Compressor Power Monitoring for Air Leakage Detection
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Solution Overview
Problem
Current methods for detecting fluid leakage in compressed air systems are limited by noise interference, require costly installation of multiple sensors, and often result in overlooked leaks due to irregular patrols.
Innovation Solution
A detecting apparatus that utilizes power consumption measurements of the fluid supply apparatus to detect fluid leakage, eliminating the need for extensive sensor installations and allowing for real-time monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If sound-based detection methods are used to detect fluid leakage, then detection capability is improved, but detection reliability deteriorates due to noise interference from vibrations and other sounds in the factory environment
Solution Approach 1:
The patent replaces sound-based detection with power consumption-based detection. Instead of using acoustic sensors to listen for leakage sounds, the system uses power meters to measure the electrical power consumption of the fluid supply apparatus. This substitution eliminates the interference from factory noise and vibrations, providing reliable detection based on the correlation between power consumption and fluid leakage conditions.
2Measurement precision
If flowmeters and pressure sensors are installed in each important pipe line to monitor air leakage, then detection precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the detection function from the pipe line infrastructure and relocates it to the fluid supply apparatus. Instead of installing sensors throughout the pipe network to detect leakage, the system measures power consumption at the source (the fluid supply apparatus). This extraction eliminates the need for extensive sensor installation while maintaining detection precision through the relationship between power consumption and leakage conditions.
Solution Approach 2:
The power consumption measurement serves multiple functions: it monitors the operational status of the fluid supply apparatus, detects fluid leakage conditions, and provides energy management data. By using a single measurement parameter (power consumption) for multiple purposes, the system avoids the need for multiple specialized sensors, thereby reducing device complexity while maintaining comprehensive monitoring capability.
3Loss of energy
If irregular patrols are conducted to detect air leakage, then operational costs are reduced, but detection reliability deteriorates due to overlooked leaks
Solution Approach 1:
The patent implements continuous monitoring of power consumption by the fluid supply apparatus. Unlike irregular manual patrols, the power measurement system operates continuously, constantly detecting changes in power consumption that indicate fluid leakage. This continuous action ensures that leaks are detected promptly without being overlooked, while the automated nature of the system keeps operational costs low by eliminating the need for frequent manual inspections.
Data Source
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AI summary
A detecting apparatus (90) detects air leakage in a system which has: air ejectors (50A, 50B), take-out robots (60A, 60B), pallet changers (70A, 70B), and resin dryers (80A, 80B), which use compressed air; and a compressor (10) for supplying the compressed air to the apparatuses that use compressed air. The detecting apparatus detects whether there is air leakage or not on the basis of power consumption of the compressor (10).