Variable Pre-Pressure Control in Parallel Air Compressors
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Solution Overview
Problem
Compressed air systems with fluctuating demand suffer from significant energy inefficiencies due to overcompression, leaks, and frequent compressor switching, leading to high operational costs and maintenance needs.
Innovation Solution
A compressed air system with parallel-connected compressors and a pressure-boosting apparatus upstream, controlled by a regulating device to vary pre-pressure, allowing efficient operation without pressure bands and reducing the number of compressors needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential pressure band control is used to switch compressors on and off, then compressed air supply to consumers with fluctuating demand is achieved, but significant energy loss occurs due to permanent overcompression
Solution Approach 1:
The patent applies dynamics by replacing the static sequential pressure band control with a dynamic demand-responsive control system. The control device continuously monitors actual consumer demand and adjusts compressor operation in real-time, allowing the system to adapt its compression level to match actual needs rather than following fixed pressure bands, thereby eliminating permanent overcompression.
Solution Approach 2:
The patent changes the control parameter from fixed pressure bands to variable demand-based pressure control. By monitoring actual consumer demand and adjusting the compression parameters dynamically according to real-time conditions, the system optimizes energy consumption while maintaining adequate supply, resolving the contradiction between supply capability and energy loss.
2Adaptability or versatility
If compressors are frequently switched on and off to compensate for demand fluctuations, then supply adaptability is improved, but maintenance needs and wear increase due to temperature changes and material expansion
Solution Approach 1:
The patent implements continuity of useful action by maintaining compressors in continuous or extended operation rather than frequent on-off cycling. The demand-responsive control system adjusts compression levels and operates compressors continuously at optimized levels, eliminating the harmful thermal cycling and material expansion/contraction associated with frequent switching, thereby improving reliability while maintaining supply adaptability.
Solution Approach 2:
The control device performs preliminary action by predicting and preparing for demand fluctuations through continuous monitoring and proactive adjustment of compressor operation. This prevents the need for reactive on-off switching by maintaining optimal compression levels in advance, reducing wear and improving reliability while adapting to demand changes.
3Adaptability or versatility
If a relatively large number of compressed air compressors with different power ratings are used for energy-efficient operation, then operation flexibility is improved, but overall operating costs increase due to idle operation and shutdown procedures
Solution Approach 1:
The patent applies universality by using a reduced number of multi-functional compressors that can operate across a wide range of conditions. The demand-responsive control system enables these compressors to adapt their operation to different power requirements and demand levels, eliminating the need for multiple specialized compressors and reducing idle operation costs while maintaining operating flexibility.
Solution Approach 2:
The patent changes operational parameters by allowing compressors to vary their compression level and operating point dynamically rather than requiring fixed power ratings. This parameter flexibility enables a smaller number of compressors to handle varying demands efficiently, reducing the need for multiple units and minimizing idle operation energy consumption.
4Productivity
If pressure-boosting apparatus is added upstream of compressors to variably increase pre-pressure, then delivery capacity and efficiency are improved, but device complexity increases
Solution Approach 1:
The patent introduces a pressure-boosting apparatus as an intermediary component upstream of the compressors. This mediator increases the pre-pressure of the intake air, allowing compressors to operate more efficiently and deliver higher capacity. The control device integrates this additional component seamlessly, managing the pre-pressure variation to improve productivity while keeping the overall system complexity manageable through centralized control.
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 configuration achieves up to 15% energy savings, lowers maintenance costs, and stabilizes system operation by minimizing compressor switchings, ensuring efficient and reliable compressed air supply.
Implementation Method 1
a pressure-boosting apparatus arranged upstream of at least some of the compressed air compressors for variably increasing an pre-pressure
Implementation Method 2
a control and/or regulating device which is configured to control and/or regulate the pressure-boosting apparatus based on a target pressure and/or actual pressure on the consumer side
Data Source
AI summary
The invention relates to a compressed air system (10), in particular for the compressed air supply of at least one consumer with varying demand, having a plurality of compressed air compressors (12) connected in parallel, having a pressure boosting device (14) which is connected upstream of at least some of the compressed air compressors for the variable boosting of a preliminary pressure, and having a control and/or regulating device (18) which is set up for controlling and/or regulating the pressure boosting device in accordance with a desired pressure and/or actual pressure on the consumer side.