Gas Compressor Speed Control for Fast Compressed-Air Recovery
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Solution Overview
Problem
Conventional gas compressors face issues with supply delays during transitions from no-load to load operation and inefficient motive power consumption due to fixed target rotation speeds independent of air supply system capacity.
Innovation Solution
A gas compressor system that adjusts the target rotation speed of the electric motor based on the capacity and operation duration of the air supply system, using a controller to manage suction throttle and air release valves according to delivery-side pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a fixed low target rotation speed is set for no-load operation, then motive power consumption is reduced, but supply delay of compressed air occurs during transition from no-load to load operation
Solution Approach 1:
The patent applies dynamics by making the target rotation speed adjustable rather than fixed. The controller dynamically changes the target rotation speed based on operational state: during no-load operation, a lower target rotation speed is set to reduce power consumption, while during load operation, a higher target rotation speed is set to ensure adequate compressed air supply. This dynamic adjustment resolves the contradiction between energy efficiency and supply responsiveness.
Solution Approach 2:
The patent implements parameter changes by modifying the target rotation speed parameter according to operational conditions. The controller switches between different target rotation speed values (first value during no-load, second value during load) based on the operational state, thereby optimizing both power consumption and supply performance without requiring complex additional hardware.
2Loss of time
If a fixed high target rotation speed is set for no-load operation, then supply delay of compressed air is inhibited, but there is room for reduction of motive power consumption
Solution Approach 1:
The controller dynamically adjusts the target rotation speed based on the operational state. During no-load operation, it sets a lower first target rotation speed to minimize power consumption, and during load operation, it sets a higher second target rotation speed to ensure adequate supply. This dynamic behavior eliminates the need to maintain a constantly high speed, thereby reducing overall energy consumption while maintaining supply readiness when needed.
Solution Approach 2:
The controller prepares for load operation by setting appropriate target rotation speeds in advance. When transitioning from no-load to load operation, the controller switches to the higher second target rotation speed, ensuring the motor is ready to provide adequate compressed air supply without excessive delay. This preliminary preparation resolves the contradiction by ensuring supply readiness only when actually needed.
3Productivity
If the target rotation speed is adjusted based on air supply system capacity, then both supply delay inhibition and power consumption reduction are achieved, but controller complexity increases
Solution Approach 1:
The controller manages complexity by focusing on adjusting a single key parameter (target rotation speed) based on operational state. Rather than complex multi-parameter control, the system uses simple parameter switching between no-load and load conditions, achieving optimized compressed air supply efficiency without requiring sophisticated control algorithms or additional complex hardware.
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
Inhibits supply delays and reduces motive power consumption by optimizing rotation speed settings based on air supply system capacity, ensuring efficient operation transitions.
Implementation Method 1
a pressure sensor arranged on a delivery side of the compressor body
Implementation Method 2
an electric motor; a compressor body that is driven by the electric motor
Implementation Method 3
a compressor body that is driven by the electric motor and compresses a gas
Data Source
AI summary
A gas compressor inhibits a supply delay of a compressed gas at a time of a return from no-load operation to load operation, and also reduces the consumed motive power. A controller switches between load operation and no-load operation by controlling a suction throttle valve according to a sensed delivery-side pressure, and also controls a rotation speed of an electric motor that drives the compressor. The controller is configured to compute a capacity C of an air supply system that supplies a compressed air generated by the air compressor to a use location of the compressed gas on a basis of load operation duration t1 and no-load operation duration t2, and set a target rotation speed of the electric motor at a time of no-load operation on a basis of the capacity C of the air supply system.