Compressor Pressure Control Settings for Fewer Start-Stop Cycles
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Solution Overview
Problem
Existing methods for controlling compressor settings in air supply systems face challenges in determining appropriate combinations of setting values, leading to issues such as frequent compressor start/stop cycles, energy inefficiency, and potential heat-up problems.
Innovation Solution
A device that assists in assigning compressor controller setting values by inputting acquired appropriate combinations to the controller, utilizing an input unit for receiving network and compressor specifications, a simulator for calculating time-series data of supply pressure and compressor operation, and an output unit for displaying the optimal setting values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the time interval ΔT for estimating pressure is made small, then the responsiveness of pressure control is improved, but the compressor starts or stops frequently leading to energy loss and heat-up
Solution Approach 1:
The patent applies preliminary action by calculating the pressure change rate in advance and using it to predict future pressure values. This allows the system to anticipate pressure changes and adjust compressor operation proactively, avoiding frequent reactive start/stop cycles while maintaining responsive pressure control.
Solution Approach 2:
The patent implements dynamics by making the time interval ΔT adjustable rather than fixed. The system can dynamically adapt ΔT based on operating conditions, allowing longer intervals during stable operation to reduce start/stop frequency, and shorter intervals when rapid pressure changes are anticipated, thus balancing responsiveness with energy efficiency.
2Loss of energy
If the time interval ΔT for estimating pressure is made large, then the compressor start/stop frequency is reduced improving energy saving, but the supply pressure control becomes delayed causing pressure to exceed limits
Solution Approach 1:
The patent applies feedback by continuously monitoring actual pressure values and comparing them with predicted pressure values. This feedback mechanism allows the system to detect when predictions deviate from actual behavior and adjust the time interval ΔT or other parameters accordingly, ensuring pressure control reliability even with larger time intervals that reduce start/stop frequency.
Solution Approach 2:
By calculating pressure change rates and predicting future pressure values in advance, the system can prepare for upcoming pressure changes. This preliminary action allows the use of larger time intervals for energy saving while still maintaining reliable pressure control, as the system anticipates pressure trends rather than merely reacting to current conditions.
3Reliability
If skilled engineers determine controller setting values using know-how, then appropriate settings can be achieved, but the process becomes difficult for inexperienced personnel and inflexible to changes in air consumption requirements
Solution Approach 1:
The patent applies self-service by enabling the system to automatically determine and optimize controller setting values without requiring skilled engineers' know-how. The automated optimization process allows inexperienced personnel to configure the system easily while adapting to changes in air consumption requirements, thus improving both ease of operation and flexibility while maintaining reliability through systematic optimization methods.
Data Source
AI summary
A device for assisting in assigning setting values of a compressor operation controller for starting or stopping one or more compressors, collecting discharged air of the compressors in an air tank, and supplying the air tank as a compressed air source in a predetermined pressure range, includes: an input unit that receives piping network information which is an element of a pressure loss of a piping flow from the compressor to a pressure control position of the controller, compressor specifications which are an upper limit of a discharge pressure of the compressor and a number of compressor starts/stops, a supply flow rate condition which is time change data of a flow rate flowing from the pressure control position of the controller, and a supply pressure condition which is a lower limit of the supply pressure at the pressure control position of the controller.