JP2875702B2 - Automatic operation system for compressed air equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a compressed air device automatic operation system for controlling and operating a plurality of compressed air generators (hereinafter referred to as air compressors) for supplying compressed air to various production facilities.

[0002]

2. Description of the Related Art Conventionally, when a plurality of air compressors are controlled and operated, an air supply amount is divided and set in advance according to the number of air compressors to be operated. That is, it detects the compressed air pressure supplied to the load, and controls the start / stop of the air compressor based on the air pressure that changes as the load increases and decreases. A specific example will be described with reference to FIGS. .

FIG. 7 is an overall configuration diagram of a conventional compressed air device automatic operation system. This compressed air device automatic operation system supplies synthetic compressed air pumped from a total of four air compressors CMP21 to CMP24 to pipes P21 to P21.
24, and is accumulated in the compressed air spare tank AT21, and the loads LD21 to LD23 are connected through the pipes PL21 to PL23.
Supplied to

[0004] The compressed air reserve tank AT21 has:
Each air compressor CMP21-C at tank pressure
A pressure detector PS for starting / stopping the MP24 is connected, and the control panel C of the compressed air device automatic operation system is connected.
It is electrically connected to R2. Furthermore, this control panel C
R2 is an air compressor CMP21 to CM
An electric connection line SL22 for controlling P24 is connected to the air compressors CMP21 to CMP24.

Next, a specific operation example of the automatic operation system for a compressed air device will be described with reference to FIGS. First, the air compressors CMP21 to CMP24 are operated, for example, from CMP21 to CM in accordance with a start program predetermined by a start signal of the control panel CR2 in FIG.
In order of P22 → CMP23 → CMP24, 3 from 15 seconds
It rises at an interval of 0 seconds, and the compressed air is supplied to pipes P21 to P21.
24, compressed air spare tank AT21 and pipe PL21
Through PL23 to the loads LD21 to LD23.

In the air pressure curve of FIG. 8, all the air compressors CMP21 to CMP24 are continuously operated under load, and the supply flow rate (air compressor CMP21 to CMP23) is calculated based on the load flow rate (the flow rate of air flowing into the loads LD21 to LD23).
When the flow rate of the air supplied from the MP 24 is excessive, the air pressure of the air piping network including the pipes P21 to P24, PL21 to PL23 and the compressed air reserve tank AT21 gradually increases, and the discharge pressure previously input to the program is increased. The pressure detector PS operates at the point A at which the maximum value (programmed maximum discharge pressure) Pmax of the air compressor is reached, and the air compressor CMP24 enters the no-load operation.

Further, when the air supply amount increases and the air pressure in the air pipe network increases and reaches point B, the air compressor C
MP23 enters the no-load operation. Further, when the air pressure rises and reaches the point C, the air compressor CMP22 enters a no-load operation, and when the air pressure reaches the point D, the air compressor CMP22 operates.
MP21 enters the no-load operation. These air compressors CMP21 to CMP24 automatically stop their operation after the no-load operation state continues for a set time according to the program.

Conversely, when the air consumption of the loads LD21 to LD23 is increased, the air network pressure drops, and the point E in the air pressure curve in FIG. 8, that is, the minimum value of the programmed discharge pressure (the programmed discharge pressure). When the air pressure Psi (minimum discharge pressure) close to Pmin (set to a pressure slightly higher than Pmin) reaches Psi, the air compressor CMP21 enters load operation, and continues to descend. At point F, the air compressor CMP22 enters load operation. At point G, the air compressor CMP23 enters load operation, at point H, the air compressor CMP24 enters load operation, and all four units enter the load operation state.

If this state continues, the air pressure reaches the maximum value Pmax of the discharge pressure set in the program, that is, the point I, at which point the air compressor CMP 24 enters the no-load operation. In this state, when the load flow rate increases and the air pressure decreases and reaches the point J, the air compressor CMP24 starts the load operation again. As described above, in the compressed air device automatic operation system of the air pressure detection control system, each of the air compressors CMP21 to CMP is controlled within a predetermined air pressure range.
The compressed air of the load is supplied while repeating the starting, the load operation, the no-load operation, and the stop operation of the MP24.

[0010]

However, the automatic operation of the conventional air compressor of the above-described air compression detection method has the following problems. (1) When the load flow rate suddenly increases, the air pressure drop occurs and the pressure detector PS senses it, and the next air compressor starts.However, since the rise cannot follow the change and the load air pressure drops, the change A compressed air reserve tank AT21 to absorb is required.

(2) The operation order of each of the air compressors CMP21 to CMP24 incorporated in the compressed air device automatic operation system, such as start, load operation, no-load operation, and stop, for example, the start order is CMP1, CMP2, CMP3, and CMP4.
And the stop order is CMP4 → CMP3 → CMP2
→ If the program is set in advance so that it is in the order of CMP1, it is possible to take detailed measures when various combinations of air compressors with different output capacities (discharge capacities) or when the load flow rate pattern deviates from the predicted pattern are changed. It is difficult, and the program needs to be changed each time.

(3) Activating the air compressors CMP21 to CMP24 to be incorporated in the compressed air device automatic operation system;
The information of the stop, the load operation, and the no-load operation is based on the number of the air compressors CMP21 to CMP24, which is based on the signal of the pressure detector PS. As a result, the pressure detection range cannot be divided into small portions, so that the number of air compressors incorporated in the compressed air device automatic operation system is limited, and generally about four.

(4) Individual air compressor CMP21
If the characteristics of the CMP 24, that is, the startup time at start-up, the minimum time from operation to stop, and the like differ depending on the manufacturer and the model, the operation program becomes complicated.
The automatic operation system for the compressed air system, which combines air compressors from different manufacturers, had significant limitations. (5) The air compressors CMP21 to CMP24 are operated until the entire piping network including the compressed air spare tank AT21 reaches the specified air pressure when the automatic operation system for the compressed air device starts up.
Since all the units were started and operated, the consumption of electrical energy was large, and energy conservation and economic issues were also issues.

(6) Air compressor CMP21-CM
Due to the configuration of the operation pattern of P24, in this example, the frequency of use of the air compressor CMP21 is high, and the frequency of use of the air compressor CMP24 is low. There was a problem that the life would be reached.

An object of the present invention is to provide a compressed air device automatic operation system that can eliminate the need for a spare compressed air tank. Another object of the present invention is to provide a compressed air device automatic operation system capable of responding finely to a change in load. Still another object of the present invention is to provide an automatic compressed air generator capable of controlling a large number of compressed air generators without limitation on the number thereof, and capable of controlling even a state in which compressed air generators having different characteristics are mixed. It is to provide a driving system.

Still another object of the present invention is to provide a compressed air device automatic operation system capable of averaging the frequency of use of a plurality of air compressors.
Yet another object of the present invention is to provide a compressed air device automatic operation system that can reduce the consumption of electric energy and realize operation with less loss. Still another object of the present invention is to provide an automatic pneumatic device capable of performing fine control in response to a change in conditions such as automatic operation corresponding to a momentary power failure or power failure, and capable of easily performing unmanned operation for 24 hours. It is to provide a driving system.

[0017]

To achieve this object, an automatic operation system for a compressed air device according to the present invention comprises a plurality of compressed air generators for supplying compressed air to a load; And a detection device that mainly detects a change in air flow (hereinafter abbreviated as a load flow) flowing into the load, and a load flow change range divided into a plurality of load flow ranges. Predetermine a plurality of types of combination operation patterns of a plurality of compressed air generators in advance so as to have a discharge capacity suitable for the flow rate, and detect a load flow rate detection result detected by the detection device for a plurality of currently selected Compare with the conditions of the specified range of the load flow rate corresponding to the discharge capacity of the combination operation pattern of the compressed air generator, and if the load flow rate detection result is within the specified range, perform the continuous operation. If it becomes larger, the combination operation pattern of the plurality of compressed air generators is re-selected so that the combination becomes larger in discharge capacity. the by performing operation reselect a combination operation pattern plurality of compressed air generator, and a control device for controlling the air flow rate supplied from a plurality of compressed air generating device in response to the load flow rate detection result As a condition for selecting a combination operation pattern of a plurality of compressed air generators, the flow confirmation time of the detection device is shortened when the discharge capacity is increased, and the flow confirmation time of the detection device is determined when the discharge capacity is reduced. , The compressed air generator is started up in a short time when the load flow rate increases, and it responds quickly to a sudden increase in the load flow rate. While, when the load is decreasing flow to ensure minimum hot start time of the compressed air generator, and having a function to extend the life of equipment. However, operation is stopped during the shortest hot start time
Time from when you can restart without trouble
It is. Specifically, the operation of the compressed air generator
Immediately after stopping the compressed air generator
When starting and stopping are repeated in the state of
Motor start-up current may cause motor burnout.
To prevent such motor burnout.
For each device in order to restart without trouble.
Has been, up to be restarted from the time of stopping the operation
It's about time. Further, in the compressed air device automatic operation system according to claim 2, in the compressed air device automatic operation system according to claim 1, when the combined operation pattern of the plurality of compressed air generators is in a state other than the specified operation pattern, When the load flow rate detected by the detection device becomes constant, the control device forcibly returns to the combination operation pattern of the plurality of compressed air generation devices. The starting time of the compressed air generator is shortened by setting the combination operation pattern of the compressed air generator to the prescribed operation pattern. Further, the compressed air device automatic operation system according to claim 3 is the compressed air device automatic operation system according to claim 1, wherein the pressure is lower than a set value due to a power failure, power failure, equipment failure, or the like before the flow control. It is characterized in that it has a function of automatically starting the start-up load operation and suppressing the start-up current one by one at a specified time interval for all the compressed air generators in an emergency.

[0018]

According to the first aspect of the present invention, the flow confirmation time of the detection device is shortened when the discharge capacity is increased, and the flow confirmation time of the detection device is lengthened when the discharge capacity is reduced. When the load flow rate increases, the compressed air generator is started within a short period of time to quickly respond to a sudden increase in the load flow rate, and when the load flow rate decreases, the shortest hot start time of the compressed air generator is ensured, and the equipment life Can be extended. According to the configuration of the second aspect, when the combination operation pattern of the plurality of compressed air generators is in a state other than the specified operation pattern, the combination operation pattern of the plurality of compressed air generators is always forced to a predetermined combination operation pattern. Since the pressure is returned to normal, the start-up time of the compressed air generator can be reduced. According to the configuration of the third aspect, the starting load operation can be automatically started and the starting current can be suppressed one by one all the compressed air generators at a predetermined time interval.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The dynamic operation system has a connection between the air compressor and the load.
Install a flow meter in the middle of the pipe and set the load flow rate (air flowing to the load).
Flow rate), add the load flow rate, and calculate the load flow rate.
Control the number of air compressors corresponding to the amount
The load flow and the air supplied from the air compressor
Air flow (hereinafter abbreviated as supply flow)
You. With this configuration, multiple air compressors
After the compressed air to be discharged is synthesized,
Supplied to Check the load flow rate for each pipe connected to the load.
Output device, converts it to an electrical signal,
And the addition is calculated by the control device. Based on that value
Air compressor cab in response to changes in load
Automatic selection of numbers into pre-programmed combinations
Thus, operation with less loss can be performed under optimal conditions. Hereinafter, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is an overall block diagram showing a compressed air device automatic operation system of the present invention. This compressed air device automatic operation system automatically operates a plurality of air compressors by an air flow rate detection method. The compressed air discharged from the air compressors CP1 to CP5 is once synthesized by the air header AH1, and the loads L1 to L5 are combined. Piping to L3
1 through P3. The air header AH1
Is smaller than the conventional compressed air reserve tank and is provided for synthesizing the pressures of a plurality of air compressors, and has a different function from the compressed air reserve tank.

Further, air flow meters FS1 to FS3 are provided in the pipes P1 to P3 near the air header AH1 to constantly measure the amount of air flowing to the loads L1 to L3. Also,
An emergency pressure detector PS1 and a stationary pressure detector PS2 are installed in the air header AH1, and the discharge pressure from the air compressors CP1 to CP5 is constantly monitored.

As the air flow meters FS1 to FS3, hot wire mass flow meters having a function of automatically correcting an air flow rate that changes with temperature or pressure using an orifice are used. The signals of the pressure detectors PS1 and PS2 and the three loads L1 for confirming the operation status of the five air compressors CP1 to CP5 and the air pressure of the air header AH1.
Flow meters FS1 to FS measuring the air flow rate to L3
3 are fed back through the signal line SL of the control unit CR11.

The control unit CR11 includes “up control” for controlling the operation pattern of the air compressors CP1 to CP5 when the load flow rate increases, and “down control” for controlling the operation pattern of the air compressors CP1 to CP5 when the load flow rate decreases. "Continuous control" in which load flow fluctuation is relatively small and operation is continued, and the air compressor CP1 in operation
"Emergency control" for emergency situations such as failure of CP5
In addition, "forced control" for forcibly shifting the operation state of the air compressors CP1 to CP5 to the set operation pattern is incorporated, and the feedback signals are integrated, processed and processed as control signals in accordance with each operation pattern. Air compressors CP1 to C through signal line SP
P5 is controlled.

FIG. 2 is a flowchart showing the flow of control in this automatic operation system for compressed air equipment. In this flowchart, flow control is started (step 1).
1) First, it is determined whether the pressure detector PS1 of the air header AH1 is within the emergency pressure range (step 1).
2). If the air pressure is emergency (in this case, the air pressure is almost lower than normal), the "emergency control" is activated and the air compressor is operated to increase the pressure (step 13). The detailed operation will be described later.

If the pressure is not an emergency pressure, the process then proceeds to recognition of the current operation pattern (step 14). That is, the current state of the air compressors CP1 to CP5 is pre-programmed to correspond to the load flow rate in FIG.
Alternatively, it is determined whether or not the operation pattern is the operation pattern shown in FIG. 6, and if the operation pattern is not the above operation pattern, the operation is forcibly shifted to P3 of the ascending operation pattern shown in FIG. 5 (steps 15 to 1).
7).

Specifically, the air compressors CP1 to CP1
The operation status of CP5 is confirmed (step 15), and then an air compressor required for executing the ascending operation pattern P3 is started (step 16), and an unnecessary air compressor is stopped for executing the ascending operation pattern P3 (step 16). Step 17). This control is a process for shifting the air compressors CP <b> 1 to CP <b> 5 in any state to within the control range of the compressed air device automatic operation system.

Next, the air compressors CP1 to CP
5 it is determined whether the all aircraft load operation state (step 18), if e All A compressor CP1~CP5 is not load operating state, and within normal flow range (step 19), the condition (Step 24). If all the units are in the load operation state, or if the flow rate measured and added and calculated by each of the flow meters FS1 to FS3 is larger than the detected flow rate range of the prescribed operation pattern shown in FIG. 5, the flow chart in FIG. Proceeding to the left step, the pressure of the pressure detector PS2 is determined (step 20). If the pressure is lower than the specified value, the flow rate in that state is sampled for 5 seconds (step 22).
An ascending flow control command for shifting to the higher-level operation pattern is issued (step 23). This causes a transition to a higher-level operation pattern. The setting for 5 seconds is made short in consideration of the capacity of the equipment in order to quickly respond to the increase in the load flow rate and the supply flow rate.

If there is no pressure drop in step 20, it is reconfirmed whether the load flow rate is within the flow rate detection range of the next upper operation pattern (step 21). After confirming the flow rate for 5 seconds (step 22), a command to raise the flow is issued (step 23). At this time, similarly, the operation shifts to the higher-level operation pattern. If "NO" in the step 21, the process returns to the step 18.

In step 19, if the value of the load flow rate is smaller than the flow rate range of the operation pattern, the process proceeds to the right step to determine whether the flow rate is in the flow rate detection range of the lower operation pattern (step 25). If it is within the range, the flow rate in that state is sampled for 25 minutes (step 26), and a descending flow rate control command is issued (step 2).
7), the operation pattern shifts to a lower operation pattern.

If it is determined in step 25 that the flow rate is out of the range of the lower operation pattern, the flow returns to step 18. The sampling for 25 minutes is defined in order to reduce the frequency of the same air compressor repeating on and off by a program in combination operation of a plurality of air compressors CP1 to CP5, and to extend the machine life.

Next, the "emergency control" of step 13 will be described with reference to the block diagram of FIG. Pressure detector P
In S1, when it is determined that the pressure is an emergency, sampling is performed for 2 seconds.
A start command is issued to all the P1 to CP5 machines, and as shown in FIG. 3, a specified time lag is set by a timer which sets the time of 15, 50, 95, and 110 SEC attached to each of the air compressors CP1 to CP5. The air compressors CP1 to CP5 are sequentially activated. As a result, the emergency pressure is released and the control state shown in FIG. 2 is entered.

FIG. 4 is a diagram showing a specific example of a change in the operation pattern of the air compressor with respect to a change in the load flow rate for each hour of the day. In this figure, when the load increases,
The "rise operation pattern" shown in FIG. 5 corresponds, and the "fall operation pattern" shown in FIG. 6 corresponds to each flow rate range when the load decreases. In FIG. 4, the solid line indicates the load flow curve,
The broken line indicates the operation pattern curve, and the numbers “17, 38, 47, 67, 79” in the figure indicate the rising operation switching flow rate [m ³ / min], and “60, 45, 35, 30, 2”.
"1" indicates a descending operation switching flow rate [m ³ / min].

[0032]

As described above, according to the present invention, by constructing an automatic operation system of a compressed air device mainly for detecting a flow rate, the following is compared with a conventional automatic operation system of a compressed air device based on air pressure detection. The same effect was obtained. (1) In the pressure detection method, the detector sensitivity is usually 0.2 kg /
In order to perform the operation of starting and stopping the air compressor by setting it to about cm ² , the detection accuracy is limited and the configuration of up to four units is limited. Therefore, the present invention can be applied to a large-scale system with no limitation on the number of units, and the compressed air spare tank as in the conventional example can be eliminated.

(2) In connection with the above (1), since control becomes difficult when the target system becomes large in the related art, it has been possible to perform centralized management at one point instead of performing distributed management. (3) Different types and different types of air compressors have different specifications such as start-up time, stop time, no-load timing, etc., so it was practically difficult to incorporate them in the same control range.
In the present invention, since many flow patterns can be obtained, fine control can be performed from a small-scale to a large-scale system.

(4) Since a detailed response can be made in response to a change in the load pattern, the air compressor can be operated effectively, and electric energy can be saved. Conventionally, in the pressure method, when starting up, it is necessary to operate all air compressors until the air pressure of the piping network including the compressed air reserve tank reaches the specified value. Although air compressors have increased, these energy losses can be reduced.

(5) Since the air compressors can be configured in various combinations in accordance with the ascending and descending operation patterns by a program, the operation time of each machine can be averaged, and the long life of the equipment can be achieved. (6) Regardless of the conventional example and the present invention, the hunting phenomenon that occurs in the compressed air in the air piping network prevents the detection from being inaccurate or impossible, and eventually leading to equipment damage Therefore, in the present invention, it is possible to respond finely by a program, such as changing the sampling time when the flow rate is increased or decreased or changing the number of operating units in accordance with the load flow rate.

As described above, the pressure according to claim 1 of the present invention.
Since the compressed air automatic operation system constantly detects the load flow rate and operates in combination with multiple compressed air generators corresponding to it, efficient operation can be realized under optimal conditions, and unmanned operation can be realized. Become. In particular, more discharge capacity
When increasing the flow rate, shorten the flow rate check time
Checking the flow rate of the detector when making the output capacity smaller
To increase compressed air flow when load flow increases.
Start the production equipment within a short period of time to quickly increase the load flow
Compressed air generator when load flow is reduced
The shortest hot start time of the equipment and extend the life of the equipment.
I can skip it. The compression according to claim 2 of the present invention.
According to the pneumatic device automatic operation system, multiple compressed air
The combination operation pattern of the generator is other than the specified operation pattern
Is always in the state of
Forcibly return to the combined operation pattern of the compressed air generator
Therefore, the startup time of the compressed air generator can be reduced.
Wear. Furthermore, the compressed air device according to the third aspect of the present invention is provided.
According to the dynamic operation system, all compressed air generators are regulated.
Start load operation is automatically started one by one at regular intervals.
The starting current can be suppressed.

[Brief description of the drawings]

FIG. 1 is an overall block diagram of an air flow detection type compressed air device automatic operation system according to an embodiment of the present invention.

FIG. 2 is a flowchart showing an operation in the embodiment of FIG.

FIG. 3 is a block diagram showing emergency control in the embodiment of FIG. 1;

FIG. 4 is an application example diagram in the embodiment of FIG. 1;

FIG. 5 is an air compressor rising operation pattern diagram in the embodiment of FIG. 1;

FIG. 6 is an air compressor descending operation pattern diagram in the embodiment of FIG. 1;

FIG. 7 is an overall block diagram of a conventional compressed air device automatic operation system of an air pressure detection system.

FIG. 8 is an explanatory diagram of air pressure and air compressor operation in a conventional example.

[Explanation of symbols]

 CR11 Control unit CP1 to CP5 Air compressor AH1 Air header PS1, PS2 Pressure detector FS1 to FS3 Flow meter L1 to L3 Load SL Signal line P1 to P3 Piping SP Control signal

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Toshiro Yuasa 2-16-16 Hamacho, Moriguchi-shi, Osaka Built-in Sumiju Kogyo Co., Ltd. (56) References JP-A-55-92902 (JP, A) (58) Survey Field (Int.Cl. ⁶ , DB name) F04B 49/00 F04D 27/00 G05D 5/00

Claims (3)

(57) [Claims] A plurality of compressed air generators for supplying compressed air to a load; a detector for detecting a change in the load as a change in an air flow rate (hereinafter, abbreviated as a load flow rate) mainly flowing into the load; A change range of the load flow rate is divided into a plurality of sections in advance, and a plurality of types of combination operation patterns of the plurality of compressed air generators are provided so as to have a discharge capacity suitable for the load flow rate for each of the plurality of divided ranges of the load flow rate. The load flow rate detection result detected by the detection device is compared with a condition of a load flow rate specified range corresponding to the discharge capacity of the currently selected combination operation pattern of the plurality of compressed air generation devices. If the load flow rate detection result is within the specified range, the continuous operation is performed. With reselecting combination operation pattern number units of the compressed air generator, the combination operation pattern plurality of compressed air generating device as may become smaller than the prescribed range is a smaller combination operation pattern of the discharge capacity A control device for controlling the air flow supplied from the plurality of compressed air generators in accordance with the load flow detection result by performing the operation again by selecting the combination of the plurality of compressed air generators. As a condition for selecting an operation pattern, when the discharge capacity is increased, the flow confirmation time of the detection device is shortened, and when the discharge capability is reduced, the flow confirmation time of the detection device is increased, thereby increasing the load flow rate. Sometimes, the compressed air generator is started within a short time to quickly respond to a sudden increase in the load flow rate, Compressed air system automatic operation system characterized by securing the minimum hot start time of compressed air generator, and has a function to extend the life of equipment. However, the shortest hot start time is
From when it was stopped until it can be restarted without hindrance
It's time. 2. When the combination operation pattern of a plurality of compressed air generators is in a state other than the prescribed operation pattern, the combination operation pattern of the plurality of compressed air generators is forcibly returned to a predetermined combination operation pattern and detected. When the load flow rate detected by the apparatus becomes constant, the control apparatus sets the combined operation pattern of the plurality of compressed air generators to a specified operation pattern based on the load flow rate detection result, thereby starting the compressed air generator. 2. The compressed air device automatic operation system according to claim 1, wherein time is shortened. 3. If the pressure is lower than a set value due to a power failure, equipment failure, or the like before the flow control is started, all the compressed air generators are automatically activated one by one after a specified time as an emergency. 2. The compressed air device automatic operation system according to claim 1, further comprising a function of starting operation and suppressing a starting current.