Air compressors are used in a wide range of applications, including industrial and agricultural, defense, technology, and civil. The air compressor runs for a long time, consumes a large amount of electricity, has a large amount of maintenance, and has high cost. Especially for large-scale air compressors for mining, it runs 24 hours a day, and it takes a long time to run under no load or light load. It can be seen that in use, the effective operation of the air compressor is improved, the pressure loss and leakage in the gas pressure pipeline are reduced, the consumption of the compressor gas is saved, and the working reliability of the compressor is improved, which is of great significance for maintaining its efficient operation and reducing energy consumption.
There are many data on air compressor monitoring and transformation, but most of them focus on the monitoring and management of the air compressor's operating status. Some data also provide the use of frequency converter to control the operation of the air compressor, and adjust the running speed of the inverter to achieve energy-saving operation, but Since the air compressor is running at a low speed for a considerable part of the time, there is still considerable energy saving potential.
The main purpose of this project is to reduce the starting current of the air compressor through a number of transformations to achieve intermittent operation of the air compressor, thereby maximizing energy conservation.
2 Air compressor intermittent operation innovation content
21 Change the motor starting mode to change the starting mode of the frequency sensitive resistor, and use the ABB imported soft starter to control the motor starting. The controller has better starting performance, can reliably limit the starting current and voltage of the motor, and gives alarms to the motor's phase loss, short circuit and various faults of the soft starter, and performs related protection actions. At the same time, remove the motor carbon brush and short the motor to the reactor outlet. After this transformation, the motor starting current is greatly reduced, the starting performance is improved, and the electrical control automatically starts and stops.
22 Installation and modification of the check valve To prevent backflow of gas, ensure that the two air compressors operate in parallel and do not affect each other. The gate valve on the pipeline between the outlet of the air compressor and the inlet of the gas tank should be replaced with a one-way check valve. . At present, the check valves sold on the market are of the flap type and the lift type. Since the flap type check valve frequently swings, the impact, the noise is large, and the flap is easy to fall. The check valve suitable for the air compressor has a relatively good effect and is a lift check valve. In the system test, it is found that there are still many unsatisfactory aspects of this kind of check valve: 1) due to the operating characteristics of the air compressor, the intake of the cylinder, the exhaust process alternates, and the random variation of the external air consumption, decided The air pressure at the outlet end of the air compressor is unstable and jumps, causing the active valve core to move up and down frequently in the check valve, impacting the valve body and its internal sealing surface, so that the pipeline vibration is large, the metal impact clinks, noise Large, affecting the working environment of the air compressor driver.
2) Due to the frequent impact of the valve core, the sealing surface of the valve is also easy to break (the debris sometimes falls into the gas storage tank), the check valve is invalid and needs to be replaced, which inevitably increases the maintenance cost of the system.
During the observation of the air compressor maintenance process, it was found that during the suction and exhaust process of the cylinder of the air compressor, the intake valve, the exhaust valve and the check valve acted in the same unidirectional conduction. After consulting the relevant data and technical design, after deciding to modify the inner cavity of the check valve, put the suction valve or exhaust valve of the air compressor into it, and carry out related processing and transformation.
The operation result shows that the new check valve is used in the air pipeline, which completely cures the various drawbacks caused by the lift type and the flap type check valve. It not only runs smoothly, has no noise, no vibration, and has a long service life.
23 vent valve modification The 15 gate valve used for venting on the air outlet side of the air compressor is replaced with a 40 solenoid valve, so that the air compressor can be quickly and automatically deflated before starting. It is opened before starting and during start-up, and by the cooperation with the check valve, the load on the outlet side of the hollow press during the starting process is reduced. In order to reduce the harsh noise generated when the deflation valve is deflated, the air compressor deflation valve can be extended to the water to greatly reduce the noise.
The 24 load-reduction mode is modified with the pressure regulator in parallel with the 25 solenoid valve to change the air compressor load reduction mode. The normal load reduction process of the air compressor is: the air compressor driver manually rotates the unloading valve handwheel before starting, thereby closing the air. The inlet makes the air unable to enter the air compressor, and then starts the air compressor at no load. After the air compressor starts to reach the rated speed of the motor, the unloading valve is gradually opened to operate the air compressor. In the operation of the air compressor, when the pressure of the gas tank reaches the set value of the pressure regulator, the high pressure gas from the gas storage tank enters the cavity of the unloading valve server through the pressure regulator, pushing the valve core to close the air inlet.
In order to achieve automatic start of electrical control, the pressure regulator needs to be replaced with a solenoid valve or a bypass solenoid valve in parallel with the pressure regulator. In order to maintain compatibility with the original system, a method of bypassing the solenoid valve in parallel with the pressure regulator may be employed, and the solenoid valve shall be a normally open solenoid valve. In this way, if a new system line, sensor, programmable controller, soft starter, etc. fails, it can be immediately switched to the original method to start. After the transformation, when the motor is started for the first time, if the pressure of the gas storage tank is small, the starting method is the same as above. If the pressure of the gas storage tank is large (requires more than 05MPa), no manual intervention is required. When it is automatically started in normal operation, the high pressure gas from the gas storage tank enters the relief valve servo cavity through the pressure regulator or the bypass solenoid valve, pushing the valve core to close the air inlet, thereby achieving automatic no-load start.
25 unloading valve modification In order to realize the automatic control of the air compressor, the air compressor automatically starts and stops, so that the air compressor does not need to operate the hand wheel when starting, so that the high pressure gas from the gas storage tank enters the unloading valve through the electromagnetic valve or the pressure regulator. The air inlet can be completely closed, and the air supply pressure range of the air compressor can be increased as much as possible, thereby reducing the number of frequent starts of the air compressor. To this end, the relief valve is modified according to the structure and changed to electromagnet control. The original air compressor relief valve spring needs to be replaced with the same material, the same length, the same diameter but less rigid spring.
26 Installation of remote transmission pressure In order to realize automatic stop when the air compressor reaches the set high pressure, it will automatically start when it is lower than the normal supply pressure low limit. At the same time, it can realize the tracking and detection of the real-time gas pressure of the gas storage tank, and it is also convenient to adjust the relevant parameters. . The pressure of the gas tank needs to be replaced with a remote pressure sensor. In addition to normal display of working pressure, the sensor can convert the pressure signal into a 4~20mA current signal and output it to the PLC and a display that can receive the current signal.
27Installing the current transmitter is to detect the motor current under the starting and running state of the air compressor, realize the overcurrent of the motor, overload protection, and more importantly, transmit the motor current signal to the PLC, and the PLC according to the motor current signal and storage. The gas tank pressure signal comprehensively judges the operating status of the air compressor: start, load, unload, idling, and the like.
28 electronic control system transformation to facilitate automatic control intermittent operation, the original electronic control system needs to be replaced by soft starter, PLC (programmable controller), pressure sensor, current sensor and various AC contactors, intermediate relay The automatic monitoring system consisting of thermal relay and protection circuit protects the air compressor from oil cut, water cut, over temperature, over pressure, and motor overcurrent overload.
3 air compressor intermittent operation transformation benefits 1) greatly save energy. After the intelligent monitoring and energy-saving transformation of the air compressor, the actual working time of the air compressor is greatly shortened, and the phenomenon of no-load operation of the air compressor is basically eliminated, and the power consumption of the no-load is fundamentally saved.
2) Reduce the starting current. The device soft start is implemented to reduce the impact on the power supply system. The starting current of a single air compressor will be 400A or even 300A from the original 600A.
3) Reduced fuel consumption. Because the working time of the air compressor is proportional to the amount of oil injection, the working time of the air compressor is greatly reduced, and the corresponding fuel consumption is also greatly reduced.
4) Extend the service life of the equipment. Due to the shortened running time of the equipment, the mechanical wear of the equipment is reduced, which prolongs the service life of the air compressor.
5) Reduce noise pollution. Since the original no-load operation time of the air compressor basically changes to the downtime, the noise pollution during the shutdown is basically eliminated. Give the air compressor driver and staff a long and quiet environment.
The air compressor intermittent operation innovation system has achieved a complete success through nearly one year of research and experiment, and has achieved considerable economic and social benefits, and has a large universal promotion value.
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