JP7239416B2 - Gas separator and maintenance service system - Google Patents

Description

The present invention relates to gas separation devices.

Patent document 1 exists as a background of this technical field. Japanese Patent Application Laid-Open No. 2002-200000 includes various types of abnormality detection means, and controls the oxygen concentrator to stop when the detected result is out of a predetermined range. Furthermore, in Patent Document 1, abnormality determination is performed by detection by each sensor such as an oxygen sensor and a pressure sensor alone, and when the oxygen concentration or pressure value exceeds the threshold value for abnormality determination, an abnormality or an alarm is issued to notify the user. It is described to notify that a is occurring.

JP 2007-190314

Patent Literature 1 does not suggest a technique for remotely monitoring sensor information and performing maintenance services such as failure diagnosis using IoT (Internet of Things).

When IoT is used to remotely monitor sensor information and perform maintenance services such as fault diagnosis, the time interval and frequency of data communication should be limited to, for example, once every 30 minutes in consideration of cost. be done. In this case, the pressure data of the gas separation device fluctuates about every minute of the adsorption cycle, so the instantaneous pressure value is sent to the server once every 30 minutes.

Also, data such as maximum and minimum values should be updated on the device side at reasonable intervals to avoid sending old detection values that are not recent operating conditions to the server.

However, if the communication timing for communicating data between the device and the cloud overlaps with the data update timing, data such as relatively new maximum and minimum values will not be sent, and data that is not the maximum or minimum value will be sent to the server. may occur. If such a thing occurs, it is not possible to correctly detect an abnormality in the pressure of the gas separation device or a sign of an abnormality in the pressure by remote monitoring.

SUMMARY OF THE INVENTION An object of the present invention is to provide a gas separator and a maintenance service system that can notify a user or the like of an abnormality at an early stage.

As a preferred example of the present invention,
a compressor that compresses air, an air tank that stores the compressed air compressed by the compressor, an adsorption tank that adsorbs a part of the compressed air stored in the air tank, and the adsorption tank. a product gas storage tank for storing product gas that has not been adsorbed; a control section for controlling the operation of the adsorption tank; pressure detection means for detecting pressure in the tank; and a communication section,
The control unit
When updating the maximum value or the minimum value,
leaving the maximum value or the minimum value before updating, and determining the maximum value or the minimum value including the detected pressure at the time of updating and the maximum value or the minimum value before updating;
The communication unit
A gas separation device communicating with the outside about said maximum or said minimum data.

According to the present invention, a user or the like can be notified of an abnormality at an early stage.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an overall configuration diagram showing a gas separation device in Example 1 of the present invention; 1 is a configuration diagram of a maintenance service system including a gas separation device; FIG. It is a figure which shows the relationship of the pressure and time which were detected by the pressure detection means.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

Example 1 will be described with reference to FIG. The overall configuration of the PSA type gas separation apparatus in this embodiment will be described with reference to FIG. The gas separation device 1 shown in FIG. 1 is a PSA type gas separation device. The gas separation device 1 comprises an air supply unit 2 for supplying air and a PSA unit 3 for producing product gas.

In this embodiment, as an example, the air supply unit 2 and the PSA unit 3 are housed in separate housings, but the two units may be housed in the same housing.

This air supply unit includes a compressor 4 for compressing air, an inverter circuit 10 for performing capacity control (including capacity control and number control), an air tank 5 for storing compressed air, and a dehumidifier for dehumidifying the compressed air. It has an air dryer 6 and a drain filter 7 that removes impurities while recovering the precipitated drain water. In this embodiment, as an example, the compressor 4, the air tank 5, the air dryer 6, and the drain filter 7 are housed in a housing.

On the other hand, the PSA unit 3 has an adsorption tank A 19A and an adsorption tank B 19B that generate product gas by separating a predetermined gas from the compressed air supplied from the air supply unit 2, and a nitrogen tank that stores the product gas (nitrogen). It has a tank (product gas storage tank) 41 .

Compressed air stored in the air tank 5 is supplied to an adsorption tank A19A and an adsorption tank B19B, which will be described later, and a predetermined gas is separated from the compressed air stored in the air tank 5 . In this embodiment, a case will be described in which nitrogen is separated by adsorbing oxygen in the adsorption tank A19A and the adsorption tank B19B. It may be one that separates other gases from.

As the compressor 4, a reciprocating double-acting compressor, a screw compressor, a scroll compressor, or the like, or a booster compressor that recompresses the primary pressure supplied from the outside, or the like is used.

A pipe 16 for flowing compressed air from the air tank 5 is connected to the air tank 5 , and pipes 17 A and 17 B branched into two systems are connected to terminal positions of the pipe 16 . The pipes 17A and 17B are provided with supply valves 18A and 18B for opening and closing the flow paths, respectively. It is connected.

This adsorption tank has a constant volume. Pipes 21A and 21B are connected to the pipes 17A and 17B at positions between the supply valves 18A and 18B and the adsorption tanks A19A and B19B, respectively. Exhaust valves 22A and 22B for opening and closing are provided, and an exhaust silencer 23 with a filter for silencing is provided at the terminal.

This exhaust silencer may be provided for each of the adsorption tanks A19A and B19B. Pipes 25A and 25B are connected to the pipes 17A and 17B so as to connect positions between the pipes 21A and 21B and the adsorption tank A19A and the adsorption tank B19B. are provided with lower equalizing valves 26A and 26B for opening and closing the .

The adsorption tank A19A and the adsorption tank B19B are filled with, for example, an adsorbent which is an adsorption means for adsorbing oxygen molecules. Specifically, molecular sieve carbon, zeolite, or the like is used as the adsorbent. Pipes 31A and 31B that merge with each other are connected to the adsorption tank A19A and the adsorption tank B19B, respectively.

Pipes 32A and 32B are connected to these pipes 31A and 31B so as to connect the adsorption tank A 19A and adsorption tank B 19B sides with each other.

Further, pipes 35A and 35B are connected to the pipes 31A and 31B so as to connect the sides of the pipes 32A and 32B opposite to the adsorption tank A19A and the adsorption tank B19B. Upper equalizing valves 36A and 36B are provided to open and close the passages.

Further, the pipes 31A and 31B are provided with take-out valves 38A and 38B for opening and closing the flow paths, respectively, on the opposite side of the pipes 35A and 35B from the adsorption tank A19A and the adsorption tank B19B. A pipe 40 is connected to the confluence position of the pipes 31A and 31B, and a nitrogen tank 41 is connected to the pipe 40 as a product gas storage tank for storing nitrogen gas.

A pipe 43 provided with a discharge port 42 is connected to the nitrogen tank 41. Filters for removing dust and the like and for adjusting the gas pressure are installed in order from the nitrogen tank 41 side in the middle of the pipe 43. A regulator 44, a discharge valve 45 for opening and closing the flow path, a flow control valve 46 for adjusting the flow rate of the product gas, and a flow rate detection means 61 for sensing the flow rate of the product gas are provided.

A pipe 48 and a pipe 49 are connected to a position between the filter regulator 44 and the discharge valve 45 of the pipe 43. The pipe 48 has, in order from the pipe 43 side, an on-off valve 50 for opening and closing the flow path, and a gas flow. A flow control valve 51 for adjusting the flow rate and a silencer 52 are provided.

The pipe 49 is provided with, in order from the pipe 43 side, an on-off valve 54 for opening and closing the flow path, a flow control valve 55 for adjusting the gas flow rate, and an oxygen sensor 56 for detecting the oxygen concentration. The oxygen sensor 56 and the flow rate detection means 61 are communicably connected to the control section 60 and output detection signals to the control section 60 . The control unit 60 is configured to include a CPU (Central Processing Unit). It consists of a microcomputer (Micro controller) or FPGA (Field-Programmable Gate Array).

The control unit 60 receives the detection signal and controls the generation of nitrogen gas in the adsorption tank A19A and the adsorption tank B19B. Specifically, the supply valves 18A, 18B, the exhaust valves 22A, 22B, the lower pressure equalizing valves 26A, 26B, the upper pressure equalizing valves 36A, 36B, the take-out valves 38A, 38B, the discharge valve 45, the on-off valves 50 and 54 are controlled by the control unit. 60 and operates according to commands from the control unit 60 .

The air tank 5, the adsorption tank A19A, the adsorption tank B19B, and the nitrogen tank 41 are provided with pressure detection means 63 for detecting pressure. Further, the gas separation device 1 is provided with a temperature sensor 62 (not shown) for detecting the ambient temperature.

The configuration of the gas separation device 1 has been described so far, and now the gas separation method performed in the gas separation device will be described.

In the gas separation device 1, a compression step of compressing air with a compressor 4, a storage step of storing the air compressed in the compression step in an air tank 5, a dehumidification step of dehumidifying the compressed air with an air dryer 6, and a dehumidification step. A separation step is performed to separate the gas from the entrained air.

In the separation process of the gas separation device 1, the following processes (a) to (d) are sequentially repeated.

(a) Adsorption/reflux step: The compressed air compressed by the compressor 4 and stored in the air tank 5 is supplied to the adsorption tank A 19A and the adsorption tank B 19B filled with the adsorbent by opening the supply valves 18A and 18B. At the same time, the nitrogen gas remaining in the nitrogen tank 41 is circulated to the adsorption tank A19A and the adsorption tank B19B by opening the take-out valves 38A and 38B to increase the pressure in the adsorption tank A19A and the adsorption tank B19B, and utilize the pressure. to cause the adsorbent to adsorb oxygen molecules.

(b) Extraction step: Continuing from the adsorption step, compressed air is continuously supplied from the air tank 5 to the adsorption tank A19A and the adsorption tank B19B, and at the same time, the nitrogen gas separated and generated by the adsorbent is discharged into the adsorption tank A19A and the adsorption tank B19B. A step of taking out from the nitrogen tank 41 and storing it in the nitrogen tank 41 .

(c) Equalizing process: By opening and closing the upper equalizing valves 36A and 36B and the lower equalizing valves 26A and 26B, the pair of adsorption tanks A 19A and B 19B after the removal process is finished is pressure equalized, and the next adsorption process is carried out. A process for increasing efficiency and producing higher purity nitrogen gas.

(d) Regeneration step: By opening the exhaust valves 22A and 22B in the adsorption tank A 19A and the adsorption tank B 19B after the pressure equalization step, the oxygen molecules adsorbed by the adsorbent are desorbed through the pipe 21. A step of regenerating the adsorbent. In this regeneration process, the supply valves 18A and 18B related to the adsorption tank A 19A and the adsorption tank B 19B other than the exhaust valves 22A and 22B, the lower pressure equalizing valves 26A and 26B, the upper pressure equalizing valves 36A and 36B, the upper and take-out valves 38A, 38B is closed.

While the adsorption step and extraction step (steps (a) and (b)) are being performed in the adsorption tank A19A, the regeneration step (step (d)) is performed in the adsorption tank B19B. Thereafter, (c) the pressure equalization step is performed simultaneously, and the adsorption tank A 19A and the adsorption tank B 19B are exchanged to perform the adsorption step/removal step (steps (a) and (b)) and the regeneration step (step (d)).

The adsorption/reflux step (a), the removal step (b), the pressure equalization step (c), and the regeneration step (d) are combined and defined as the cycle time of the adsorption cycle.

FIG. 2 shows a maintenance service system in which a gas separation device 1, a cloud 101 connected to the gas separation device 1 via a network 100 such as a dedicated line or a mobile network, and a network 200 connecting the cloud 101 and a user terminal 201. FIG. 10 shows. Here, the cloud includes a computer (web server) 102 and a database (DB) 103, and the web server 102 receives data from the gas separation device 1. User terminals 201 include PCs (personal computers), tablets, and mobiles.

When remotely monitoring via the cloud 101 , the data recorded in the control unit 60 is transmitted from the communication unit 70 to the cloud 101 . A user can access the Internet 200 with a user terminal 201 such as a PC, display information obtained from the cloud 101, and remotely monitor the information.

In the gas separator, the pressure detection means 63 provided in the air tank 5, the adsorption tank A19A, the adsorption tank B19B, and the nitrogen tank 41 constantly sense the pressure of each tank and send a signal to the controller 60 as an instantaneous value. Usually the instantaneous value may be used for indication of the gas separation device. Moreover, a threshold value can be provided and the normal instantaneous value can be used for abnormality determination.

FIG. 3 is a diagram showing the relationship between the pressure detected by the pressure detecting means in the air tank 5, the adsorption tank A 19A, the adsorption tank B 19B, and the nitrogen tank 41 and time. Repeated pressure fluctuations in the cycle time (approximately 1 minute) are normal conditions.

In this embodiment, the pressures of all of the air tank 5, adsorption tank A19A, adsorption tank B19B, and nitrogen tank 41 are detected. The pressure may be sent to the control unit 60 to determine abnormality.

Each adsorption cycle consists of an adsorption/reflux step (a), a withdrawal step (b), a pressure equalization step (c), and a regeneration step (d), and the steps proceed in order from (a) to (d).

As shown in FIG. 3, the PSA operation of the gas separation device causes the pressure to fluctuate about every minute. Instantaneous values are transmitted and cannot be determined as abnormal by remote monitoring.

Even if data is transmitted to the cloud 101 side (once every 30 minutes), the cloud 101 side can detect an abnormality in the gas separation device. The maximum and minimum values of pressure are recorded for each tank for a predetermined period of time and stored in an internal memory. The communication unit 70 receives the recorded data from the control unit 60 and transmits it to the cloud 101 .

The recorded maximum and minimum values are sent to the maintenance service server 102 on the cloud 101 once every 30 minutes instead of the instantaneous values once every 30 minutes. Therefore, the pressure state of each tank can be confirmed on the screen on the cloud 101 side, for example, on the remote monitoring display unit (remote monitoring screen) 202 connected to the PC, which is the user terminal 201 . Even in the case of remote monitoring via the cloud 101, it is possible to inform the user of potential anomalies at an early stage.

The control unit 60 that records the maximum and minimum values and the communication unit 70 that communicates data to the cloud 101 are operated by respective timers. If the timing immediately after resetting the maximum and minimum values coincides with the timing of data transmission to the cloud 101 (computer), the values that have not reached the maximum and minimum values will be recognized as the maximum and minimum values. You will end up making a bad judgment.

For example, the data to be detected is the maximum value of the value A before updating, but immediately before the timing of sending data to the cloud, the maximum value A is reset (updated). When the value was detected, it settled down to the value of B (B<A), which did not reach A, so it ended up being the value of B when it was sent to the cloud.

However, the maximum value just before the reset is not so old timing detection data (within one cycle time from the current state), and originally should have detected that an abnormality had occurred.

However, after the maximum value A, the value decreases, and if the reset timing and the timing to communicate with the cloud overlap as described above, the maximum value that should be sent to the cloud is not sent, and a different value is sent. data will be sent. A similar case can occur for the minimum value.

As a countermeasure, when resetting the maximum and minimum values of the control unit 60, the values are compared with the previously recorded maximum and minimum values, and by recording the values, an erroneous value is detected in the cloud 101 (computer). prevent it from being sent to

In other words, in this embodiment, when updating the maximum value or minimum value, the control unit 60 does not reset the maximum value or minimum value before updating and leaves the detected pressure when updating and the maximum value before updating. Determining the maximum or minimum value including the value or minimum value.

As for the maximum value before update, the data one cycle time before is not reset (updated). That is, only the maximum value or minimum value one cycle time (duration of the adsorption cycle) before is not reset. The maximum and minimum values set two cycle times before are reset.

Alternatively, the maximum value of the period after the previous communication with the cloud should not be reset (updated). In other words, only the maximum or minimum value after the timing of the previous communication with the cloud is not reset. Resets the maximum and minimum values that were set before the timing of the previous communication with the cloud.

By doing so, it is possible to prevent a mistake in not sending data indicating a sign of a relatively new abnormality or abnormal data, and notify the cloud of the abnormality at an early stage.

When the control unit 60 sets the update interval for communicating the maximum and minimum values to be performed every adsorption cycle (about 1 minute), it is possible to send to the information cloud close to the timing at which the communication unit 70 communicates. . If the control unit 60 lengthens the update interval to a time interval for data communication (approximately every 30 minutes), the average pressure status of each tank can be monitored in the cloud.

DESCRIPTION OF SYMBOLS 1... Gas separation apparatus 5... Air tank 19A... Adsorption tank A
19B... Adsorption tank B
41... Nitrogen tank 63... Pressure detecting means 70... Communication unit

Claims (6)

a compressor for compressing air;
an air tank for storing compressed air compressed by the compressor;
an adsorption tank that adsorbs a part of the compressed air stored in the air tank;
a product gas storage tank for storing product gas not adsorbed in the adsorption tank;
a control unit that controls the operation of the adsorption tank;
pressure detection means for detecting pressure in any one of the air tank, the adsorption tank, and the product gas storage tank ;
and a communication unit,
The control unit
recording the maximum and minimum values of the pressure detected by the pressure detection means;
when updating the maximum and minimum values of the pressure, holding without resetting the maximum or minimum value recorded one cycle time before;
Determining the maximum value or the minimum value including the maximum value or the minimum value recorded one cycle time before the previous time and the pressure detected when updating,
When the communication unit communicates with the outside,
A gas separation apparatus, wherein data of the maximum value or the minimum value of the pressure determined by the control unit is communicated with the outside. The gas separation device of claim 1, wherein
The pressure detection means is
A gas separation apparatus characterized by detecting the pressure in all of the air tank, the adsorption tank, and the product gas storage tank . The gas separation device of claim 1, wherein
The product gas storage tank is a nitrogen tank,
The pressure detection means is
A gas separator, wherein the pressure of the nitrogen tank is detected. The gas separation device of claim 1, wherein
The control unit
A period for updating the maximum value or the minimum value,
The gas separation device is characterized in that it is set during an adsorption cycle or during a communication interval with the outside. The gas separation device of claim 4, wherein
The adsorption cycle is
A gas separation apparatus comprising an adsorption/reflux process, a withdrawal process, a pressure equalizing process, and a regeneration process. A gas separation device according to claim 1;
a calculator that receives the maximum value and the minimum value from the gas separation device;
A maintenance service system for a gas separation device, comprising: a terminal equipped with a display for remote monitoring and connected via a network to said computer.

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