System for controlling compressor
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Solution Overview
Problem
Conventional compressor control methods, such as load-unload driving, inverter control, and mechanical proportional control, face issues like shortened component life, high energy loss, maintenance costs, and inability to uniformly control pressure, leading to noise and vibration due to excessive suction pressure.
Innovation Solution
A compressor control system with a cylinder containing first and second pistons, a pressure control valve, a control valve, a fluid condition transmission unit, and a control unit that detects pressure or flow rate and adjusts the control valve to prevent the compressor suction valve from being fully closed, using a mechanical proportional control method to maintain uniform pressure or flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical proportional control is used to control compressor pressure, then initial investment cost is low, but accurate pressure control is impossible due to slow response speed
Solution Approach 1:
The control system is segmented into multiple functional components: a control valve for rapid response, a pressure control valve for proportional control, a fluid condition transmission unit for sensing, and a control unit for coordination. This segmentation allows each component to specialize in specific functions, achieving both fast response and accurate pressure control while maintaining cost-effectiveness through modular design
Solution Approach 2:
The fluid condition transmission unit acts as an intermediary between the compressor system and the control unit, converting fluid conditions into electrical signals. This intermediary enables accurate sensing and transmission of pressure/flow rate information, bridging the gap between mechanical control and electronic control for improved precision
2Measurement precision
If compressor suction valve is fully closed to control pressure, then pressure control is achieved, but noise and vibration occur due to excessive suction pressure control
Solution Approach 1:
Instead of fully closing the suction valve, the system applies partial action by keeping it slightly open. The control valve and pressure control valve work together to achieve the desired pressure control with the suction valve partially open, preventing excessive suction pressure control that causes noise and vibration while maintaining effective pressure regulation
Solution Approach 2:
The fluid condition transmission unit continuously monitors the fluid condition and converts it to an electrical signal that feeds back to the control unit. This feedback mechanism allows the system to adjust the control valve and pressure control valve in real-time, maintaining optimal suction valve opening that prevents noise and vibration while achieving accurate pressure control
3Reliability
If load-unload driving method is used, then pressure control in tank is achieved, but energy loss is high due to frequent control when load ratio is low
Solution Approach 1:
The control valve maintains continuous operation to regulate fluid supply to the pistons, enabling continuous compression operation. This continuous useful action eliminates the frequent start-stop cycles of load-unload driving, maintaining pressure control reliability while significantly reducing energy loss during low load ratio conditions
Solution Approach 2:
The system dynamically adjusts the opening degree of the control valve and pressure control valve based on real-time fluid condition feedback. This dynamic adjustment allows the compressor to operate efficiently across varying load conditions, maintaining pressure control while optimizing energy consumption and avoiding the energy losses associated with frequent load-unload cycling
4Loss of energy
If inverter control method is used, then energy saving effects are achieved when load ratio is low, but maintenance and repair costs are high
Solution Approach 1:
The system uses pneumatic control through the control valve and pressure control valve to regulate compression operation. This pneumatic control approach achieves energy saving effects similar to inverter control at low load ratios while avoiding the complex electronics and high maintenance costs associated with inverter systems, providing a more reliable and cost-effective solution
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 solution allows for accurate and uniform control of compressor pressure or flow rate, reducing noise and vibration while achieving energy savings by preventing the compressor suction valve from being fully closed, thus improving operational efficiency and reducing energy consumption.
Implementation Method 1
a fluid condition transmission unit which detects fluid condition (pressure or flow rate) at a rear end of a compressor, and converts the detected fluid condition value to an electrical signal
Implementation Method 2
a pressure control valve which supplies fluid to operate the second piston to an area above the second piston
Implementation Method 3
a control valve which supplies fluid to operate the first piston to an area above the first piston, and supplies fluid to the pressure control valve
Implementation Method 4
a cylinder including a first piston and a second piston therein
Data Source
AI summary
The present disclosure relates to a compressor control system that detects the pressure (or flow rate) at the rear end of a compressor and performs proportional control in mechanical manner to uniformly control the pressure (or flow rate) of the compressor while preventing a compressor suction valve from being fully closed. To this end, the present disclosure includes a cylinder including a first piston and a second piston therein, a pressure control valve which supplies fluid to operate the second piston to an area above the second piston, a control valve which supplies fluid to operate the first piston to an area above the first piston, and supplies fluid to the pressure control valve, a fluid condition transmission unit which detects fluid condition (pressure or flow rate) at a rear end of a compressor, and converts the detected fluid condition value to an electrical signal and outputs it.