Compressed Air Network Control Box for Multi-Compressor Pressure Stability
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Solution Overview
Problem
Existing compressed air installations with multiple compressors experience significant pressure fluctuations, leading to high energy consumption, increased leakage losses, and inefficient operation of compressors outside their optimal working conditions, limiting the ability to combine more than two types of compressors effectively.
Innovation Solution
A method that adjusts the pressure in a compressed air network by controlling electrically driven compressors of different types using a control box with a pressure sensor and evaluation table, optimizing compressor operation to maintain pressure within set limits, and utilizing an algorithm to select the most favorable control orders based on scores assessing energy consumption and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compressors are switched on and off in cascade at different switching pressures, then simultaneous compressor switching is prevented, but large pressure fluctuations still occur in the compressed air network
Solution Approach 1:
The patent implements dynamic pressure control by continuously adjusting compressor output based on real-time network pressure measurements. Instead of fixed switching pressures, the system dynamically modulates compressor delivery to maintain pressure within a narrow band around a setpoint, eliminating large pressure fluctuations while preventing simultaneous switching.
Solution Approach 2:
The system employs feedback control by continuously monitoring compressed air network pressure and using this information to adjust compressor operation. The control system receives pressure signals, compares them with the desired setpoint, and automatically adjusts compressor output accordingly, creating a closed-loop control system that maintains stable pressure.
2Ease of operation
If the average pressure in the compressed air network is kept relatively large to prevent simultaneous compressor switching, then compressor operation is simplified, but energy consumption and leakage losses increase
Solution Approach 1:
The patent changes the pressure parameter dynamically rather than maintaining a constantly high average pressure. By adjusting pressure around a setpoint within a narrow band, the system reduces the average pressure level while maintaining operational stability through continuous control adjustments, thereby reducing energy consumption and leakage losses.
Solution Approach 2:
Through feedback control, the system maintains pressure within optimal limits rather than operating at consistently high pressure. The control system automatically reduces compressor output when pressure approaches the upper limit of the narrow band, preventing excessive average pressure and associated energy losses while ensuring pressure remains within acceptable operational ranges.
3Stress or pressure
If compressors operate outside their optimal working domain to meet pressure control requirements, then pressure stability is improved, but energy consumption increases and wear accelerates
Solution Approach 1:
The system dynamically adjusts each compressor's operating point to maintain it within or near its optimal working domain. By continuously modulating compressor delivery rather than operating at fixed high pressure, the system keeps compressors running at efficient operating points, reducing energy consumption and wear while maintaining pressure stability.
4Stress or pressure
If compressors are frequently switched on and off to control pressure, then pressure control is achieved, but power consumption increases and compressor life span decreases
Solution Approach 1:
The patent implements continuous compressor operation with dynamic output adjustment instead of frequent on/off switching. Compressors run continuously but modulate their delivery to match network demand, maintaining pressure control while avoiding the mechanical stress and power consumption associated with frequent starting and stopping, thereby extending compressor life span.
5Adaptability or versatility
If more than two different types of compressors are combined in a single compressed air installation, then system versatility is improved, but control complexity increases
Solution Approach 1:
The control system is designed with universal functionality to manage multiple compressor types through a unified control architecture. The same control principles and algorithms apply regardless of compressor type, allowing the system to handle diverse compressor configurations without proportionally increasing control complexity.
Data Source
AI summary
Method for adjusting a compressed air installation using several electrically driven compressors of what is called the “loaded/unloaded” type and/or the turbo compressor type and/or the compressor type with variable rotational speed, wherein these compressors are each connected to a single compressed air network with their outlets, and wherein use is made of a control box which makes it possible to adjust the pressure in the compressed air network around a target pressure to be set. The adjustment takes place by controlling the flow of one or several of the compressors, in particular in order to increase the overall flow supplied by the compressors when the pressure drops too much, and in order to lower the overall supplied flow when the pressure becomes too high.