Compressor control system and method
First Claim
1. A method for optimizing the operating efficiency of a compressor having a compression module for compressing a fluid, the compression module including an inlet for receiving the fluid and an outlet for discharging compressed fluid, the compressor including a prime mover for driving the compression module and a rotatable fan for drawing ambient air into the compressor, the compressor including a first temperature sensor for sensing the temperature of compressed fluid discharged from the compression module, a second temperature sensor for sensing the temperature of a coolant circulating through the prime mover, a third temperature sensor for sensing the temperature of the fluid entering the compression module, and a fourth temperature sensor for sensing the temperature of a lubricant mixed with the fluid as the fluid is compressed in said compression module, the compressor including an electronic control module (ECM) electrically connected to the temperature sensors for receiving signals therefrom, the ECM including a non-volatile memory containing empirical data relating to optimal operating set points of the compressor and a logic routine for controlling the rotational speed of the fan and the volume of the lubricant mixed with the fluid so as to optimize the efficiency of the compressor, the method comprising the steps of:
- A) executing a temperature sensing subroutine whereby the first, second, third and fourth temperature sensors collect temperature data during operation of the compressor and relay the temperature data to the ECM;
B) executing a fan speed subroutine whereby the ECM generates signals in response to the temperature data received for controlling the rotational speed of the fan; and
C) executing a lubricant volume control subroutine whereby the ECM generates signals in response to the temperature data received for controlling the volume of the lubricant mixed with the fluid during compression of the fluid in the compression module.
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Abstract
A method for optimizing the operating efficiency of a compressor having a compression module for compressing a fluid, the compression module including an inlet for receiving the fluid and an outlet for discharging compressed fluid, the compressor including a prime mover for driving the compression module and a rotatable fan for drawing ambient air into the compressor. The compressor includes a first temperature sensor for sensing the temperature of compressed fluid discharged from the compression module, a second temperature sensor for sensing the temperature of a coolant circulating through the prime mover, a third temperature sensor for sensing the temperature of the fluid entering the compression module, and a fourth temperature sensor for sensing the temperature of a lubricant mixed with the fluid as the fluid is compressed in the compression module. The compressor includes an electronic control module (ECM) electrically connected to the four temperature sensors for receiving signals therefrom. The ECM includes a non-volatile memory containing empirical data relating to optimal operating set points of the compressor and a logic routine for controlling the rotational speed of the fan and the volume of the lubricant mixed with the fluid so as to optimize the efficiency of the compressor. The method includes the steps of executing a temperature sensing subroutine whereby the first, second, third and fourth temperature sensors collect temperature data and relay the temperature data to the ECM, executing a fan speed subroutine whereby the ECM generates signals in response to the temperature data received by the ECM for controlling the rotational speed of the fan, and executing a lubricant volume control subroutine whereby the ECM generates signals in response to the temperature data received by the ECM for controlling the volume of the lubricant mixed with the fluid in the compression module.
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Citations
19 Claims
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1. A method for optimizing the operating efficiency of a compressor having a compression module for compressing a fluid, the compression module including an inlet for receiving the fluid and an outlet for discharging compressed fluid, the compressor including a prime mover for driving the compression module and a rotatable fan for drawing ambient air into the compressor, the compressor including a first temperature sensor for sensing the temperature of compressed fluid discharged from the compression module, a second temperature sensor for sensing the temperature of a coolant circulating through the prime mover, a third temperature sensor for sensing the temperature of the fluid entering the compression module, and a fourth temperature sensor for sensing the temperature of a lubricant mixed with the fluid as the fluid is compressed in said compression module, the compressor including an electronic control module (ECM) electrically connected to the temperature sensors for receiving signals therefrom, the ECM including a non-volatile memory containing empirical data relating to optimal operating set points of the compressor and a logic routine for controlling the rotational speed of the fan and the volume of the lubricant mixed with the fluid so as to optimize the efficiency of the compressor, the method comprising the steps of:
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A) executing a temperature sensing subroutine whereby the first, second, third and fourth temperature sensors collect temperature data during operation of the compressor and relay the temperature data to the ECM; B) executing a fan speed subroutine whereby the ECM generates signals in response to the temperature data received for controlling the rotational speed of the fan; and C) executing a lubricant volume control subroutine whereby the ECM generates signals in response to the temperature data received for controlling the volume of the lubricant mixed with the fluid during compression of the fluid in the compression module. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A method for optimizing the operating efficiency of a compressor having a compression module for compressing a fluid, the compression module including an inlet for receiving the fluid and an outlet for discharging compressed fluid, the compressor including a prime mover for driving the compression module and a rotatable fan for drawing ambient air into the compressor, the compressor including a first temperature sensor for sensing the temperature of compressed fluid discharged from the compression module, a second temperature sensor for sensing the temperature of a coolant circulating through the prime mover, a third temperature sensor for sensing the temperature of the fluid entering the compression module, and a fourth temperature sensor for sensing the temperature of a lubricant mixed with the fluid as the fluid is compressed in said compression module, the compressor including an electronic control module (ECM) electrically connected to the temperature sensors for receiving signals therefrom, the ECM including a non-volatile memory containing empirical data relating to optimal operating set points of the compressor and a logic routine for controlling the rotational speed of the fan and the volume of the lubricant mixed with the fluid so as to optimize the efficiency of the compressor, the method comprising the steps of:
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A) executing a temperature sensing subroutine routine comprising the steps of; (i) sensing the actual temperature of the compressed fluid discharged from the outlet of the compression module; (ii) sensing the actual temperature of the coolant circulating through the prime mover; (iii) sensing the actual temperature of the fluid entering the inlet of the compression module; (iv) sensing the actual temperature of the lubricant mixed with the fluid in the compression module; and (v) sending the temperature data compiled in subroutine steps (i)-(iv) to the ECM; and
thenB) executing a fan speed subroutine for modulating the rotational speed of the fan comprising the steps of; (i) comparing the actual temperature of the compressed fluid discharged from the compression module with a set point compressed fluid discharge temperature stored in the ECM memory; (ii) increasing the speed of the fan if the actual temperature of the compressed fluid discharged from the compression module is greater than the set point fluid discharge temperature stored in the ECM memory; (iii) comparing the actual prime mover coolant temperature with a set point prime mover coolant temperature stored in the ECM memory; (iv) decreasing the speed of the fan if the actual prime mover coolant temperature is less than the set point prime mover coolant temperature; and (v) proceeding to the lubricant volume control subroutine if the actual prime mover coolant temperature is greater than the set point temperature stored in the ECM memory; and
thenC) executing the lubricant volume control subroutine comprising the steps of; (i) subtracting the actual temperature of the lubricant mixed with the fluid in the compression module from the actual temperature of the fluid entering the inlet of the compression module for calculating an actual temperature differential; (ii) comparing the actual temperature differential calculated in step (i) with a predetermined set point temperature differential stored in the ECM memory; (iii) increasing the volume of the lubricant mixed with the fluid in the compression module if the actual temperature differential is greater than the predetermined set point temperature differential; (iv) decreasing the volume of the lubricant mixed with the fluid in the compression module if the actual temperature differential is less than the predetermined set point temperature differential.
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Specification