Compressor Control via Tank Pressure Change Rate
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Solution Overview
Problem
Existing air-compressing apparatuses inefficiently control the number of compressors based on tank pressure, leading to excessive power consumption due to unnecessary operation of compressors, and the addition of flow sensors increases production costs.
Innovation Solution
A control system that adjusts the number of air compressors based on the rate of pressure change in the tank, using existing pressure sensors to optimize compressor operation and reduce power consumption without the need for additional flow sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of compressors is controlled based on tank pressure threshold values, then the discharge flow rate can be adjusted, but unnecessary compressors operate leading to excessive power consumption
Solution Approach 1:
The control system continuously monitors tank pressure and dynamically adjusts the number of operating compressors based on the rate of pressure change. When pressure increases rapidly (indicating low consumption), compressors are stopped earlier than traditional threshold-based systems. When pressure increases slowly (indicating high consumption), compressors remain operating longer, ensuring adequate supply. This feedback mechanism optimizes power consumption while maintaining productivity.
Solution Approach 2:
The invention transitions from static pressure threshold control to dynamic rate-of-change control. The control thresholds are not fixed values but vary based on the current pressure increase rate, allowing the system to adapt to changing consumption patterns in real-time, thereby reducing unnecessary compressor operation and power consumption.
2Use of energy by moving object
If a flow sensor is added to detect compressed air consumption, then compressor control can be optimized according to consumption, but production cost increases due to additional sensors and installation
Solution Approach 1:
The system uses the existing pressure sensor in the tank to self-determine compressed air consumption by calculating the rate of pressure change. Instead of requiring an external flow sensor to measure consumption directly, the system derives consumption information from the pressure dynamics already being monitored, eliminating the need for additional sensors and reducing production costs.
Solution Approach 2:
The existing pressure sensor, originally intended only for pressure monitoring and threshold-based control, is repurposed to also determine compressed air consumption through rate-of-change analysis. This multi-functionality eliminates the need for dedicated flow measurement equipment, reducing system complexity and manufacturing costs while achieving optimized power consumption control.
Data Source
AI summary
An air-compressing apparatus has four compressors individually supplying compressed air to a tank having a pressure sensor. The pressure sensor is connected to control circuits of the compressors. The control circuits compute times needed for the tank pressure to reach minimum and maximum pressures, respectively, of the tank by using the detected tank pressure and also using a tank pressure change value. The computed time values correspond to the consumption of compressed air. Thus, the control circuits can control the number of compressors to be operated according to the consumption of compressed air.