Compressor system and method and control for same

• US 6,471,486 B1
• Filed: 06/12/2000
• Issued: 10/29/2002
• Est. Priority Date: 10/28/1997
• Status: Expired due to Term

• Current Assignee: Quincy Compressor LLC (Atlas Copco AB)
• Original Assignee: Coltec Industries Incorporated (Enpro Industries Incorporated)
• Inventors: Moffat, Paul G., Centers, Steven D.
• Primary Examiner(s): Freay, Charles G.
• Assistant Examiner(s): GRAY, MICHAEL KUHN
• Application Number:
  US09/592,489
• Time in Patent Office: 869 Days
• Field of Search: 417/18, 417/17, 417/32, 417/44.4, 417/53, 417/286
• US Class Current: 417/18
• CPC Class Codes: F04B 2205/05 Pressure after the pump outlet
• CPC Class Codes: F04B 2205/07 Pressure difference over the pump
• CPC Class Codes: F04B 2205/11 Outlet temperature
• CPC Class Codes: F04B 2207/703 Stopping
• CPC Class Codes: F04B 49/10 Other safety measures

Abstract

An electronic control system is disclosed to control and to prevent damage to a standalone or a network of oil free, two stage compressor packages. The electronic control system uses pressure and temperature sensors to detect actual shutdown conditions or predict shutdown conditions based on the operating state of the compressor package and the current temperatures or pressures of the air at strategic locations in the compressor package. It has been determined through experimentation that, if the pressure at the inlet of the stage two compressor is less than the discharge pressure of the stage two compressor by more than an allowable value, then a high temperature condition will occur in the stage two compressor and cause the compressor to seize. It has also been determined the pressure differential occurs first in this situation and that the electronic control system can predict the failure based on the pressure differential data and to shut the compressors down before the stage two compressor failure occurs. The electronic control system then records the shutdown event in an area of nonvolatile memory and displays the reason for the shutdown on a LCD display visible to the compressor operator. A plurality of electronic control systems can be connected in a peer-to-peer network to coordinate control of a plurality of compressors connected to the same air distribution system. A modem connected to the electronic control system supports remote diagnostics, monitoring, and control. Methods for controlling the operation of the compressor packages using the electronic control system are also disclosed.

Claims

1. An electronic control system for controlling the operation of at least one or a network of compressor packages, the system comprising:

at least one or a network of oil less, two stage compressor packages, operatively connected to a pressure system in which pressure is to be maintained within a predetermined range of allowable set point pressure values;

measuring means, operatively connected to the first and the second compressor stages, for determining the pressure value exiting the first and the second compressor stages;

processing means, operatively connected to the measuring means, for receiving signals from the measuring means and for comparing the determined pressure values exiting the first compressor and the second compressor stages with the predetermined range of allowable set point pressure values; and

means, operatively connected to the oil free, two stage compressor package and the processing means, for shutting down the compressor package when at least one determined pressure value exceeds the predetermined range of allowable set point pressure values before the compressor package is damaged.

2. The system of claim 1, further comprising:

monitoring means, operatively connected to the processing means, for indicating basis for shutdown.

3. The system of claim 2, wherein the monitoring means includes an annunciating device for displaying the location on a graphic where a shutdown has occurred.

4. The system of claim 2, wherein the monitoring means further includes a LCD device for displaying status messages of the system thereon.

5. The system of claim 1, wherein the system provides means for unloading each stage simultaneously.

6. An electronic control system for controlling the operation of at least one or a network of compressor packages, the system comprising:

at least one or a network of oil less, two stage compressor packages, operatively connected to a pressure system in which pressure is to be maintained within a predetermined range of allowable set point pressure data values;

memory means for storing data and at least one program thereon;

input means for entering the predetermined allowable set point pressure data values;

indicating means for exhibiting data;

measuring means for determining actual temperature and actual pressure data values and relaying the actual data values to a processing means;

communication means, operatively connected to the compressor package, for remotely accessing the electronic control system via a computer;

processing means, operatively connected to the compressor package, for receiving the actual data values from the measuring means, for receiving the entered set point data values from the input means and communications means and for processing the data pursuant to at least one program; and

means, operatively connected to the compressor package, for shutting down the compressor package when at least one pressure value exceeds the predetermined range of allowable set point pressure data values before the compressor package is damaged.

7. The system of claim 6, wherein the memory means is a computer readable storage medium.

8. The system of claim 6, wherein the memory means comprises:

at least one microchip.

9. The system of claim 6, wherein the memory means is selected from the group comprising:

an eprom and an eeprom.

10. The system of claim 6, wherein the memory means includes a type of memory selected from the group comprising:

volatile, non-volatile, flash and non-flash memory.

11. The system of claim 6, wherein the memory means is able to store at least one program selected from the group comprising:

software and firmware.

12. The system of claim 6, wherein the input means is selected from the group comprising:

a keyboard, a mouse, a touchpad, a keypad and a joystick.

13. The system of claim 6, wherein the indicating means is selected from the group comprising:

an enunciator, a LED, a LCD and a computer monitor.

14. The system of claim 6, wherein the measuring means includes at least one sensor.

15. The system of claim 6, wherein the measuring means includes at least one intelligent sensor.

16. The system of claim 6, wherein the measuring means includes at least one sensing circuit.

17. The system of claim 6, wherein the communication means includes at least one modem.

18. The system of claim 6, wherein the processing means includes at least one microprocessor.

19. An electronic control system for controlling the operation of at least one or a network of compressor packages, the system comprising:

at least one or a network of oil less, two stage compressor packages, operatively connected to a pressure system in which pressure is to be maintained within a predetermined range of allowable set point pressure data values for at least one sensor within each compressor package; and

a computer program stored on a computer readable storage medium comprising;

setting up a microprocessor to define specific ports to be used;

powering up a display;

testing each sensor for a valid input condition;

testing for duplicate user ID, if found, requesting user to enter a different ID;

setting up the system timers, time and dates, along with schedules and modem configurations;

starting background operations that monitor the Network, modem, keyboard and sensor inputs;

restoring the node number via the Network, and retesting at least once;

entering the main menu when the compressor is idle, receiving a start command such that the compressor package will enter the run mode that was last selected;

processing any input key sequence entered that accesses the hidden key parameter menus; and

reverting the display to the main menu from any sub-menu on a time out.

20. An article of manufacture comprising:

a computer usable medium having a computer readable program code means embodied therein for controlling the operation of at least one or a network of compressor packages, the computer readable program code means comprising;

computer readable program code means for setting up a microprocessor to define specific ports to be used;

computer readable program code means for powering up a display;

computer readable program code means for testing each sensor for a valid input condition;

computer readable program code means for testing for duplicate user ID, if found, requesting user to enter a different ID;

computer readable program code means for setting up the system timers, time and dates, along with schedules and modem configurations;

computer readable program code means for starting background operations that monitor the Network, modem, keyboard and sensor inputs;

computer readable program code means for restoring the node number via the Network, and retesting at least once;

computer readable program code means for entering the main menu when the compressor is idle, receiving a start command such that the compressor package will enter the run mode that was last selected;

computer readable program code means for processing any input key sequence entered that accesses the hidden key parameter menus; and

computer readable program code means for reverting the display to the main menu from any sub-menu on a time out.

21. An article of manufacture as in claim 20, wherein the computer readable program code means embodied therein includes controlling the operation of at least one or a network of oil less two stage compressor packages, operatively connected to a pressure system in which pressure is to be maintained within a predetermined range of allowable set point pressure data values for at least one sensor within each compressor package.

22. An article of manufacture comprising:

a computer usable medium having a computer readable program code means embodied therein for an electronic control system for controlling the operation of at least one or a network of compressor packages, the system comprising;

at least one or a network of oil less, two stage compressor packages, operatively connected to a pressure system in which pressure is to be maintained within a predetermined range of allowable set point pressure values;

measuring means, operatively connected to the first and the second compressor stages, for determining the pressure value exiting the first and the second compressor stages;

processing means, operatively connected to the measuring means for receiving signals from the measuring means, for comparing the determined pressure values exiting the first compressor and the second compressor stages with the predetermined range of allowable set point pressure values; and

means, operatively connected to the oil free, two stage compressor package and the processing means, for shutting down the compressor package when at least one determined pressure value exceeds the predetermined range of allowable set point pressure values before the compressor package is damaged.

23. The article of manufacture of claim 22, wherein the system further comprises monitoring means, operatively connected to the processing means, for indicating basis for shutdown.

24. The article of manufacture of claim 22, wherein the system further comprises monitoring means which include an annunciating device for displaying the location on a graphic where a shutdown has occurred.

25. The article of manufacture of claim 24, wherein the monitoring means further includes a LCD device for displaying status messages of the system thereon.

26. The article of manufacture of claim 22, wherein the system further comprises means for unloading each stage simultaneously.