Drilling Device Compressor Unload Control for Energy Efficiency
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Solution Overview
Problem
In drilling devices, the existing unload control of compressors leads to high energy consumption and increased environmental impact due to maintaining high air pressure for extended periods, which is inefficient and wasteful, especially when not needed for flushing operations.
Innovation Solution
Implementing a control system that maintains air pressure at a low level until flushing is required, then increases it to a higher pressure only when necessary, and returns to low pressure after flushing is completed, using a computer program to manage the compressor's unload control and optimize energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air pressure in the air tank is kept at a high pressure (1.03 MPa) to ensure sufficient compressed air supply for dust removal by pulse jet, then the dust removal function is reliable, but the energy consumption increases and the load on the compressor and air tank becomes larger
Solution Approach 1:
The patent applies dynamic pressure control by switching between high pressure mode (when dust removal is needed) and low pressure mode (when dust removal is not needed). The control unit dynamically adjusts the compressor operation based on the actual need for compressed air, making the system adaptive rather than static. This resolves the contradiction by ensuring high pressure is maintained only when necessary for reliable dust removal, while reducing pressure to low levels during normal operation to minimize energy consumption.
Solution Approach 2:
The patent changes the operating parameter (air pressure) between two distinct states: high pressure (1.03 MPa) and low pressure (0.5 MPa). By controlling the compressor to operate in these different pressure states based on the dust removal requirement, the system optimizes the balance between reliability and energy efficiency. The parameter change allows the system to provide sufficient compressed air when needed while minimizing energy consumption during non-dust-removal periods.
2Quantity of substance
If the air pressure in the air tank is kept at a high pressure (1.03 MPa) to ensure sufficient compressed air supply, then the compressed air availability is improved, but the fuel efficiency decreases and environmental impact increases
Solution Approach 1:
The patent implements periodic switching between high pressure operation (when compressed air is needed for dust removal) and low pressure operation (when it is not needed). This periodic action ensures that sufficient compressed air supply is maintained during dust removal events while minimizing energy consumption and fuel usage during normal drilling operations, thereby reducing environmental impact.
3Quantity of substance
If the compressor operates frequently to maintain high air pressure, then the compressed air supply is sufficient, but the power loss increases due to frequent starting and stopping
Solution Approach 1:
The control unit monitors the dust removal requirement in advance and proactively controls the compressor operation. When dust removal is detected or anticipated, the system prepares by maintaining or increasing pressure to the high level, avoiding the need for frequent emergency compressor startups. This preliminary action reduces power loss by preventing frequent cycling while ensuring sufficient compressed air supply is available when needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances fuel efficiency and reduces environmental impact by minimizing energy usage and compressor load, ensuring air pressure is only elevated when needed for flushing operations.
Implementation Method 1
a compressor (16a) that compresses air
Implementation Method 2
decompressing compressed air supplied from the air tank to a predetermined air pressure (0.5 MPa) by means of a decompression valve
Implementation Method 3
the pulse jet injects the decompressed air into the dust collector
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A drilling device with improved fuel efficiency, reduced impact on the environment, and the like is provided. Specifically, a drilling device (1) performs unload control of a compressor (16a) when an engine (21) starts up, and brings the air pressure in an air tank (16c) to a first air pressure. Moreover, the air pressure in the air tank (16c) is kept at the first air pressure while the engine (21) is driven and a flushing mechanism (17) is not driven. In addition, unload control of the compressor (16a) is performed when the flushing mechanism (17) starts up, and the air pressure in the air tank (16c) is increased to a second air pressure that is higher than the first air pressure. For example, the first air pressure and the second air pressure are a low pressure (0.5 MPa) and a high pressure (1.03 MPa), respectively.