Refueling Screw Compressor Diagnostic Mode
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Solution Overview
Problem
Accurate diagnosis of a refueling screw compressor is challenging due to fluctuating load conditions and measurement result variability, making it difficult to prevent abnormal stops and maintain compressor efficiency.
Innovation Solution
A diagnostic mode is introduced where the compressor operates at a constant load factor of 100% with a fixed cooling fan speed, disconnecting the compressed air flow from the user and using a dedicated orifice to maintain a specified rotation speed, allowing for stable measurement conditions and accurate diagnosis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the compressor operates under normal variable load conditions, then the compressor can adapt to different usage requirements, but the measurement results become unreliable for accurate diagnosis
Solution Approach 1:
The system performs preliminary diagnostic measurements under controlled constant load conditions before normal variable load operation. By establishing baseline measurements under standardized conditions, the system can accurately diagnose component states without the interference of load fluctuations during normal operation.
Solution Approach 2:
The operation is segmented into distinct phases: a diagnostic mode with constant load for accurate measurement, and a normal mode with variable load for adaptive operation. This segmentation allows the system to switch between prioritizing measurement accuracy and operational flexibility depending on the current mode.
2Loss of energy
If the cooling fan speed is variable to optimize cooling efficiency, then energy consumption is reduced, but measurement conditions become unstable
Solution Approach 1:
Before performing diagnostic measurements, the system stabilizes the cooling fan speed to a predetermined constant value. This preliminary stabilization ensures that cooling conditions remain constant during measurement, eliminating variability that would otherwise compromise measurement accuracy.
Solution Approach 2:
The cooling fan speed is made dynamic with two distinct states: a variable state during normal operation for energy optimization, and a constant stabilized state during diagnostic measurements. The system transitions between these states based on operational requirements.
3Reliability
If the compressor prioritizes accurate diagnosis through controlled operation, then diagnostic reliability improves, but operational flexibility is reduced
Solution Approach 1:
The control system is segmented into distinct operational modes: a diagnostic mode with controlled constant parameters for reliable measurement, and a normal mode with variable parameters for flexible operation. The microcontroller switches between these modes based on diagnostic requirements.
Solution Approach 2:
The control system serves multiple functions: it manages both normal variable load operation for adaptability and controlled constant load operation for accurate diagnosis. By integrating both operational requirements into a single control system, the compressor maintains both flexibility and diagnostic reliability.
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 enables accurate and stable compressor diagnosis, preventing abnormal stops by using measurement results from a controlled diagnostic mode, ensuring consistent operation and extending component life.
Implementation Method 1
a suction filter that removes foreign matter, dust, or the like in suction air of the compressor body
Implementation Method 2
an oil separator installed downstream of the oil tank, in which a filtration element is mounted
Implementation Method 3
a first cooler installed downstream of the oil separator to cool the compressed air
Implementation Method 4
a second cooler connected to the oil tank to cool the lubricant
Implementation Method 5
a cooling fan that cools the first cooler and the second cooler
Implementation Method 6
an oil filter provided in a circulation path circulating the cooled lubricant to the compressor body again, to prevent contamination of the lubricant
Data Source
AI summary
In the operation of a refueling screw compressor, when load conditions constantly fluctuate or when the rotation speed control of a cooling fan is performed, it is difficult to accurately perform a diagnosis predicted from measurement results of devices inside the compressor, so a diagnostic mode stably creates an operating condition under which an accurate diagnosis can be performed. In the refueling screw compressor, a discharge electric valve is provided downstream of an air cooler, and an air release electric valve and a dedicated orifice are provided to connect an oil separator inner space and a suction throttle valve space. In the diagnostic mode, the discharge electric valve is closed, the air release electric valve is opened, and while an upstream pressure of the oil separator is maintained at a specified pressure, a rotation speed control operation of a compressor body and the diagnosis of internal devices are performed.