CN112211813A - Air compressor unit cooperative control system - Google Patents
Air compressor unit cooperative control system Download PDFInfo
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- CN112211813A CN112211813A CN202011097914.6A CN202011097914A CN112211813A CN 112211813 A CN112211813 A CN 112211813A CN 202011097914 A CN202011097914 A CN 202011097914A CN 112211813 A CN112211813 A CN 112211813A
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- 238000004891 communication Methods 0.000 claims abstract description 22
- 230000003993 interaction Effects 0.000 claims abstract description 9
- 238000012544 monitoring process Methods 0.000 claims description 14
- 238000012216 screening Methods 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 description 12
- 230000009467 reduction Effects 0.000 description 7
- 238000006073 displacement reaction Methods 0.000 description 6
- 239000007789 gas Substances 0.000 description 4
- 238000012423 maintenance Methods 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 230000009471 action Effects 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
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- 230000002035 prolonged effect Effects 0.000 description 1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/06—Control using electricity
- F04B49/065—Control using electricity and making use of computers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/02—Stopping, starting, unloading or idling control
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/10—Other safety measures
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- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Computer Hardware Design (AREA)
- Control Of Positive-Displacement Pumps (AREA)
Abstract
The invention discloses a cooperative control system of an air compressor unit, which comprises a PLC control unit, an industrial touch screen, the air compressor unit and an exhaust main pipe; wherein: the industrial touch screen comprises a human-computer interaction interface, a target exhaust pressure value is set, the maximum operation time of the air compressors is set, the pressure value collected by the PLC control unit is received and is compared with the target exhaust pressure value in a calculation mode; the PLC control unit includes: the RS485 communication module is connected with the industrial touch screen and the air compressor unit through an RS485 bus and used for transmitting real-time operation parameters of the air compressor unit to the industrial touch screen for display; the starting and stopping control function module is used for controlling the starting and stopping of the air compressor, and the air compressor set is convenient to cooperatively control and is stable in control.
Description
Technical Field
The invention relates to the technical field of air compressor control, in particular to a cooperative control system of an air compressor unit.
Background
In recent years, the safety consciousness of factory production is increased, and more factories begin to abandon the original electric production equipment for explosion prevention and safety, use pneumatic power production tools and production equipment thereof, especially for some factories producing flammable and explosive chemical gases, pay more attention to the production equipment using compressed air as power, so that the production equipment of compressed air, namely an air compressor, is purchased and used by more and more factories.
The air compressors sold in the market at present are basically provided with a single machine automatic control system, the load can be automatically adjusted according to the exhaust pressure of the single machine, and when the exhaust pressure reaches a set value, the unit can be automatically stopped and enters a standby state. The air compressor with a single machine control system sold in the market at present has four working flows: shutdown, load, auto-restart (standby state), where shutdown state is least power idle. The air compressors with various models in the air compressor market at present are various in models, a common factory can select a proper air compressor according to the amount of compressed air required by the factory, but the air consumption of the factory in production per day is greatly changed, the production capacity in daytime is large, the air consumption is increased along with the large production capacity at night, the relative air consumption is small, if the air compressor with large air displacement is selected, the production requirement can be really met, but the air compressor with small air displacement is redundant in small time, electric energy is consumed, maintenance cost is consumed, if the air compressor with small air displacement is selected, the air compressor with large air displacement in daytime is obviously insufficient to meet the production requirement, so that the factory can generally select a plurality of air compressors with small air displacement when selecting, and the air compressors with different air displacements in one day can be met by.
The current single air compressor automatic logic is that when the exhaust pressure of the single air compressor is lower than the target exhaust pressure, the air compressor can automatically load, when the exhaust pressure reaches the automatic stop pressure, the air compressor can enter a standby state, and the target exhaust pressure and the automatic stop pressure are all stored on a control unit in the single air compressor. When the air consumption of the system is increased, obviously, the production requirement is difficult to meet when one air compressor is used, and at the moment, another air compressor needs to be started, but because the existing air compressors are single-machine systems, machines can only be increased by manual starting, and if the air consumption changes greatly in one day, maintenance personnel in a factory need to continuously change the number of the air compressors according to the pressure of an air supply main pipe, so that the energy-saving cost is achieved. If all the air compressors are started, maintenance personnel do not need to worry about pressure change, all the air compressors are loaded and standby according to self-set parameters, but a problem is generated, when all the air compressors are fully opened, the exhaust capacity of the main pipe is increased, when the exhaust pressure is lower than the target exhaust pressure, a plurality of air compressors can quickly reach the automatic stop pressure, because the total exhaust capacity is too strong, the air compressor can be frequently started and stopped, although the variable air consumption in one day can be met, however, frequent starting and stopping of the air compressor greatly reduces the service life of the air compressor, increases the loss of equipment and increases the maintenance cost, so an accessory control system is urgently needed to solve the two contradictions, all the air compressors can work alone or work in cooperation with one air compressor without being attended by people.
Disclosure of Invention
The invention aims to provide a cooperative control system of an air compressor unit, which is simple to operate and convenient to stably control.
In order to solve the technical problems, the invention provides the following technical scheme: a cooperative control system of an air compressor unit comprises a PLC control unit, an industrial touch screen, the air compressor unit and an exhaust main pipe; wherein:
the air compressor unit is composed of a plurality of air compressors, the air compressor unit is connected with an exhaust main pipe,
the PLC control unit is connected with the air compressor unit and is used for driving each air compressor to start and stop,
the PLC control unit is also connected with an exhaust main pipe and is used for acquiring the pressure value in the exhaust main pipe in real time,
the industrial touch screen comprises a human-computer interaction interface which is used for setting a target exhaust pressure value, setting the maximum operation time of the air compressor, receiving a pressure value acquired by the PLC control unit and calculating and comparing the pressure value with the target exhaust pressure value;
the PLC control unit includes:
the RS485 communication module is connected with the industrial touch screen and the air compressor unit through an RS485 bus and used for transmitting real-time operation parameters of the air compressor unit to the industrial touch screen for display;
the start-stop control function module is used for controlling the start and stop of the air compressor;
the air compressor adding and subtracting module is used for screening the air compressor which has the shortest running time and good running state to start when the air supply is less than the target exhaust pressure value; when the air supply is larger than the target exhaust pressure value, screening the air compressor with the longest operation time to shut down;
the unit switching module is used for replacing each air compressor;
the fault switching module is used for monitoring the fault conditions of all air compressors in real time and driving the fault machine to stop;
and the operation counting module is used for counting and recording different states of each air compressor.
Furthermore, each air compressor is provided with a single machine control unit, each single machine control unit is provided with a serial communication interface, and the serial communication interfaces are connected with the RS485 communication module.
Further, a pressure sensor is arranged in the exhaust main pipe and used for detecting the pressure in the pipeline in real time; the pressure sensor is connected with the PLC control unit and used for transmitting pressure data to the PLC control unit.
Furthermore, the RS485 communication module, the start-stop control function module, the add-subtract machine function module, the unit switching module, the fault switching module and the operation statistics module are connected with the analog quantity unit and the digital quantity unit together, and the analog quantity unit is connected with the pressure sensor through a signal cable.
Furthermore, each air compressor is respectively provided with an equipment start-stop hard contact, and each equipment start-stop hard contact is connected with the digital quantity unit.
Furthermore, the human-computer interaction interface consists of a parameter monitoring module and a parameter control module;
the parameter monitoring module is used for monitoring the running state of each device;
and the parameter control module is used for inputting parameters and instructions into the PLC control unit.
Furthermore, the operation panel of the air compressor can set pressure parameters and transmit the pressure parameters to the PLC control unit, and the PLC control unit receives the set parameters and modifies the target pressure value of the single-machine control unit.
Compared with the prior art, the invention has the following beneficial effects:
1. the air compressor unit is controlled by the PLC control unit, and the functions of automatic plus-minus machine, automatic alternation, fault switching and the like of the air compressor unit are driven, so that the exhaust main pipe can meet the air quantity requirement conveniently, and the air utilization requirement in a factory is ensured;
2. the PLC control unit controls the multiple air compressor units to work cooperatively, so that the control effect is good;
3. through the rotation of air compressor machine, be convenient for prolong air compressor machine long service life, improve the security performance of air compressor machine.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 is a workflow block diagram of the present invention;
in the figure: 100. a PLC control unit; 110. an RS485 communication module; 120. a start-stop control function module; 130. a plus-minus machine module; 140. a unit switching module; 150. a fail-over module; 160. running a statistical module; 170. an analog quantity unit; 180. a digital quantity unit; 200. an industrial touch screen; 210. a human-computer interaction interface; 211. a parameter monitoring module; 212. a parameter control module; 300. an air compressor unit; 310. an air compressor; 320. a single machine control unit; 330. the equipment start-stop hard contact; 400. an exhaust manifold.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, the present invention provides a technical solution: the cooperative control system for the air compressor units comprises a PLC control unit 100, an industrial touch screen 200, the air compressor units 300 and an exhaust main pipe 400, wherein the PLC control unit 100 is connected with the air compressor units 300, and the PLC control unit 100 can store and update the running state of each air compressor 300 into a database inside the air compressor unit in real time;
the air compressor unit 300 is composed of a plurality of air compressors 310, and the output end of each air compressor 310 is connected with an exhaust manifold 400 for air supply.
The PLC control unit 100 is connected to the air compressor unit 300, and is used for driving each air compressor 310 to start and stop,
the PLC control unit 100 is connected with a pressure sensor in the exhaust main pipe 400 and is used for acquiring the pressure value in the exhaust main pipe in real time,
the PLC control unit includes:
the RS485 communication module is connected with the industrial touch screen 200 and the air compressor unit 300 through an RS485 bus and used for transmitting real-time operation parameters of the air compressor unit 300 to the industrial touch screen 200 for display;
the start-stop control functional module 120 is used for controlling the start and stop of the air compressor 310, so that the purpose of remotely starting and stopping the air compressor 310 can be conveniently achieved;
the air compressor adding and subtracting module 130 is used for screening the air compressor which has the shortest running time and good running state to start when the air supply is less than the target exhaust pressure value; when the air supply is larger than the target exhaust pressure value, screening the air compressor with the longest operation time to shut down; the plus-minus machine module 130 is used for controlling the starting and stopping of the air compressors 310, when the air volume supply of all the running air compressors 310 is smaller than a target exhaust pressure value, the PLC control unit 100 sends a plus-minus machine command to the plus-minus machine module 130, the plus-minus machine module 130 receives the command, and controls the starting of one air compressor 310 with the shortest running time, no fault and good running state in the air compressor unit 300, if the air volume requirement cannot be met at the moment, the PLC control unit 100 sends the plus-minus machine command to the plus-minus machine module 130, and the plus-minus machine operation is repeated until the pressure of the exhaust main pipe 400 reaches the target exhaust pressure, and the plus machine is stopped; when the air volume supply of all the running air compressors 310 is larger than the target exhaust pressure value, the PLC control unit 100 sends a machine reduction command to the machine reduction module 130, the machine reduction module 130 receives the command and controls one air compressor 310 with long running time in the air compressor unit 300 to stop.
The unit switching module 140 is used for replacing the air compressors 310; when the operation time of a certain air compressor 310 reaches the set maximum operation time parameter of the air compressor, the PLC control unit 100 controls and drives one air compressor, which is not working, in the air compressor unit 300 to replace the machine with long operation time to work by turns through the unit switching module 140, thereby achieving the purpose of alternate work and being beneficial to prolonging and balancing the service life of each air compressor 310.
The fault switching module 150 is used for monitoring the fault conditions of all the air compressors 310 in real time and driving the fault machines to stop; when some air pressure has a fault, the function can immediately drive the digital quantity unit 180 to stop the air compressor 310 with the fault through a signal cable, so that the safety of equipment is ensured, and meanwhile, the air compressor 310 with the shortest running time and a good running state is screened out through the adding and subtracting module 130 to be started to take over the work of the fault machine, so that the field air supply quantity is ensured.
And the operation counting module 160 is used for counting and recording different states of each air compressor 310.
The industrial touch screen 200 comprises a human-computer interaction interface 210, wherein the human-computer interaction interface 210 is used for setting a target exhaust pressure value, setting the maximum operation time of an air compressor, receiving a pressure value in an exhaust main pipe collected by a PLC control unit, and calculating and comparing the pressure value with the target exhaust pressure value; when the pressure value in the collected exhaust main pipe is smaller than the target exhaust pressure value, the PLC control unit 100 is controlled to drive the air compressor unit 300 to start, namely, the air compressor 310 with the shortest running time, no fault and good running state in the air compressor unit 300 is driven to start through the plus-minus machine module, and when the pressure value in the collected exhaust main pipe is larger than the target exhaust pressure value, the PLC control unit 100 drives the air compressor unit 300 to reduce, namely, drives the air compressor 310 with long running time in the air compressor unit 300 to stop.
Each air compressor 310 is provided with a single machine control unit 320, each single machine control unit 320 is provided with a serial communication interface, and the serial communication interfaces are connected with the RS485 communication module 110; the interface can read parameters such as target pressure, fault codes and running states, and the communication interfaces of all the air compressors 310 are connected with the communication modules of the PLC control system according to the communication connection mode of the RS485 bus, so that targets of all the air compressors 310 can be set at one time through the communication bus, and after the parameters are set on the control panel of the air compressor 310, the PLC control unit 100 receives an instruction and drives the RS485 communication module to modify the target pressure value of the single-machine control unit 320 of each air compressor 310 through a copying program.
Be equipped with pressure sensor in the exhaust manifold 400 for pressure in the detection pipeline, through the mode at air compression exhaust manifold 400 installation pressure sensor, weigh the gas use condition in factory at present, pressure is low explains that the gas consumption is big, need add air compressor machine 310, and the gas consumption is little the pressure on the high side explains and will subtract the machine, needs to reduce air compressor machine 310 quantity, is connected PLC control unit 100 analog input unit with pressure sensor through signal cable and gathers PLC control unit 100 during pressure signal.
The RS485 communication module 110, the start-stop control function module 120, the add-subtract function module, the unit switching module 140, the fault switching module 150 and the operation statistics module 160 are connected with the analog quantity unit 170 and the digital quantity unit 180 together, and the analog quantity unit 170 is connected with the pressure sensor through a signal cable, so that pressure data collected by the pressure sensor can be conveniently transmitted to the PLC control unit 100.
Each air compressor 310 is provided with an equipment start/stop hard contact 330, and each equipment start/stop hard contact 330 is connected with the digital quantity unit 180, so that the purpose of remotely starting and stopping the air compressor 310 is conveniently achieved.
The human-computer interaction interface 210 consists of a parameter monitoring module 211 and a parameter control module 212; a parameter monitoring module 211 for monitoring the operation state of each air compressor 310; and the parameter control module 212 is used for inputting parameters and instructions into the PLC control unit 100.
The working principle of the invention is as follows:
when the system works, the PLC control unit 100 is connected with the air compressor unit 300, the PLC control unit 100 stores and updates the running condition and running data of each air compressor 310 in the air compressor unit 300 in real time, and the start and stop of the air compressors 310 are conveniently controlled through the start and stop control function module 120; the plus-minus machine module 130 is used for controlling the starting and stopping of the air compressors 310, when the air volume supply of all the running air compressors 310 is smaller than a target exhaust pressure value, the PLC control unit 100 sends a plus-minus machine command to the plus-minus machine module 130, the plus-minus machine module 130 receives the command, and controls the starting of one air compressor 310 with the shortest running time, no fault and good running state in the air compressor unit 300, if the air volume requirement cannot be met at the moment, the PLC control unit 100 sends the plus-minus machine command to the plus-minus machine module 130, and the plus-minus machine operation is repeated until the pressure of the exhaust main pipe 400 reaches the target exhaust pressure, and the plus machine is stopped; when the air supply of all running air compressors 310 is larger than the target exhaust pressure value, the PLC control unit 100 sends a machine reduction command to the machine reduction module 130, the machine reduction module 130 receives the command and controls one air compressor 310 with long running time in the air compressor unit 300 to stop, and the machine reduction and the machine increase are conveniently and automatically carried out according to the pressure value of the exhaust main pipe 400 without human interference through the control mode; through the unit switching module 140, replacement among the air compressors 310 is performed, the air compressor 310 with the shortest running time and a good running state is screened out to be started, and machines with long running time are replaced to work, so that the purpose of alternate work is achieved, and the service life of each air compressor 310 is prolonged and balanced; the system is used for monitoring the fault conditions of all air compressors 310 in real time through the fault switching module 150 and driving the fault machine to stop, when one air compressor 310 has a fault, the module can immediately drive the digital quantity unit 180 to stop the work of the fault machine through a signal cable, so that the equipment safety is ensured, meanwhile, the air compressor 310 with the shortest running time, no fault and good running state in the air compressor unit 300 is controlled to start through the air compressor adding and reducing module 130 and replaces the work of the fault machine to ensure the field air supply quantity, the running statistical module 160 is used for counting and recording different states of each air compressor, the system controls the air compressor unit 300 through the PLC control unit, and the automatic air compressor adding and reducing, automatic rotation and fault switching functions of the air compressor unit 300 are realized.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (7)
1. The utility model provides an air compressor unit cooperative control system which characterized in that: the industrial touch screen air compressor comprises a PLC control unit, an industrial touch screen, an air compressor unit and an exhaust main pipe; wherein:
the air compressor unit is composed of a plurality of air compressors, the air compressor unit is connected with an exhaust main pipe,
the PLC control unit is connected with the air compressor unit and is used for driving each air compressor to start and stop,
the PLC control unit is also connected with an exhaust main pipe and is used for acquiring the pressure value in the exhaust main pipe in real time,
the industrial touch screen comprises a human-computer interaction interface which is used for setting a target exhaust pressure value, setting the maximum operation time of the air compressor, receiving a pressure value acquired by the PLC control unit and calculating and comparing the pressure value with the target exhaust pressure value;
the PLC control unit includes:
the RS485 communication module is connected with the industrial touch screen and the air compressor unit through an RS485 bus and used for transmitting real-time operation parameters of the air compressor unit to the industrial touch screen for display;
the start-stop control function module is used for controlling the start and stop of the air compressor;
the air compressor adding and subtracting module is used for screening the air compressor which has the shortest running time and good running state to start when the air supply is less than the target exhaust pressure value; when the air supply is larger than the target exhaust pressure value, screening the air compressor with the longest operation time to shut down;
the unit switching module is used for replacing each air compressor;
the fault switching module is used for monitoring the fault conditions of all air compressors in real time and driving the fault machine to stop;
and the operation counting module is used for counting and recording different states of each air compressor.
2. The air compressor unit cooperative control system according to claim 1, wherein: each air compressor is provided with a single machine control unit, each single machine control unit is provided with a serial communication interface, and the serial communication interfaces are connected with the RS485 communication module.
3. The air compressor unit cooperative control system according to claim 2, wherein: a pressure sensor is arranged in the exhaust main pipe and used for detecting the pressure in the pipeline in real time; the pressure sensor is connected with the PLC control unit and used for transmitting pressure data to the PLC control unit.
4. The air compressor unit cooperative control system according to claim 3, wherein: the RS485 communication module, the start-stop control function module, the plus-minus machine function module, the unit switching module, the fault switching module and the operation statistic module are connected with the analog quantity unit and the digital quantity unit together, and the analog quantity unit is connected with the pressure sensor through a signal cable.
5. The air compressor unit cooperative control system according to claim 4, wherein: each air compressor is provided with an equipment start-stop hard contact respectively, and each equipment start-stop hard contact is connected with the digital quantity unit.
6. The air compressor unit cooperative control system according to claim 1, wherein: the human-computer interaction interface consists of a parameter monitoring module and a parameter control module;
the parameter monitoring module is used for monitoring the running state of each device;
and the parameter control module is used for inputting parameters and instructions into the PLC control unit.
7. The air compressor unit cooperative control system according to claim 6, wherein: the operation panel of the air compressor can set pressure parameters and transmit the pressure parameters to the PLC control unit, and the PLC control unit receives the set parameters and modifies the target pressure value of the single-machine control unit.
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| CN113279948A (en) * | 2021-06-23 | 2021-08-20 | 浙江益海嘉里食品工业有限公司 | Centralized control system and control method for air compressor |
| CN113323853A (en) * | 2021-07-08 | 2021-08-31 | 北京康吉森自动化技术股份有限公司 | Unattended full-automatic control method for air compressor group of air compressor station |
| CN113374680A (en) * | 2021-06-18 | 2021-09-10 | 国家石油天然气管网集团有限公司西气东输分公司 | Compressor unit combined operation control method and system |
| CN113417843A (en) * | 2021-08-10 | 2021-09-21 | 天津森普捷电子有限公司 | Control method of multi-machine-head air compressor controller |
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| CN117869252A (en) * | 2023-12-15 | 2024-04-12 | 佛山中车四方轨道车辆有限公司 | An intelligent management system for air compressors |
| CN118705173A (en) * | 2024-05-29 | 2024-09-27 | 广东恒益数智科技有限公司 | An air compressor control system with power saving and speed regulation functions |
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