CN208778228U - A kind of large scale industry air compressor pressure adjusting optimizing redundancy system - Google Patents
A kind of large scale industry air compressor pressure adjusting optimizing redundancy system Download PDFInfo
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- CN208778228U CN208778228U CN201821616854.2U CN201821616854U CN208778228U CN 208778228 U CN208778228 U CN 208778228U CN 201821616854 U CN201821616854 U CN 201821616854U CN 208778228 U CN208778228 U CN 208778228U
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Abstract
The utility model provides a kind of large scale industry air compressor pressure adjusting optimizing redundancy system, including pneumatic actuating element, air compressor, DCS control unit and motorized adjustment unit；Motorized adjustment unit is series in the air pipeline of pneumatic actuating element；DCS control unit control pneumatic actuating element and motorized adjustment unit individually adjust or common adjusting.Large scale industry provided by the utility model adjusts optimizing redundancy system with air compressor pressure, provides the pressure regulative mode of two kinds of mutual backup for air compressor, improves the reliability of air compressor；Pneumoelectric mixing is adjusted by DCS control unit and carries out smooth control with pneumatically adjusting switching, improves the anti-interference ability of whole system, guarantees steady, normal operation of the air presses in mode handover procedure.
Description
Technical field
The utility model relates to air compressor pressures to adjust field, in particular to a kind of large scale industry air compressor
Pressure adjusts optimizing redundancy system.
Background technique
Screw air compressor is a kind of equipment to compressed gas.Most of large scale industry productions are equipped with now
Distributed Control System (abbreviation DCS).DCS system is based on microprocessor, using control function dispersion, display operation collection
In, take into account point and the blind controller system of autonomous and comprehensive coordination design principle.
The screw air compressor in industrial premises still uses simple suction modulation formula air compressor, pressure mostly at present
It is still more extensive mechanical-pneumatic regulating system that power adjusts control mode mostly, and adjustable extent is narrow, and regulated variable is
Suction port of compressor inspiratory capacity, control power are the pressure in gs-oil separator without cooling driers processing containing a large amount of oils, moisture
Contracting air, this leads to each pneumatic control components frequent jams and corrosion, and causing air compressor to go out, fluctuation is big, frequently adds unloading
It is even unable to operate normally, pneumatic control components are also one of main consumption source of annual air compressor maintenance cost, are reduced
The reliability and economy of air compressor.
Electronic adjustment system can preferably substitute mechanical-pneumatic regulating system, increase adjustable range, possess gear on worm
The electric control valve of case can preferably guarantee that the accurate and smooth closed loop of positioning is adjusted, and the wave of quick response system pressure
It is dynamic, keep the liftings such as air compressor exhaust, oil temperature, electric current smooth, reduce the abrasion of mechanical part and motor part, improves air
The economy of compressor.But the air compressor for having electronic adjustment system needs complete machine to replace, complete machine design in advance regulated variable,
Instruction and feedback etc. are converted into electric signal input air compressor controller and participate in PID logic operation to form closed loop
Control, in the case where air compressor motor and capability of engineering equipment still safeguard preferable situation, cost waste is larger.And in practical life
During production, air compressor working environment high temperature and humidity, the continuous production time is longer, even if reliability is again under these conditions
High Local Controller and built-in electric controller, cannot guarantee that failure rate is zero, these all make the reliable of air compressor
Property reduce.
Utility model content
To solve the problems, such as to mention in above-mentioned background technique, the utility model provides a kind of large scale industry air compressor
Pressure adjusts optimizing redundancy system, including pneumatic actuating element and air compressor, DCS control unit and motorized adjustment unit；
The motorized adjustment unit is series in the air pipeline of the pneumatic actuating element；The DCS control unit control
It makes the pneumatic actuating element and motorized adjustment unit individually adjusts or common adjusting.
Further, the motorized adjustment unit is electric control valve and its feedback mechanism.
It further, further include information acquisition unit；Information acquisition unit and DCS control unit communication connection；The letter
Cease the operating state signal of acquisition unit acquisition air compressor.
It further, further include isolated location；The isolated location be connected to pneumatic actuating element and catch pot it
Between；The isolated location includes manual isolation valve and distant place automatic isolating valve on the spot；The distant place automatic isolating valve and DCS is controlled
Unit communications processed；The isolated location is for switching shaping modes.
Large scale industry provided by the utility model adjusts optimizing redundancy system, main regulative mode with air compressor pressure
For pneumoelectric mixing adjustable type；When DCS control unit judges the system failure by the signal and preset condition of acquisition, report is issued
Alert signal, and mix to adjust pneumoelectric automatically by DCS control unit and be switched to pneumatic adjusting, or in air compressor hand on the spot
It is dynamic to switch to pneumatic adjusting；The dual controller used with the pneumatic design for adjusting mutual backup and DCS is adjusted by pneumoelectric mixing
Redundant configuration, improve the reliability of air compressor；Pneumoelectric mixing is adjusted by DCS control unit simultaneously and is adjusted with pneumatic
Section switching carries out smooth control, and presets several accident pretreatment logics, improves the anti-interference ability of whole system, guarantees empty
Steady, normal operation of the aerostatic press in mode handover procedure.
Detailed description of the invention
In order to illustrate the embodiment of the utility model or the technical proposal in the existing technology more clearly, below will be to embodiment
Or attached drawing needed to be used in the description of the prior art is briefly described, it should be apparent that, the accompanying drawings in the following description is
Some embodiments of the utility model, for those of ordinary skill in the art, without creative efforts,
It is also possible to obtain other drawings based on these drawings.
Fig. 1 is that large scale industry air compressor pressure provided by the utility model adjusts the signal of optimizing redundancy system structure
Figure；
Fig. 2 is pneumatic control valve structural schematic diagram；
Fig. 3 is the composition block diagram that large scale industry air compressor pressure adjusts optimizing redundancy system；
Fig. 4 is that pneumoelectric mixing adjusts Booting sequence figure；
Fig. 5 is pneumatic adjusting Booting sequence figure；
Fig. 6 is the flow chart of pneumoelectric mixing shaping modes；
Fig. 7 is after adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Continuous operation 2 minutes air compressor electric currents and system pressure tendency chart after air compressor starting；
Fig. 8 is before adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Continuous operation 2 minutes air compressor electric currents and system pressure tendency chart after air compressor starting；
Fig. 9 is after adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Continuous operation 60 minutes air compressor electric currents and system pressure tendency chart after air compressor starting；
Figure 10 is before adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Air compressor starting after continuous operation 60 minutes air compressor electric currents and system pressure tendency chart；
Figure 11 is after adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Air compressor starting after continuous operation 2 days air compressor electric currents and system pressure tendency chart；
Figure 12 is before adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Air compressor starting after continuous operation 2 days air compressor electric currents and system pressure tendency chart；
Figure 13 is after adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Air compressor starting after continuous operation 1 day air compressor electric current and system pressure tendency chart；
Figure 14 is same production area, using 1 day air of screw air compressor continuous operation of mechanical adjustment mode
Compressor current and system pressure tendency chart；
Figure 15 is same production area, using 1 day air of screw air compressor continuous operation of mechanical adjustment mode
Compressor current tendency chart.
Appended drawing reference:
101 pressure transmitter of 20DCS control unit, 102 current transducer
301 pneumatic control valves 302, which hold, adjusts 303 first solenoid valve of valve
304 second solenoid valves 305 load 306 first reciprocable valve of air accumulator
307 second reciprocable valve, 308 electric control valve, 401 manual isolation valve
The pneumatic reset spring of 402 automatic isolating valve, 3011 pneumatic control valve position cylinder 3012
3013 pneumatic regulating butterfly valves
Specific embodiment
It is practical new below in conjunction with this to keep the objectives, technical solutions, and advantages of the embodiments of the present invention clearer
Attached drawing in type embodiment, the technical scheme in the utility model embodiment is clearly and completely described, it is clear that is retouched
The embodiment stated is the utility model a part of the embodiment, instead of all the embodiments.Based on the implementation in the utility model
Example, every other embodiment obtained by those of ordinary skill in the art without making creative efforts belong to
The range of the utility model protection.
In the description of the present invention, it should be noted that term " center ", " longitudinal direction ", " transverse direction ", "upper", "lower",
The orientation or positional relationship of the instructions such as "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outside" is
It is based on the orientation or positional relationship shown in the drawings, is merely for convenience of describing the present invention and simplifying the description, rather than indicate
Or imply that signified device or element must have a particular orientation, be constructed and operated in a specific orientation, therefore cannot understand
For limitations of the present invention.In addition, term " first ", " second " and similar word are used for description purposes only, without
It can be interpreted as indication or suggestion relative importance." connection " either similar word such as " connected " and non-limiting with physics or machinery
Connection, but may include electrical connection, light connects etc., it is either direct or indirectly.
The utility model provides a kind of large scale industry air compressor pressure adjusting optimizing redundancy system, including information is adopted
Collect unit, DCS control unit 20, pneumatic actuating element, motorized adjustment unit and isolated location；
The DCS control unit 20 respectively with information acquisition unit, motorized adjustment unit and isolated location communication connection；Institute
State the operating status of information acquisition unit acquisition air compressor；The pneumatic actuating element and motorized adjustment unit and air pressure
The connection of contracting machine；The isolated location is connect with pneumatic actuating element；
The pneumatic actuating element and the motorized adjustment unit individually adjust or common adjusting；The isolated location
Switch for shaping modes.Automatically controlled by manual or DCS control unit carry out pneumatic shaping modes, motorized adjustment mode or
The switching of pneumoelectric mixed mode；Main regulative mode is pneumoelectric mixing shaping modes；When pneumoelectric, which mixes, adjusts failure, open
It takes offence dynamic shaping modes, guarantees the normal operation of air compressor.
Large scale industry provided by the utility model adjusts optimizing redundancy system, main regulative mode with air compressor pressure
For pneumoelectric mixing adjustable type；Pass through information acquisition unit acquisition system operating status；When information acquisition unit collects system event
When barrier, pneumoelectric is mixed automatically by adjusting by manual or DCS control unit and is switched to pneumatic adjusting, passes through spare pneumatic tune
Section, guarantees the normal operation of air compressor.
Preferably, the pneumatic actuating element includes pneumatic control valve 301, holds and adjust valve 302, the first solenoid valve 303, second
Solenoid valve 304, load air accumulator 305, the first reciprocable valve 306, the second reciprocable valve 307；
Described first reciprocable valve, 306 one end is connect with the pneumatic control valve 301；First reciprocable valve, 306 other end
It is divided into two-way, is connect all the way by second solenoid valve 304 with the air compressor output end, another way and the second reciprocable valve
The connection of 307 one end；Second reciprocable valve, 307 other end adjusts 302 one end of valve to connect with 303 one end of the first solenoid valve and appearance；Institute
State 303 other end of the first solenoid valve by load air accumulator 305 and holding adjust 302 other end of valve and manual isolation valve 401 and
Automatic isolating valve 402 connects.
Preferably, the pneumatic control valve 301 is gentle including pneumatic control valve position cylinder 3011, pneumatic reset spring 3012
Dynamic regulating butterfly valve 3012；Pneumatic control valve position cylinder 3011 is connect with first reciprocable valve 306；The pneumatic adjusting butterfly
Valve 3012 is connect by pneumatic reset spring 3012 with pneumatic control valve position cylinder 3011.
It preferably, further include isolated location；The isolated location is connected between pneumatic actuating element and catch pot；
The isolated location includes manual isolation valve and distant place automatic isolating valve on the spot；The distant place automatic isolating valve and DCS controls
Unit communications；The isolated location is for switching shaping modes.
Preferably, the isolated location includes manual isolation valve 401 and automatism isolation solenoid valve 402；The pneumatic adjusting
Unit passes through manual isolation valve 401 and automatism isolation solenoid valve 402 respectively and connect with system compresses air outlet side.
Under pneumoelectric mixing shaping modes, holds and adjust the air inlet source of valve 302 by manual isolation valve 401 or automatic isolating valve
402 isolation；The regulatory function of pneumatic actuating element is isolated, and is retained it and changed up pass function fastly.To guarantee air compressor
The function of rapidly switching off is realized in the needs and unloading and stopping process of quick load up when starting, prevents compressor
The failure of intake valve oil spout.
It includes fast pneumatic startup stage and low-speed electric adjusted stage that pneumoelectric mixing, which is adjusted, is acquired in the two session informations single
Member sends the electric signal of equipment state, current of electric and system pressure on the spot, information acquisition unit to DCS control unit in real time
Acquire and the electric signal that sends include: air compressor load signal, unloader signal, electric control valve state and valve position signal,
Air compressor motor real-time current value Di, air compressor be vented real-time pressure value P1；In the step, by DCS control unit control
The electronic adjustment system of system is that exit pressure for air compressor and Electric Actuator valve position feedback are established and optimized by test
Aperture/pressure function curve, the pressure built in DCS system/aperture PI D operational loop realize precise positioning and smooth
Closed loop adjust, keep the liftings such as air compressor exhaust, oil temperature, electric current smooth, reduction mechanical part and motor part abrasion,
Improve the economy of air compressor；Meanwhile DCS control unit working environment constant temperature and humidity is with favourable conditions, has unperturbed redundancy
Function, being effectively ensured can run without interruption to the control section of electronic adjustment system, final to guarantee that air compressor be safer
While reliability service, there is better economy.The utility model can modular applications to most of helical-lobe compressor.
Preferably, the motorized adjustment unit is electric control valve 308 and its feedback mechanism.
When it is implemented, motorized adjustment unit includes electric control valve 308 and its feedback mechanism；Feedback mechanism is electric adjustable
Save the mechanism that the operating statuses such as aperture, failure are fed back on valve 308, such as circuit.
A kind of large scale industry air compressor pressure adjusting optimization method, the pneumatic actuating element and the electric adjustable
The method and step that section unit is adjusted jointly is as follows:
S10, starting air compressor；Bypass pneumatic regulating loop；In the step, air compressor machine regulative mode is switched to
" distant place DCS control mode "；Bypass pneumatic regulating loop；Start air compressor.More specifically, in local operation panel
On, the shaping modes of air compressor are switched to distant place DCS shaping modes, isolation solenoid valve 402 is closed at this time, is disconnected with regard to ground vapour
The compressed gas source of dynamic regulating loop, bypasses pneumatic regulating loop；Start air compressor；In the step, the utility model is mentioned
The regulating system of confession can be grafted in existing air compressor regulating system, the adjusting of air compressor by all means, because using this
The mode of sample grafting can save a large amount of cost, and can be by the original all intact guarantors of protection of air compressor
It stays, protection part is also controlled by single-chip microcontroller on the spot, and the system newly grafted controls the adjusting of air compressor.
Because air compressor is equipment that is a set of while possessing multiple systems.It is safer by using the mode of this grafting, can
It leans on, is reduced as far as possible because of the uncertainty that transformation introduces.
S20, DCS control unit acquire the run signal of air compressor by information acquisition unit；
S30, information acquisition unit give collected run signal to DCS control unit；
If DCS control unit receives the normal enabling signal of air compressor, motorized adjustment unit matching gas is controlled
The dynamic unit that adjusts carries out fast pneumatic starting；
If DCS control unit receives fault-signal, DCS control unit issues the 4th default valve seat opening and keeps signal
To motorized adjustment unit；By T3Second sends open signal to isolated location；Using T4It in 8 stages of second point, successively sends
25%, 35%, 45%, 55%, 65%, 75%, 85%, 100% 60 seconds aperture pulse signals are to motorized adjustment unit；Make
Air compressor realizes that pneumoelectric shaping modes are converted to pneumatic shaping modes in operation；In the step, in T4It is repeatedly sent out in second
The regulating power for sending aperture pulse signal to allow for Rong Tiaofa to motorized adjustment unit is limited, and holds and adjust valve from receiving disturbance
Start to adjust until the time of balance is long, in order to avoid electrically operated valve unlatching is too fast, the adjusting of Rong Tiaofa is not caught up with, because
Electric control valve is opened too fast, and the oscillation of caused regulating system, toning or less stress are excessive, so cause air compressor unload or
The failures such as thermocouple action protection shutdown.10% is only opened every time, this aperture is held and adjusts valve that excessive excessive adjusting vibration will not occur
It swings, achievees the effect that balance can be reached in 1 minute.
After S40, fast pneumatic starting, DCS control unit controls motorized adjustment unit and carries out low-speed electric adjusted, realizes air pressure
Contracting machine pressure adjusts optimization.
Large scale industry provided by the utility model adjusts optimization method with air compressor pressure, by adjusting list pneumatic
Structure in the grafting of series connection motorized adjustment unit, is retaining the same of that original set pneumatic regulation system of air compressor in member
When, increase motorized adjustment mode, electric control valve and pneumatic control valve be on pipeline it is existing in series, such as Fig. 1
It is shown, it is not added with before electric control valve, is one section of straight-through pipeline between pneumatic control valve and air filter.Pass through series connection
Structure design, farthest reduce the change to original mechanical part and regulative mode, and remain air-breathing part
The function of pneumatic quick closing valve adjust air compressor can not only by newly-increased electric control valve precisely, moreover it is possible to fast when shutting down
Speed closing admission line, avoids oil-spraying；The increase of new variable is reduced, caused by avoiding dependent variable to increase as far as possible not
The problem of certainty increases, and the systematization reliability avoided as far as possible reduces；
In addition, there is no since electric control valve is the suction pipe connected into original pneumatic control valve with side in parallel
Formula newly increases independent admission line all the way, so electric control valve will be in view of to original pneumatic control valve during putting into operation
Control, so electric control valve participate in control mode be called pneumoelectric mixing adjust, therefore need to carry out fast pneumatic starting with
And low-speed electric adjusted.
Also, the Industry Control in building surface in big industrial factory mostly uses greatly DCS scattered control system, such most of system are all
A considerable number of controller memory and I/0 fastener etc. are reserved, the utility model can utilize these idle resources, will newly increase
Regulating system graft in old control system, required DCS resource only accounts for very small percentage in total resources, just
Ground equipment need to only increase the electric current, pressure sensor of an electric control valve, connecting flange and corresponding output analog quantity, use
Financial charges are few, and it is wide can to apply range.
Preferably, the method and step that fast pneumatic starts in the step S30 is as follows:
If DCS control unit receives the normal enabling signal of air compressor, and the current of electric D of air compressori
When more than or equal to the first current setting value, DCS control unit controls pneumatic actuating element standard-sized sheet, then exports T1Second first is default
The pulse signal of valve seat opening gives motorized adjustment unit；Make compressed air pressure at expulsion after actuation in T5In interior quick and stable
It rises, reaches rated discharge pressure.
Preferably, the method and step of the low-speed electric adjusted in the step S40 is as follows:
S41, DCS control unit are filtered collected compressed air exhaust real value；
After S42, DCS control unit judge air compressor load starting, be delayed T2The motor of second judgement air compressor
Electric current DiThe real value P of size and the pressure at expulsion of air compressor1Size；
If DiLess than third current setting value, and P1When less than first pressure setting value；Then enter S43；
If DiGreater than third current setting value, and P1When greater than first pressure setting value；Then DCS control unit is by PID arithmetic
Result bypass is exported, the second default valve seat opening of output, which instructs, gives motorized adjustment unit, keeps motorized adjustment unit holding second pre-
If valve seat opening is until DiAnd P 10A smaller than third setting electric current threshold value1It is 15Kpa smaller than first pressure setting value；
S43, DCS control unit judge the real value P of the pressure at expulsion of air compressor1Whether in exhaust target pressure value
P2In range；
If P1Beyond P2± 5Kpa range, then enter step S44；
If P1In P2Within the scope of ± 5Kpa, then DCS control unit issues opening degree instruction to motorized adjustment unit and keeps current value
Signal, until P1Beyond P2± 5Kpa range；
S44, DCS control unit, which calculate, to be needed to export to the opening degree instruction out of motorized adjustment unit, until P1In setting
P2When ± 5Kpa range, return step S43.
Preferably, the method that the pneumatic actuating element and the motorized adjustment unit are adjusted jointly further include:
If the current of electric D of S51, air compressoriIt decrease beyond the 4th current setting value of setting extremely in 1 second,
And the real value P of the pressure at expulsion of air compressor1When exception is increased beyond second pressure setting value and is more than 1 second, then DCS control
PID arithmetic output result bypass is issued alarm signal and exports the default valve bit instruction of third and give motorized adjustment unit by unit,
Electric current bust valve position is retracted；Until the real value P of the pressure at expulsion of air compressor1Target pressure is vented less than air compressor
The setting value P of power28Kpa-12Kpa；
If needing manual switching shaping modes when S52, DCS control unit, information acquisition unit, electric control valve failure,
Motorized adjustment unit is powered off manually and is slowly shaken to fully open position.In the step, if there is information acquisition unit, motorized adjustment
Situations such as valve failure, operations staff can open manual isolation valve 401 manually, put into the pneumatic regulating loop of air compressor, and
Stage by stage gradually hand opening electric control valve to full-gear.It solves to control power supply, motorized adjustment because of DCS controller, DCS
The equipment faults such as valve, feedback mechanism, electric current, pressure transmitter cause pneumoelectric shaping modes not put into normally.
Specifically, fast pneumatic startup stage and low-speed electric adjusted stage are specific as follows:
The control method of first stage, fast pneumatic startup stage is specific as follows:
After the start button on the spot for pressing air compressor, pneumatic control valve keeps closed positions constant, air compressor
Star-like circuit connect, drag air compressor Low loading start up, delay 5 seconds after air compressor motor switched to by star-like circuit
The operation of triangular form circuit, while single-chip microcontroller will load signal teletransmission to DCS control unit on the spot, finger is opened in the output of DCS control unit
It enables, obtains 303 coil of the first solenoid valve electric, pneumatic control valve position cylinder 3011 and atmosphere are connected, pneumatic control valve position cylinder is made
3011 lose gas, keep full-gear under the action of pneumatic reset spring 3012.When DCS control unit receives monolithic on the spot simultaneously
The load signal that machine provides, with air compressor motor real-time current value DiWhen signal more than or equal to 50 amperes, DCS control
Unit judges air compressor low-load starts successfully, opens to 5 seconds the first default valve positions of electric butterfly valve of electric control valve 308
The load pulses of degree instruct, and guarantee that air compressor unit quick and stable rising can reach specified row in the 5-11 second after actuation
Atmospheric pressure.The regulated variable of motorized adjustment unit is all pressure as pneumatic actuating element, is all by adjusting compressor air suction
The aperture of mouth to adjust inspiratory capacity, and then adjusts the capacity of air compressor (due to the bad prison of air compressor capacity
It surveys, second Conversion is needed for adjusting, therefore when the utility model progress pressure adjusting, it is all to replace capacity with pressure.)
Second stage low-speed electric adjusted stage, low-speed electric adjusted stage include filtering, inter-cell signal excision, high current high load capacity
The control strategies such as delay lock, PID arithmetic circuit；
Low-speed electric adjusted stage control when normal operation:
The first step has used the control strategy of filtering, and DCS control unit is in real time according to formula:
Wherein: Y is to export after DCS control unit filters to the real-time pressure signal on the spot in PID arithmetic circuit； YLFor DCS
The filtered output result of filtering operation module previous moment in control unit；S2For filtering operation module in DCS control unit
In can customize time constant (second, such as 2 seconds)；S1For the real value of the pressure at expulsion of air compressor；dtIt is controlled for DCS single
It is integrated this moment with the time span of previous moment during filtering operation module arithmetic in member.
By the control strategy of filtering, regulated variable air compressor is vented real-time pressure value P1It is filtered, subtracts
Small interference signal must interfere true value.
The control strategy of high current high load delay lock is utilized in second step, is that DCS control unit is judging air
After compressor low-load starts successfully, be delayed 6 seconds judgement air compressor electric current DiWhether the second setting electric current value is greater than, simultaneously
Air compressor is vented real-time pressure value P1Whether it is greater than first pressure setting value, is otherwise directly entered third step；
It is that DCS control unit exports the second default valve seat opening and instructs to electric control valve 308, makes electric control valve
308 keep this aperture until air compressor motor electric current DiLess than third setting electric current value 10A and air compressor is vented in fact
When pressure value P1Second step is transferred to when less than first pressure setting value 15KPa；
The control strategy that third step has used inter-cell signal to cut off, in the step, DCS control unit first determine whether be
It is no within the scope of pressure set points P2 ± 5KPa, otherwise enter four steps；
It is that then DCS control unit issues the opening degree instruction for keeping current value to electric control valve 308, until exceeding setting value
Third step is transferred to when ± 5KPa range；
Four steps has used PID arithmetic, and in four steps, DCS control unit is in real time according to formula:
Wherein: S is the time coefficient of calculating；KPFor proportional gain factor；K is gain multiplier；KIIt is (every for integral coefficient
Minute)；KDFor differential coefficient (per minute)；KAFor differential lag coefficient；SP is that PID arithmetic circuit is set in DCS control unit
Definite value, out represent the output result of PI D operational loop.Such as the parameter for an air compressor being transformed are as follows: K=
0.02, KP=1, KI=200, KD=0, KA=10, SP are arranged between 785Kpa-790Kpa.It calculates and needs to export to electronic
The opening degree instruction of regulating valve, until exceeding setting value P2When within the scope of ± 5Kpa, third step is gone back to.In the step, pass through reality
It is verified with the numerous experiments of novel people, P2Range in ± 5Kpa, which belongs in system, normally to be fluctuated, and is not really to disturb.
P2The design of ± 5Kpa is in order that economize on resources, although adjusting excessively, frequently system may be more stable, to electric control valve
Requirement it is very high, cost is very expensive.
Control method and low-speed electric adjusted stage in fast pneumatic startup stage, when pneumoelectric mixing, which is adjusted, encounters failure,
Emergency processing control is carried out using following three kinds of methods: first is that electric current bust valve position retracts；Second is that failure automatic interlock；Third is that
DCS Redundant Control.
(1), electric current bust valve position haul-back control method is specific as follows:
When DCS control unit receives the air compressor motor electric current D that information acquisition unit is sentiIn 1 second suddenly
It is decrease beyond the 4th current setting value 20A, while air compressor is vented real-time pressure value P1Higher than second pressure setting value
810Kpa is more than 1 second, then DCS control unit judges stand-by compressor (the production pressure in building surface in big industrial factory now on the spot
The air compressor device of contracting air is mostly more air compressors while accessing compressed air system, when normal operation, one
Platform air compressor operation, remaining air compressor do it is spare, only when the air compressor failure of operation or system disturbance are very big
When, interlocked startup stand-by compressor does not influence to do power source using compressed air in production to guarantee that system pressure is stablized
Relevant device.) started automatically, the bypass PID arithmetic logic operation result in DCS control unit exports out, gives electric adjustable
The opening degree instruction that valve 308 issues 6% is saved, after leading to standby host error starting due to standby host failure, active and standby air compressor is same
Shi Yunhang causes system pressure excessively high, increases power consumption and load fluctuates widely, and influences system safety.And issue alarm signal
Prompt collection control operations staff's stand-by compressor starts automatically, prompting operations staff to site inspection failure cause, according to
The on-demand fault of stop air compressor of actual conditions guarantees that system pressure is steady and economy.When DCS control unit detects letter
The air compressor exhaust real-time pressure value P that breath acquisition unit is sent1Target pressure value P is vented lower than air compressor210kPa
When, the PID arithmetic logic operation result output out in DCS control unit again controls the aperture of electric control valve 308
System.
(2), failure automatic interlock control method is specific as follows:
When DCS control unit receives the fault-signal of information acquisition unit sending, the transmission of DCS control unit is maintained at the
Opening degree instruction on four default valve positions is to electric control valve 308, and being delayed 5 seconds, it is automatic to air compressor to send switching value electric signal
Isolating valve 402 obtains automatic isolating valve 402 electric, and the appearance tune valve 302 in suction modulation execution unit is made to receive to carry out air compressor
Compressed air, make hold adjust valve 302 start to control pneumatic control valve, delay 60 seconds to electric control valve 308 send 8 times
60 incremental second pulse signals of aperture successively send 25%, 35%, 45%, 55%, 65%, 75%, 85%, 100% aperture
Pulse command.Air compressor is set to realize automatic switchover of the pneumoelectric shaping modes to pneumatic shaping modes in operation.Information is adopted
Collection unit issue fault-signal include: air compressor pressure at expulsion transmitter bad value signal, electric control valve fault-signal,
Or DCS control unit exports and is greater than to the opening degree instruction signal of electric control valve and the valve position feedback deviation of signal of electric control valve
30% or current transducer bad value signal.
Under pneumatic shaping modes, air compressor is vented real-time pressure value P1By the aperture of pneumatic regulating butterfly valve 3012
Control, the aperture of pneumatic regulating butterfly valve 3012 is by the appearance tune valve 302 and pneumatic reset spring 3012 in suction modulation execution unit
Co- controlling.
(3), DCS Redundant Control: the power supply and controller of DCS control unit are all made of dual redundant configuration, and two superfluous each other
Remaining power supply is controller power supply, a main preparation controller operation simultaneously and synchronous operation simultaneously, while to on-site signal and being set
It is standby to be monitored and controlled, when master controller breaks down, submaster controller adapter tube control at once, it is ensured that DCS control unit
Monitoring and control to equipment on the spot is uninterrupted, improves field device reliability and continuity.
The utility model also provides the control method of pneumatic regulating butterfly valve aperture, and steps are as follows for specific method:
Air compressor is vented real-time pressure value P1When greater than holding the preset pressure for adjusting valve 302, hold the adjusting for adjusting valve 302
Pressure just works, and system discharge pressure is higher at this time, adjusts the control pressure of the output of valve 302 higher by holding, supply cylinder
The pressure of diaphragm is higher, overcomes the ability for the resistance for closing pneumatic reset spring 3012 to get over by pneumatic control valve position cylinder 3011
Greatly, for the aperture of pneumatic regulating butterfly valve 3013 with regard to smaller, the inspiratory capacity of air compressor is also just smaller；Otherwise system discharge pressure is got over
Low, lower by holding the control pressure for adjusting valve 302 to export, the pressure of supply cylinder diaphragm is lower, passes through pneumatic control valve
Position cylinder 3011 overcomes the ability of the resistance of pneumatic reset spring 3012 with regard to smaller, and the aperture of pneumatic regulating butterfly valve 3013 is bigger,
Make the air demand of air compressor and air consumption keep balancing, realizes the function that tolerance is adjusted.
To examine large scale industry air compressor pressure provided by the utility model to adjust optimizing redundancy method in reality
In application, to use large scale industry provided by the utility model with air compressor pressure adjust optimizing redundancy system into
Row air compressor electric current and system pressure test；It is carried out pair with existing large scale industry with air compressor pressure regulating system
Than test；And use ABB Baily Symphony system testing air compressor electric current and system pressure；In the above test macro
Compressor is all made of screw air compressor；Test result such as Fig. 7, Fig. 8, Fig. 9, Figure 10, Figure 11, Figure 12, Figure 13, Figure 14, figure
Shown in 15；In figure, I is air compressor electric current, and F is system pressure.
Fig. 7 is after adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Continuous operation 2 minutes air compressor electric currents and system pressure tendency chart after air compressor starting；
Fig. 8 is before adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Continuous operation 2 minutes air compressor electric currents and system pressure tendency chart after air compressor starting；
Fig. 9 is after adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Continuous operation 60 minutes air compressor electric currents and system pressure tendency chart after air compressor starting；
Figure 10 is before adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Air compressor starting after continuous operation 60 minutes air compressor electric currents and system pressure tendency chart；
Figure 11 is after adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Air compressor starting after continuous operation 2 days air compressor electric currents and system pressure tendency chart；
Figure 12 is before adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Air compressor starting after continuous operation 2 days air compressor electric currents and system pressure tendency chart；
Figure 13 is after adjusting optimizing redundancy method using large scale industry air compressor pressure provided by the utility model
Air compressor starting after continuous operation 1 day air compressor electric current and system pressure tendency chart；
Figure 14 is same production area, using 1 day air of screw air compressor continuous operation of mechanical adjustment mode
Compressor assembly pressure trend figure；
Figure 15 is same production area, using 1 day air of screw air compressor continuous operation of mechanical adjustment mode
Compressor current tendency chart；
In above-mentioned air compressor electric current, voltage tendency chart, abscissa indicates that time shaft, ordinate indicate air compressor
Current value and system pressure value；
According to Fig. 7, Fig. 8, Fig. 9, Figure 10 it is found that the trend from 2 minutes and 1 hour compares come from, it is practical to use this
The large scale industry of novel offer air compressor pressure adjusts the air compressor of optimizing redundancy method in start-up course electric current
Change it is smoother slowly starting peak point current is smaller, while reducing the disturbance of the process for system pressure of start-up loading.
According to Figure 11, Figure 12, the trend of comparison two days, display uses large scale industry provided by the utility model
It is significantly improved with the ability that air compressor pressure adjusts the anti-system disturbance of air compressor of optimizing redundancy method, abatement disturbance
Time shorten, influence of the adjustment process to system pressure be greatly reduced.Simultaneously because using the air pressure of new regulating system
The adjustable range of contracting machine it is wider more precisely, can by the way that the pressure at expulsion of air compressor is reasonably reduced in rated load,
Making the running current of air compressor reduces, and while needing air compressor satisfaction production, avoids producing gas excess, and then produce
Raw energy-efficient effect.
According to Figure 13, Figure 14, Figure 15, from the screw air compressor for using this technology and existing machinery tune is used
The 1 day trend of screw air compressor of section mode compares to observe, and adjusts pressure using the screw air compressor of this technology
Continuity be much better than the screw air compressor using other mechanical adjustment modes, avoid air compressor from making because of frequent start-stop
At mechanical part abrasion, electric current and system pressure also more smooth steady, in terms of influence of the adjustment process to system pressure,
Had using the screw air compressor of this technology with the obvious advantage.
By comparative analysis as above it is found that using large scale industry provided by the utility model air compressor pressure tune
Optimizing redundancy method, adjustment precision are saved, it is strong to run continuity for high reliablity；Air compressor start-up course curent change more
It is smooth slow, reduce the disturbance of the process for system pressure of start-up loading；Also, the ability of the anti-system disturbance of whole system
It is significantly improved, the time for cutting down disturbance shortens, and reduces the influence in adjustment process to system pressure.
Above-mentioned large scale industry is adjusted in optimizing redundancy method with air compressor pressure:
1. first pressure setting value: air compressor sets pressure P1+50%, and (air compressor overload protection pressure is fixed
Value-air compressor setting pressure P1).For example, air compressor overload protection pressure set points are 860Kpa, air compression
Machine sets pressure P1 as 790Kpa, then first pressure setting value should be 825Kpa.
2. second pressure setting value: the setting pressure P1+20Kpa of air compressor, for example, if the setting of air compressor
Pressure P1 is 790Kpa, then second pressure setting value can be 810Kpa.
3. the first current setting value: judging one of the condition that air compressor motor has rotated, should be less than air compressor
Electric current when motor star-like mode of connection rotation, for example, rotating electric current under air compressor star-connection mode is 100A, then the
One current setting value is 50A.
4. the second current setting value: minimum current value when separate unit air compressor is with rated load, for example, air compresses
Minimum current when machine is with rated load operation is 295-300A.
5. third current setting value: less than air compressor thermocouple protection act value 10A, such as the heat of air compressor in text
Even protection act value is 360A, then third current setting value should be 350A.
6. the 4th current setting value: the collected current value of DCS decrease beyond 20A in 1 second, such as air compressor in text
The current value that a scan period acquires in DCS control unit is 320A, then the 4th current setting value this moment should be 310A.
7. the first default valve position: under pneumatic control valve full-gear, the minimum pressure in outlet can be reached after light-load starting, in 5 seconds
The motor-driven valve minimum aperture of power valve setting valve, if the first default valve position of air compressor in text is 10%-18%.
8. the second default valve position: the setting value of air compressor overload in order to prevent, by under rated load, making separate unit air
The maximum opening that Compressor Discharge Pressure no longer improves, if the second default valve position of air compressor in text is 8%-17%.
9. third presets valve position: accidentally closing associated compression air pipeline or dedicated air compression due to operations staff for avoiding
Chance error starting causes running air compressor pressure to adjust concussion or rob load, it is arranged side by side to be set as two air compressors
When operation, guarantee that system pressure does not decline, and the aperture of 10Kpa is risen above in 1 minute.Such as air compressor in text
Third preset valve position be 6%-10%.
10. the 4th default valve position: for when occur current transducer bad value signal, back pressure transducer bad value signal,
DCS control unit is exported to be greater than to the opening degree instruction signal of electric control valve and the valve position feedback deviation of signal of electric control valve
When 30%, motor-driven valve accurately can not carry out pressure adjusting to air compressor, need to put into spare pneumatic regulating loop.
It is single when guaranteeing rated load by a valve opening of test setting in order to guarantee the controllability in handoff procedure as far as possible
When machine is run, air compressor works under this aperture, system, the not super 5Kpa/mi n of the speed risen or fallen.
11. time T1: system is under rated pressure, and after air compressor is stopped transport suddenly, system pressure declines 20KPa's
Shortest time.As the time T1 of air compressor in text is set as 5-6 seconds.
12. time T2: being 4-8 seconds.
13. time T3: the initial switching process of pneumatic shaping modes is switched to for air compressor pneumoelectric shaping modes,
It is used cooperatively with the 4th default valve position.As the time T3 of air compressor in text is set as 5-10 seconds.
14. time T4: the transient process of pneumatic shaping modes is switched to for air compressor pneumoelectric shaping modes, it should not
Less than the shortest time for holding the adjustment needs for adjusting valve.As the time T4 of air compressor in text is set as 60 seconds.
15. time T5: air compressor breaks down chaser or mistakenly stop when transporting, and system pressure drops to dedicated air compression
The shortest time of machine interlocked startup pressure definite value.If the time T5 of the air compressor run in text is 5-7 seconds.
Large scale industry provided by the utility model adjusts optimizing redundancy method with air compressor pressure, has following excellent
Point: the pressure regulative mode of two kinds of mutual backup is provided for air compressor, the pressure controlled controller of air compressor machine is also used
Redundant configuration considerably increases air compressor reliability of operation；Pass through the pressure/aperture PID fortune built in DCS system
Circuit is calculated, realizes that precise positioning and smooth closed loop are adjusted, keeps the liftings such as air compressor exhaust, oil temperature, electric current smooth, reduce
The abrasion of mechanical part and motor part improves the economy of air compressor.Large scale industry provided by the utility model is empty
Air compressor pressure adjusts optimizing redundancy method, by fast pneumatic starting and low-speed electric adjusted, realizes in pattern switching mistake
Smooth control, adjustment precision in journey；Reduce the disturbance of the process for system pressure of start-up loading；It reduces in adjustment process
Influence to system pressure；To some unusual conditions progress prediction failure that can be potentially encountered during compressor operation, and
Counter-measure is set in Logical Configuration, reduces abnormal expansion and operating condition as far as possible and further deteriorates, that improves air compressor machine can
Control property and adjusting and adaptability to system condition, and guarantee that air compressor is steady, controllable in mode handover procedure；
Most of helical-lobe compressor can be applied to.
Finally, it should be noted that the above various embodiments is only to illustrate the technical solution of the utility model, rather than it is limited
System；Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should
Understand: it is still possible to modify the technical solutions described in the foregoing embodiments, or to some or all of
Technical characteristic is equivalently replaced；And these are modified or replaceed, it does not separate the essence of the corresponding technical solution, and this is practical new
The range of each embodiment technical solution of type.
Claims (4)
1. a kind of large scale industry air compressor pressure adjusts optimizing redundancy system, including pneumatic actuating element and air compression
Machine, it is characterised in that: further include DCS control unit and motorized adjustment unit；
The motorized adjustment unit is series in the air pipeline of the pneumatic actuating element；The DCS control unit controls institute
It states pneumatic actuating element and motorized adjustment unit individually adjusts or common adjusting.
2. large scale industry according to claim 1 adjusts optimizing redundancy system with air compressor pressure, it is characterised in that:
The motorized adjustment unit is electric control valve and its feedback mechanism.
3. large scale industry according to claim 1 adjusts optimizing redundancy system with air compressor pressure, it is characterised in that:
It further include information acquisition unit；Information acquisition unit and DCS control unit communication connection；The information acquisition unit acquires air
The operating state signal of compressor.
4. large scale industry according to claim 1 adjusts optimizing redundancy system with air compressor pressure, it is characterised in that:
It further include isolated location；The isolated location is connected between pneumatic actuating element and catch pot；The isolated location with
The communication of DCS control unit；The isolated location is for switching shaping modes.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109026688A (en) * | 2018-09-30 | 2018-12-18 | 厦门华夏国际电力发展有限公司 | A kind of large scale industry air compressor pressure adjusting optimizing redundancy system and method |
| CN114352533A (en) * | 2022-01-24 | 2022-04-15 | 南通市红星空压机配件制造有限公司 | Control method for electric air inlet valve of movable air compressor |
-
2018
- 2018-09-30 CN CN201821616854.2U patent/CN208778228U/en active Active
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109026688A (en) * | 2018-09-30 | 2018-12-18 | 厦门华夏国际电力发展有限公司 | A kind of large scale industry air compressor pressure adjusting optimizing redundancy system and method |
| CN109026688B (en) * | 2018-09-30 | 2024-04-26 | 厦门华夏国际电力发展有限公司 | Pressure regulation optimization redundancy system and method for large industrial air compressor |
| CN114352533A (en) * | 2022-01-24 | 2022-04-15 | 南通市红星空压机配件制造有限公司 | Control method for electric air inlet valve of movable air compressor |
| CN114352533B (en) * | 2022-01-24 | 2023-11-21 | 南通市红星空压机配件制造有限公司 | Control method for electric air inlet valve of mobile air compressor |
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