H ydroCOM gas quantity stepless adjustment system 2 1 Basic principle The energy consumption of the compressor is mainly proportional to the actual compressed gas volume during each cycle. At present, the flow regulation of reciprocating compressors in China generally adopts the method of step-by-step return or outlet returning to the inlet. After the gas is compressed and then returned, it is inevitable that energy can not be saved. In response to this shortcoming, HOERBIGER developed the Hydro COM gas volume stepless adjustment technology. This technology refers to the technology of injection components in large diesel engines, and combined with intelligent control technology, through the hydraulic transmission device, the compressor becomes a controlled air valve during the compression process, that is, by delaying the closing of the intake valve. Part of the gas in the cylinder is returned to the intake chamber, thereby achieving a gas volume adjustment mode in which the intake valve is opened in a partial stroke. In the reciprocating motion of the piston of the compressor, when the intake of the cylinder is finished, the valve piece of the intake valve is forcibly kept open by the unloader under the action of the actuator, and the compression process does not follow the original compression curve from the position C to Position D, but first from position C to position Cr, at which point part of the gas originally sucked into the cylinder is returned to the intake pipe via the opened intake valve without being compressed; the piston is moved to a specific position Cr (corresponding to When the required air volume is), the actuator causes the forced external force of the top opening valve to disappear, the intake valve piece falls back to the valve seat and closes, and the remaining gas in the cylinder begins to be compressed. This is the principle of the return flow of the HydroCOM system.
2 2 The specific configuration of the H ydroCOM system is as shown.
HA is the hydraulic actuator for controlling the opening and closing of the intake valve; CIU is the intermediate interface unit; HU is the hydraulic power unit; BUS RS485 communication; HSS CIU configuration software; TDC is the top dead center sensor; DCS is the distributed control system.
The hydraulic actuator of the Hydro COM system is mounted above the intake valve and provides the necessary hydraulic power from the hydraulic unit HU. The actuator is driven by the RS485 signal from CIU. The CIU is the connection hub between HydroCOM and DCS. The control of the compressor is still completed by DCS.
The TDC sensor transmits the actual position information of the piston in the cylinder to the CIU, and the CIU control signal is converted to the exact time when the intake valve is opened and closed. For the operator, the compressor displacement is just a simple analog control signal. By using digital control technology, the Hydro COM system can complete the resetting of the intake valve opening and closing rules in 2 to 3 revolutions of the crankshaft to meet different exhaust volume requirements.
3 Application and analysis 3 1 Energy-saving effect The load power corresponding curve after the HydroCOM gas quantity stepless adjustment system is added to the compressor. From the load power corresponding curve can also be analyzed and concluded that the HydroCOM system effectively controls the opening/closing of the intake valve, which plays a role in energy saving and emission reduction.
3 2 Unexpectedly harvested at full load, energy saving During the commissioning process, it was surprisingly found that the motor current value was only 102A at 100% load under HydroCOM control, while the previous full load current was 120A. That is to say, even if part is not considered In the case of load, there is also energy saving effect.
3 3 Energy-saving effect analysis A reciprocating stroke of a reciprocating compressor piston can be divided into four processes: high pressure residual gas expansion (AB), suction (BC), compression (CD), and exhaust (DA). Opening will bring power loss, also known as valve loss. As shown in the figure below, when the piston runs to point B1, the high-pressure residual gas in the cylinder expands, and the pressure in the cylinder is equal to the intake pressure. The ideal condition is to immediately enter the intake stroke, but in fact the intake valve is opened. A certain pressure difference is required, and the piston enters the intake stroke when it runs to point B. In this way, the efficiency of the intake valve in the above figure is lost. Under the control of HydroCOM, the intake valve can be opened at point B1, thus avoiding the intake valve loss, so that the current value of the motor naturally decreases.
4 Conclusion The H ydroCOM system can precisely control the opening and closing time of the reciprocator intake valve, thus regulating the compressor volume steplessly, and saving energy and reducing emissions.
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