Intelligent controller for a reciprocating air compressor and methods of use thereof

An intelligent controller for a multi-stage reciprocating air compressor with a tank, an air compressor pump, a motor, a motor starter, and a check valve, the intelligent controller comprising:

• a processor;
• a plurality of sensors in communication with the processor, the plurality of sensors is configured to read operating data of the multi-stage reciprocating air compressor and send the operating data to the processor, the plurality of sensors including:
• at least one interstage pressure sensor, each of the at least one interstage pressure sensor is configured to monitor pressure between stages of compression;
• a tank pressure sensor configured to monitor pressure of air in the tank;
• a final discharge pressure sensor configured to monitor pressure after an exhaust valve of a final stage, but before the check valve;
• an oil pressure sensor configured to monitor oil pressure;
• an air intake pressure sensor configured to monitor pressure at an inlet of a first stage;
• an air intake differential pressure sensor configured to monitor pressure loss across an intake filter;
• a valve temperature sensor, the valve temperature sensor is configured to measure a surface temperature of the exhaust valve or an intake valve;
• a regulated pressure sensor positioned after a tank pressure regulator, the regulated pressure sensor is configured to monitor the pressure of air exiting the tank pressure regulator;
• an oil level sensor being a float type device sensor to monitor a level of oil in the air compressor pump to protect from low oil levels;
• a plurality of peripheral devices in communication with the processor, each of the plurality of peripheral devices is configured to be controlled by the processor, the plurality of peripheral devices is configured to operatively control the multi-stage reciprocating air compressor, the plurality of peripheral devices including:
• an unloader valve configured to energize or de-energize head unloaders for unloaded operation;
• a blowdown valve configured to discharge air between the exhaust valve of the final stage and the check valve going into the tank;
• the tank pressure regulator configured to control pressure exiting the tank, the tank pressure regulator is configured to be manually controlled or digitally controlled;
• a tank drain valve configured to drain condensate from the tank;
• a tank discharge isolation valve being an electronically controlled valve at a discharge of the tank, the tank discharge isolation valve is configured to isolate a distribution network of piping and hose exiting the tank;
• a relay being an electronic on-off switch configured to control power to a starter;
• the processor is configured to use a number of networking protocols to obtain a network connection via wired or wireless communication to communicate the operating data of the multi-stage reciprocating air compressor from any of the plurality of sensors, wherein the processor is configured to make decisions to control the multi-stage reciprocating air compressor with or without the network connection;
• the operating data from the plurality of sensors can be displayed by the processor to a user through a graphical interface;
• the processor is configured to communicate with the plurality of sensors and the plurality of peripheral devices via wired communication lines or wireless communication lines;
• wherein, the processor is configured to read data from the plurality of sensors and control the plurality of peripheral devices to intelligently extend life of the multi-stage reciprocating air compressor and reduce energy consumption of the multi-stage reciprocating air compressor;
• a housing configured to house the processor, the plurality of sensors, and the plurality of peripheral devices, the housing is sized similar to a conventional pressure switch size, wherein the housing including:
• a manifold assembly including an internal passage configured to support multiple ports all connected to the tank, the multiple ports connecting the processor to a head unloader valve, a gauge, a pressure relief valve and a discharge port;
• a threaded connection point on a bottom or a side of the housing, the threaded connection point being a standard pipe thread configured to mount to a pipe nipple on the tank;
• wherein, the manifold assembly is configured to supply air to the tank and the head unloader valve through a head unloader solenoid valve;
• the manifold assembly including a second passage connected to a compressor side of the check valve, the second passage is configured to connect the processor with a pressure transducer and a blowdown valve;
• wherein the intelligent controller is powered by a dedicated power supply or from a compressor supply power, wherein a switch incorporates a relay with main power being supplied to the motor through the intelligent controller or has an electronic signal or a power supply to turn the motor on and off using a magnetic starter;
• wherein, the intelligent controller is configured to:
• calculate an optimum start and stop pressure value to maximize compressor efficiency, and minimize heat buildup without stressing the motor or the air compressor pump based on an entered minimum required pressure;
• detect a failure of the check valve and communicate the failure of the check valve and alter operation to protect the multi-stage reciprocating air compressor from damage;
• detect a failure of a failing exhaust valve and communicate the failure of the failing exhaust valve;
• utilize the operating data of the multi-stage reciprocating air compressor to diagnose subassembly or component degradation or failure and communicate the component failure to the user, and if required, limiting air compressor operation to prevent a catastrophic failure;
• control the multi-stage reciprocating air compressor to extend the life of the multi-stage reciprocating air compressor by identifying hazardous operating conditions and warning the user, and if required, limiting compressor function to protect the multi-stage reciprocating air compressor from the catastrophic failure;
• and
• improve efficiency and reliability of the multi-stage reciprocating air compressor by adjusting control methods via the processor based on contextual decisions to deliver a desired pressure without over pressurizing the multi-stage reciprocating air compressor or cycling the motor and the air compressor pump excessively;
• wherein the intelligent controller is configured to:
• detecting a faulty check valve on the multi-stage reciprocating air compressor;
• detecting a leaking exhaust valve or a plethora of leaking exhaust valves on the multi-stage reciprocating air compressor;
• protect the multi-stage reciprocating air compressor motor from failing prematurely;
• autonomously adjust start and stop pressures on the multi-stage reciprocating air compressor to reduce energy and heat;
• record a new capacity baseline for a new compressor when it is started for the first time at the factory after being assembled;
• record a current capacity baseline and calculate a current system capacitance for an installation during field commissioning or any time after the multi-stage reciprocating air compressor is installed in a system;
• identify a catastrophic leak or an excessive demand on the multi-stage reciprocating air compressor;
• detecting a leaking intake valve or a plethora of leaking intake valves between stages on the multi-stage reciprocating air compressor;
• detecting the leaking exhaust valve or the plethora of leaking exhaust valves between stages on the multi-stage reciprocating air compressor;
• testing the head unloader valve and the head unloaders;
• and
• testing the blowdown valve.

A method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor comprising:

• providing an intelligent controller for the reciprocating air compressor with a tank, an air compressor pump, a motor, a motor starter, a discharge line directly from an exhaust valve of the air compressor pump to the tank, and a check valve in the discharge line, the intelligent controller comprising:
• a processor;
• a plurality of sensors in communication with the processor, the plurality of sensors is configured to read operating data of the reciprocating air compressor and send the operating data to the processor, the plurality of sensors including:
• a tank pressure sensor configured to monitor pressure of air in the tank;
• a discharge pressure sensor in the discharge line configured to monitor pressure after the exhaust valve, but before the check valve;
• a plurality of peripheral devices in communication with the processor, each of the plurality of peripheral devices is configured to be controlled by the processor, the plurality of peripheral devices is configured to operatively control the reciprocating air compressor;
• installing the intelligent controller on the reciprocating air compressor;
• reading data from the plurality of sensors;
• and
• controlling the plurality of peripheral devices to intelligently extend life of the reciprocating air compressor and reduce energy consumption of the reciprocating air compressor.