Gas Compression System with PLC Feedback Control
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Solution Overview
Problem
Existing gas compression systems are inefficient and difficult to automate, requiring manual adjustments for pressure settings and being unable to adapt to varying gas suction pressures, leading to energy inefficiencies and the need for new equipment when expanding capacity.
Innovation Solution
A gas compression system with an electronically controlled reversing valve and programmable logic controller (PLC) that uses pressure transducers to automatically adjust oil pressure based on measured suction and delivery pressures, allowing for efficient operation and expansion without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual pressure regulators are used in the reversing valve, then the system can be simpler in structure, but the system requires manual intervention and cannot adapt to varying gas suction pressures
Solution Approach 1:
The patent implements feedback control by using pressure transducers to continuously monitor suction and delivery pressures, feeding this information to a PLC that automatically adjusts the reversing valve position and pump motor speed to maintain optimal compression ratios, eliminating manual intervention while adapting to varying operating conditions
Solution Approach 2:
The patent replaces manual mechanical pressure regulators with an electronically controlled system where a PLC receives digital signals from pressure transducers and controls electromagnetic reversing valves and variable speed motors, substituting mechanical adjustment with electronic control for automated operation
2Adaptability or versatility
If the piston speed is fixed to match the pump maximum flow rate, then the system operates efficiently at maximum capacity, but the system cannot be expanded or adapted to different flow requirements
Solution Approach 1:
The patent makes the piston speed dynamic by coupling it to a variable speed motor controlled by the PLC, allowing the compression speed to be continuously adjusted to match the pump's actual flow rate rather than being fixed, enabling both efficient operation and system expansion without sacrificing productivity
Solution Approach 2:
The patent creates a universal compression system where the same compression mechanism can handle various flow rates and pressure requirements by adjusting motor speed and reversing valve timing, allowing the system to serve multiple functions and be expanded without requiring dedicated equipment for different operating conditions
3Loss of energy
If manual pressure adjustment is used, then the system can operate with simpler control, but energy efficiency is reduced due to inability to optimize for varying suction pressures
Solution Approach 1:
The PLC receives real-time feedback from pressure transducers monitoring suction and delivery pressures, automatically calculating and adjusting the optimal compression ratio and motor speed to minimize energy consumption while maintaining required delivery pressure, eliminating the energy waste associated with manual adjustment
Solution Approach 2:
The system performs self-optimization by automatically adjusting its own operating parameters based on real-time pressure measurements, with the PLC controlling motor speed and reversing valve timing to maintain peak efficiency without external intervention, reducing energy loss through continuous self-adjustment
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
The system achieves accurate, reliable, and efficient gas compression by automatically adjusting oil pressure, reducing energy consumption, and enabling expansion without requiring new pumps, thus improving operational efficiency and versatility.
Implementation Method 1
a first signal indicative of a suction pressure of the inlet gas, indicative of a delivery pressure of the outlet gas and indicative of a pressure of the oil
Implementation Method 2
the programmable logic controller being suitable for controlling a position of the reversing valve in order to control a flow direction of the oil
Implementation Method 3
a delivery outlet (31, 41) suitable for being connected to the delivery conduit (7) that transports the compressed gas
Data Source
Figure 1~4
Figure 2
Figure 3
AI summary
A gas compression system (200) comprises a hydraulic compressor (C) connected to an oil hydraulic circuit (I) and a programmable logic circuit (PLC) (9) connected to a first pressure transducer (T1) disposed in a gas suction conduit (6), to a second pressure transducer (T2) disposed in a gas delivery conduit (7) and to pressure adjusting means (R) of electronically controlled type to adjust the pressure of the oil of the hydraulic circuit (I) at a pressure value calculated based on the pressure values measured by the first pressure transducer (T1) and by the second pressure transducer (T2). The system further comprises a third pressure transducer (T3) disposed in a reversing valve (8) of the oil hydraulic circuit (I), wherein the PLC is configured to actuate the shutter (80) of the reversing valve (8) in alternate motion when the oil pressure measured by said third pressure transducer (T3) reaches said pressure value calculated based on the pressure values measured by said first pressure transducer (T1) and by said second pressure transducer (T2).