) based on the elapsed time during no-load running. This resolves the contradiction by optimizing speed at different time stages rather than maintaining a fixed high speed.
Solution Approach 2:
The patent implements periodic action through time-based speed adjustment. The compressor operates at a higher speed during an initial period after load removal, then transitions to a lower speed after a predetermined time elapses. This periodic variation in operation resolves the contradiction between quick response and fuel efficiency.
2Use of energy by moving object
If the compressor reduces rotation speed during no-load running to save fuel, then fuel consumption decreases, but the pressure drop during tool startup increases
Solution Approach 1:
The control unit dynamically adjusts rotation speed based on operational phase. During initial no-load period, higher speed maintains pressure stability. After predetermined time, speed reduces to save fuel. This dynamic adjustment resolves the contradiction between fuel efficiency and pressure stability.
Solution Approach 2:
The system performs preliminary action by maintaining higher rotation speed during the initial no-load period before tool startup is expected. This ensures pressure stability is maintained during the critical period when tools might start, resolving the contradiction with later fuel-saving operation.
3Reliability
If the compressor operates at full-load rotation speed continuously, then the supply pressure is maintained at datum pressure, but fuel cost increases
Solution Approach 1:
The patent applies dynamics by continuously adjusting rotation speed based on real-time pressure feedback and operational phase. The control unit reduces speed from full-load levels when no longer needed, maintaining pressure only when required. This resolves the contradiction between continuous pressure maintenance and fuel efficiency.
Solution Approach 2:
The system changes operational parameters (rotation speed) based on system state. When supply pressure reaches datum pressure, the control unit reduces rotation speed from full-load to no-load levels. This parameter change resolves the contradiction by maintaining pressure at target levels while reducing energy consumption.
4Speed
If the compressor performs rapid speed increase from no-load to full-load, then the supply pressure rises quickly, but mechanical stress on components increases
Solution Approach 1:
The patent implements periodic action through staged speed increase. Rather than immediate full-speed transition, the control unit increases speed in stages: from first no-load speed to intermediate speed, then to full-load speed. This periodic acceleration reduces mechanical stress while maintaining acceptable pressure rise rate.
Solution Approach 2:
The system applies beforehand cushioning by using intermediate speed stages during the transition from no-load to full-load. This gradual acceleration cushions the mechanical stress that would otherwise occur during rapid speed changes, protecting components while still achieving quick pressure response.
Data Source
AI summary
In a method for operation control of a compressor, full-load running in which a gas intake control valve is fully open and a target rotation speed of a drive source is set to a full-load rotation speed that is a maximum rotation speed in a speed control band when pressure of compressed gas supplied to the consumption side is a datum pressure or less is carried out; then no-load running in which the valve is fully closed and a no-load rotation speed is set as the target rotation speed of the drive source when the supply pressure is a no-load running pressure or less that is a pressure higher than the datum pressure is carried out. The no-load running is started from the standard no-load rotation speed, however, after a transition time, the target rotation speed is reduced to a low speed no-load rotation speed.