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    Analysis of the causes of air compressor operation failure

    Analysis of the causes of air compressor operation failure Foreword The main medium conveyed by the air compressor is air, which provides compressed air to the ventilator, which is the basic condition for keeping the ventilator working normally. The main part of the air compressor is generally composed of driving steam turbines, compressors, low-pressure cylinders, speed-increasing tanks, compressor high-pressure cylinders, etc. This host is installed on the base of the car and provides compressed air for the ventilator during driving. Although the quality of the air compressors on the market is generally relatively good, due to its relatively high mechanical loss rate, it is easy to cause inevitable failures such as excessive fuel consumption, air leakage from the pressure release valve, and overheating of the compressor. 1 The current common operating problems of air compressors 1.1 Excessive fuel consumption Excessive fuel consumption is a common problem of air compressors currently on the market. According to the experiments and tests we have done, it can be found that after each air compressor runs for 200h, there will be a significant increase in fuel consumption, and when the air temperature is low, the air compressor will cause a decrease in evaporation pressure. Fuel consumption has risen sharply, which will greatly increase the travel costs for car owners. Despite the increase in fuel consumption, the number of kilometers traveled by the car and the working intensity of the car ’s air compressor have not been significantly improved. Then the wasted oil and gas must still exist in the entire system, so many experiments have proved that a lot of wasted The lost oil and gas still exists in the intercooler. In order to understand why a large amount of paint exists in the intercooler, many experiments were conducted afterwards, and it was found that this was due to the high power of the air compressor, which caused the bearing temperature to be high. When the bearing temperature is high, the oil and gas evaporates into gas in the bearing part due to the high temperature, and when it reaches the intercooler, it will liquefy into liquid oil and be stored in the intercooler. 1.2 Safety valves take off frequently Frequent tripping of the safety valve is also a failure of the air compressor, but frequent tripping of the safety valve during the operation of the compressor is not easy to be observed, and can only be reflected by the oil consumption in the air compressor. There are two reasons for the frequent tripping of safety valves, including failure of safety valves and clogged outlets leading to excessive pressure. If the safety valve is frequently tripped due to the failure of the safety valve, then this problem can be easily solved as long as the safety valve is replaced in a timely manner. However, if the fault persists after the safety valve is replaced, it is a phenomenon caused by excessive pressure due to the blocked outlet. The outlet blockage will cause the pressure at the outlet pipe to be too high. The excessive pressure will push up the safety valve. After releasing a certain pressure, the safety valve will fall again, which forms a phenomenon manifested in an endless cycle that is the safety valve. Take off frequently. In order to clarify the cause of the outlet clogging phenomenon, we disassembled the air compressor, and finally determined that it was caused by the failure of the minimum pressure valve at the outlet of the oil and gas barrel. This is because the spool of the minimum pressure valve often contacts the outside air, and the air is generally All contain water vapor, which will cause the valve core of the minimum pressure valve to contact the air often and cause the valve core to get wet. The valve core after the dampness will show the insensitive status of slow movement, so the outlet is blocked and the air compressor is formed. Because the compressed air is not smoothly removed, the air pressure in the compressor instantly reaches a large pressure. The solution to this problem can be achieved by cleaning the minimum pressure valve. Wash the rust on the damped pressure valve spool caused by the contact between the minimum pressure valve and the air with a special tool and apply a layer of anti-rust liquid on it. It can solve the problem of outlet blockage caused by the failure of the minimum pressure valve. 1.3 Malfunction of intake valve stepper motor Intake valve stepper motor failure is a phenomenon that often occurs in another air compressor. It needs to be inserted here. The working principle of the air compressor is that the air reaches the spiral rotor in the compressor after being filtered by the filter, and the air is compressed by the motor. At this time, the oil and gas mixture is discharged from the main compressor and enters the separation system. After exiting the separator, oil and gas generally no longer exist in liquid form. Therefore, a cooler is required to cool it. However, the failure of the intake valve stepper motor will cause the cooler to leak, which will also cause the cooling water in the cooler to overflow, and the overflowing water will enter the intake valve. If the cooler fails, the air pressure of the intake valve still cannot rise after the repair, then this is caused by the failure of the intake valve and is no longer related to the cooler. At this time, you should first check whether the wire coil of the intake valve is burned due to the high internal temperature. You can remove the original wire coil and rewind a new coil to put it into the intake valve, so that you can It was detected whether the intake valve or the cooler caused the failure. 2 Discussion on the method of fault diagnosis 2.1 Fault diagnosis method of air compressor based on RBF neural network Since the existence of the neural network system, the RBF neural network has been frequently used to detect compressor failures. RBF neural network is a relatively new type of antecedent neural network system, which is generally composed of three network layers: input layer, hidden layer and output layer. Because in the working process of the air valve of the air compressor, the valve plates of the intake valve and the exhaust valve are often ejected by the gas. This causes the valve plates to collide and compress the spring, which may easily cause the valve plate and the spring to malfunction. The simulation result of the training algorithm of the RBF neural network is relatively high. Because the training algorithm of the neural system is relatively complex and difficult to understand, I will not repeat it here, but the following data can show that the simulation result of the algorithm is relatively high. Among the 100 training samples for the simulation experiment, up to 96 groups have reached the training goal of the simulation experiment. It can be seen that the accuracy of the RBF neural network diagnosis is as high as 96.67%. This number can fully indicate that the RBF neural network is in The feasibility of the air compressor fault diagnosis in the process, so it is extremely feasible to apply it to the actual air compressor fault diagnosis. 2.2 Fault diagnosis method of air compressor based on PCA technology and RBF neural network PCA-based sensor network fault diagnosis is in the actual network diagnosis, and is generally used together with RBF neural network diagnosis. RBF will not be discussed here. PCA is a multivariate statistical method. It is often used in the field of control to process various data, and monitor and control production according to the characteristics of the data processed. This technology can be used in the fault diagnosis of air compressors. Greatly reduce the probability of failure. The air compressor fault diagnosis method based on PCA sensing technology and RBF neural network solves the problem by establishing a data model of machine operation. Its working principle is to collect all kinds of original data appearing during the operation of the air compressor. With the support of the data analysis capability of PCA sensing technology, various problems that may occur with the air compressor during the operation of the vehicle and the location where the failure may occur can be detected in advance. This method analyzes the collected data more comprehensively, and the technology's information processing ability and anti-interference ability are very strong, which can accurately determine the fault problem, so that we can prepare for the fault, Don't face it blankly when a fault occurs. 2.3 Fault diagnosis method of air compressor based on PCA technology and D-S evidence theory An air compressor fault diagnosis method based on PCA sensing technology and D-S evidence theory is a method for fault diagnosis and analysis based on data information. This analysis and diagnosis method refers to observing and analyzing data during different operations of the air compressor. According to the data characteristics obtained by this technical analysis, a comparative fusion result is formed, which in turn gives the final result of the failure cause of the air compressor. Compared with the above two methods, this method has the more outstanding advantage that it can analyze the hidden information under the collected data more comprehensively. And this method still retains the advantages of PCA sensing technology for processing data speed and strong anti-interference ability. This is a good solution to the problem that the operators in traditional fuzzy analysis do not fully understand or inaccurate the phenomenon when the air compressor fails. Conclusion In summary, through the analysis and discussion of the above three fault diagnosis methods, we have a deeper understanding of how to diagnose air compressor faults and how to prevent some of the faults that may occur during driving. Although the quality of the Rafael ventilator air compressor, screw air compressor and oil-injected screw air compressor sold on the market are relatively good, it is affected by the large output power of the compressor, which has caused The current situation of high failure rate.

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