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

Abstract

An intelligent controller for a reciprocating air compressor includes a processor, a plurality of sensors, and a plurality of peripheral devices. The plurality of sensors is in communication with the processor. The plurality of sensors is configured to read operating data of the reciprocating air compressor and send that operating data to the processor. The plurality of peripheral devices is in communication with the processor. Each of the plurality of peripheral devices are configured to be controlled by the processor. The plurality of peripheral devices is configured to operatively control the reciprocating air compressor. 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 reciprocating air compressor and reduce energy consumption of the reciprocating air compressor.

Claims

1. An intelligent controller for a 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; and 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 reciprocating air compressor and reduce energy consumption of the reciprocating air compressor.

2. The intelligent controller of claim 1 being 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 reciprocating air compressor from damage; detect a failure of an exhaust valve and communicate the failure of the exhaust valve; utilize the operating data of the reciprocating air compressor to diagnose subassembly or component degradation or failure and communicate the component failure to a user, and if required, limiting air compressor operation to prevent a catastrophic failure; control the reciprocating air compressor to extend the life of the reciprocating air compressor by identifying hazardous operating conditions and warning the user, and if required, limiting compressor function to protect the reciprocating air compressor from the catastrophic failure; improve efficiency and reliability of the reciprocating air compressor by adjusting control methods via the processor based on contextual decisions to deliver a desired pressure without over pressurizing the reciprocating air compressor or cycling the motor and the air compressor pump excessively; or combinations thereof.

3. The intelligent controller of claim 1, wherein 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 reciprocating air compressor from any of the plurality of sensors, wherein the processor is configured to make decisions to control the reciprocating air compressor with or without the network connection.

4. The intelligent controller of claim 3, whereby the operating data from the plurality of sensors can be displayed by the processor to a user through a graphical interface.

5. The intelligent controller of claim 1, wherein 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.

6. The intelligent controller of claim 1, wherein: 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; the plurality of peripheral devices including: a head unloader valve configured to energize or de-energize head loaders for unloaded operation; and a blowdown valve configured to discharge air between the exhaust valve of the final state and the check valve going into the tank.

7. The intelligent controller of claim 6, wherein: the plurality of sensors further including: 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 surface temperature of the exhaust valve or the 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 configured to monitor a level of oil in the air compressor pump to protect from low oil levels; the plurality of peripheral devices further including: 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; and a relay being an electronic on-off switch configured to control power to a starter.

8. The intelligent controller of claim 1, wherein the intelligent controller for the reciprocating air compressor including a housing configured to house the processor.

9. The intelligent controller of claim 8, wherein the housing is configured to further house the plurality of sensors and the plurality of peripheral devices; and wherein the housing is sized similar to a conventional pressure switch size.

10. The intelligent controller of claim 8, 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; and wherein, the manifold assembly is configured to supply air to the tank and the head unloader valve through a head unloader solenoid valve.

11. The intelligent controller of claim 10, wherein 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.

12. The intelligent controller of claim 1, 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.

13. The intelligent controller of claim 1, wherein the intelligent controller is configured to: detect a faulty check valve on the reciprocating air compressor; detect a leaking exhaust valve or a plethora of leaking exhaust valves on the reciprocating air compressor; protect the reciprocating air compressor motor from failing prematurely; autonomously adjust start and stop pressures on the 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 reciprocating air compressor is installed in a system; identify a catastrophic leak or an excessive demand on the reciprocating air compressor; detecting a leaking intake valve on the reciprocating air compressor or a plethora of leaking intake valves between stages on the reciprocating air compressor when the reciprocating air compressor is a multi-stage reciprocating air compressor; detecting the leaking exhaust valve on the reciprocating air compressor or the plethora of leaking exhaust valves between stages on the reciprocating air compressor when the reciprocating air compressor is the multi-stage reciprocating air compressor; testing a head unloader valve and head unloaders; testing a blowdown valve; or combinations thereof.

14. 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.

15. 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.

16. The method of claim 15, wherein the controlling the plurality of peripheral devices to intelligently extend life of the reciprocating air compressor and reduce energy consumption of the reciprocating air compressor including: calculating 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; detecting a failure of the check valve and communicating the failure of the check valve and alter operation to protect the reciprocating air compressor from damage; detecting a failure of a failing exhaust valve and communicating the failure of the failing exhaust valve; utilizing the operating data of the reciprocating air compressor to diagnose subassembly or component degradation or failure and communicating the component failure to a user, and if required, limiting air compressor operation to prevent a catastrophic failure; controlling the reciprocating air compressor to extend the life of the reciprocating air compressor by identifying hazardous operating conditions and warning the user, and if required, limiting compressor function to protect the reciprocating air compressor from the catastrophic failure; improving efficiency and reliability of the reciprocating air compressor by adjusting control methods via the processor based on contextual decisions to deliver a desired pressure without over pressurizing the reciprocating air compressor or cycling the motor and the air compressor pump excessively; or combinations thereof.

17. The method of claim 16, wherein the reciprocating air compressor is a multi-stage reciprocating air compressor, wherein, the plurality of sensors further 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; 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 the 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; the plurality of peripheral devices including: a head 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; and a relay being an electronic on-off switch configured to control power to a starter.

18. The method of claim 17, wherein the controlling 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 including: 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; protecting the multi-stage reciprocating air compressor motor from failing prematurely; autonomously adjusting start and stop pressures on the multi-stage reciprocating air compressor to reduce energy and heat; recording a new capacity baseline for a new compressor when it is started for the first time at the factory after being assembled; recording 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; identifying a catastrophic leak or an excessive demand on the multi-stage reciprocating air compressor; detecting a leaking intake valve or a plethora of 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; testing the blowdown valve; or combinations thereof.

19. The method of claim 17, wherein the controlling 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 including: 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; protecting the multi-stage reciprocating air compressor motor from failing prematurely; autonomously adjusting start and stop pressures on the multi-stage reciprocating air compressor to reduce energy and heat; recording a new capacity baseline for a new compressor when it is started for the first time at the factory after being assembled; recording 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; identifying a catastrophic leak or an excessive demand on the multi-stage reciprocating air compressor; detecting a leaking intake valve or a plethora of 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.

20. The method of claim 19, wherein: the detecting the faulty check valve on the multi-stage reciprocating air compressor including: stopping or unloading the multi-stage reciprocating air compressor; opening an electronically controlled valve to exhaust air from the discharge of the air compressor ahead of a check valve; analyzing data from a pressure sensor installed on the line between the air compressor discharge and the check valve, calculate and save time required to reduce pressure in the line to a safe start pressure for the air compressor wherein this data is used to determine when to initiate the compressor start sequence; closing the electronically controlled valve after a predetermined or calculated period of time; analyzing data from a pressure sensor installed on the line between the air compressor discharge and the check valve to identify air leaking past the check valve; communicating a check valve failure if the analysis determines the check valve is leaking; keeping the electronically controlled valve closed to prevent the compressed air leaking past the check valve from exhausting to the atmosphere saving energy by not wasting stored compressed air; and analyzing data from a pressure sensor installed on the tank circuit to calculate when to initiate a compressor start sequence so the compressor can safely start before pressure decays to a value less than a defined minimum pressure setting; the detecting the leaking exhaust valve or the plethora of leaking exhaust valves on the multi-stage reciprocating air compressor comprising: stopping or unloading the multi-stage reciprocating air compressor; keeping the blowdown valve in a closed state to not evacuate air from a discharge line of the air compressor; analyzing data from a pressure sensor installed on the line between the air compressor discharge and the check valve to identify the leaking exhaust valve; communicating an air compressor exhaust valve failure if the analysis determines one or more exhaust valves are leaking; if pressure decays to a value close to zero or less than the tank pressure this indicates the check valve is holding but the air has leaked past the exhaust valves and out through the crank case vent or intake valves if they are also leaking; evaluating exhaust valve leakage including trending compressor capacity by rate of pressure change with respect to time and also by monitoring discharge temperature, thereby increasing confidence in the failure diagnosis or evaluating severity; and if pressure tracks with the tank pressure, communicating the exhaust valves are holding and working fine; the protecting the multi-stage reciprocating air compressor motor from failing prematurely including: analyzing data from a pressure sensor while the multi-stage reciprocating air compressor is loaded to estimate the time the motor will be off after reaching the stop pressure target; analyzing the multi-stage reciprocating air compressor motor design data, loaded time, possibly pressure, possibly temperature, and possibly motor age to estimate a minimum safe motor off duration; deciding to unload the multi-stage reciprocating air compressor or stop the motor by comparing the estimated time the motor will be off after reaching the stop pressure target with the calculated minimum safe motor off duration; and deciding to temporarily raise the motor stop pressure setting to extend the calculated off time to protect the motor if the air compressor is not capable of unloading the compressor pump while keeping the motor on; the autonomously adjusting the start and stop pressures on the multi-stage reciprocating air compressor to reduce energy and heat including; analyzing data from a single or plethora of pressure sensors while the compressor is loaded and off to estimate loaded and off duration as a function of the loaded rate of change; analyzing the change in pressure with respect to time while the multi-stage reciprocating air compressor is loaded, calculate the stop-unload pressure required to satisfy the minimum threshold loaded time and off time to reliably cycle the multi-stage reciprocating air compressor; and stopping or unloading the multi-stage reciprocating air compressor using the calculated pressure value; the recording the new capacity baseline for the new compressor when it is started for the first time at the factory after being assembled including; upon the first startup of the new compressor at the factory, measuring and recording pressure rate of change as part of the initial controller registration and commissioning, wherein this value of pressure rate of change is used for quality verification by the supplier and future performance verification; and as part of the controller commissioning during the initial factory registration, the compressor model information is validated by associating the compressor factory capacity rating, tank volume and other factory settings allocated to the model for future control and calculator purposes; the recording the current capacity baseline and calculate the current system capacitance for the installation during field commissioning or any time after the multi-stage reciprocating air compressor is installed in the system including; in the field, isolating the tank and conducting a performance verification test to compare and quantify compressor performance against the factory new baseline value; and upon field installation startup, measuring and recording running pressure rate of change and off pressure rate of change, wherein the intelligent controller using this information and the factory commissioning data to calculate capacitance of the installation system, wherein this data is used to calculate volume flow rate, leak rate and as a baseline to detect degradation in compressor performance; the identifying a catastrophic leak or an excessive demand on the multi-stage reciprocating air compressor including: while the multi-stage reciprocating air compressor is running fully loaded and encounters a negative pressure rate of change, reducing pressure to a defined value below the start pressure and for a calculated period of time the compressor is stopped; if pressure stops dropping or the negative rate of change is less than or equal to the normal leak value or continues to decay to a value close to zero, automatically restarting the multi-stage reciprocating air compressor; if pressure builds in the system to some defined value above the start pressure, documenting the excessive demand event with start time, duration, and estimated volume flow rate and communicating as an exceeded capacity event warning; if pressure will not recover when the compressor is turned back on, turning off the multi-stage reciprocating air compressor and communicating a catastrophic leak message, wherein it is determined to be a catastrophic leak because the excessive demand event did not stop after pressure decreased to an unproductive level implying the event was not monitored or intentional; communicating events along with an estimated volume, time of day and duration thereby helping the compressor owner determine if they can modify their compressed air usage or consider upgrading their compressed air system; the detecting a leaking intake valve or a plethora of intake valves between stages on the multi-stage reciprocating air compressor including: analyzing data from a plethora of pressure sensors installed between stages of the multi-stage reciprocating air compressor, wherein a faulty or failing intake valve will cause interstage pressure to increase above an operating baseline value or pressure will increase after the multi-stage reciprocating air compressor stops or operates in an unloaded state; communicating an air compressor intake valve failure if the analysis determines one or more intake valves are leaking; communicating the specific stage of the multi-stage reciprocating air compressor intake valve failure if the analysis determines one or more intake valves are leaking; the detecting the leaking exhaust valve or the plethora of leaking exhaust valves between stages on the multi-stage reciprocating air compressor including: analyzing data from a plethora of pressure sensors installed between stages of the multi-stage reciprocating air compressor, wherein a faulty or failing exhaust valve will cause interstage pressure to decrease below an operating baseline value or pressure will decrease after the compressor stops or operates in an unloaded state; communicating an air compressor exhaust valve failure if the analysis determines one or more exhaust valves are leaking; communicating the specific stage of the multi-stage reciprocating air compressor exhaust valve failure if the analysis determines one or more exhaust valves are leaking; the testing the head unloader valve and the head unloaders including: when the controller logic sends a command to energize the head unloader valve, the valve opens and air at pressure is applied to the head unloaders, wherein one of the head unloaders is mounted on each first stage intake valve, and the compressor pump has one or a plethora of intake valves; after the unload command has been sent, pressurizing the head unloaders will hold the first stage intake valves open and the compressor will not be able to compress air and the mass flow of air from the compressor will become zero, wherein: if all of the head unloaders do not function, the compressor output may only be partially reduced, whereby the controller can analyze the change in tank pressure over time and if activating the head unloader circuit does not reduce the calculated output of the compressor, a head unloader fault will be identified and communicated; if the change in capacity output is only reduced but indicates the compressor is still pumping a percentage of air, the compressor motor is turned off using the motor stop control sequence; if the change in pressure is zero or drops over time this indicates a head unloader failure; if energizing the head unloaders does not change the rate of pressure increase over time in the tank, the issue is a head unloader valve failure, wherein if this occurs the compressor will operate using the motor stop/start control method until the head unloader fault has been corrected; wherein the testing of the head unloader valve and the head unloaders is configured to be manually initiated or executed at some calculated interval or when it is a utilized control mode; and the testing the blowdown valve including: manually initiating or autonomously executing the testing of the blowdown valve every time the blowdown valve is commanded to open or close; wherein: if the compressor is running and the motor is turned off and pressure in the line between the check valve and the pump does not drop at all this is an indication that the blowdown valve will not open and a blowdown valve closed valve fault shall be communicated; if the compressor pressure in this line cannot be exhausted the compressor is started using the head unloaders; if the head unloaders are not available the compressor is configured to not initiate a motor start command until the pressure drops to a predetermined acceptable value which is configured to include pressure dropping to that value in the tank; when the compressor is off and the compressor is commanded to start and load, the command is given to close the blowdown valve, wherein: if the pressure ahead of the check valve does not increase to a value greater than or equal to the tank pressure in a predetermined or calculated amount of time, this indicates the blowdown valve is open and all air from the compressor pump is exhausted through the blowdown valve, and a blowdown valve open failure is communicated and the compressor turned off since it cannot charge the tank and will run for no purpose; if the pressure increases ahead of the check valve to a value greater than or equal to the tank pressure but pressure rate of change indicates the compressor is operating under capacity, the next time compressor turns off, the blowdown valve open command will be postponed and a decreasing or no pressure in the line ahead of the check valve will indicate a blowdown valve open valve fault.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present disclosure will be better understood by reading the Detailed Description with reference to the accompanying drawings, which are not necessarily drawn to scale, and in which like reference numerals denote similar structure and refer to like elements throughout, and in which:

(2) FIG. 1 is a schematic front view of a reciprocating air compressor according to the prior art;

(3) FIG. 2 is a schematic front view of a reciprocating air compressor with the intelligent controller according to select embodiments of the instant disclosure;

(4) FIG. 3 is a schematic front view of a reciprocating air compressor with the intelligent controller according to select embodiments of the instant disclosure;

(5) FIG. 4A is a front view of the intelligent controller for a reciprocating air compressor according to select embodiments of the instant disclosure;

(6) FIG. 4B is a side view of the intelligent controller from FIG. 4A;

(7) FIG. 4C is a bottom view of the intelligent controller from FIG. 4A;

(8) FIG. 5 is a flow chart of the method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor according to select embodiments of the instant disclosure;

(9) FIG. 6 is a flow chart of the step of controlling the plurality of peripheral devices to intelligently extend life of the reciprocating air compressor and reduce energy consumption of the reciprocating air compressor according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor;

(10) FIG. 7 is a flow chart of the step of detecting a faulty check valve on the reciprocating air compressor according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor;

(11) FIG. 8 is a flow chart of the step of detecting a leaking exhaust valve or a plethora of exhaust valves on the reciprocating air compressor according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor;

(12) FIG. 9 is a flow chart of the step of protecting the reciprocating air compressor motor from failing prematurely according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor;

(13) FIG. 10 is a flow chart of the step of autonomously adjusting start and stop pressures on the reciprocating air compressor to reduce energy and heat according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor;

(14) FIG. 11 is a flow chart of the step of recording a new capacity baseline for a new compressor when it is started for the first time at the factory after being assembled according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor;

(15) FIG. 12 is a flow chart of the step of recording a current capacity baseline and calculating a current system capacitance for an installation during field commissioning or any time after the reciprocating air compressor is installed in a system according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor;

(16) FIG. 13 is a flow chart of the step of identifying a catastrophic leak or an excessive demand on the reciprocating air compressor according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor;

(17) FIG. 14 is a flow chart of the step of detecting leaking intake valve or a plethora of intake valves between stages on a multi-stage reciprocating air compressor according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor;

(18) FIG. 15 is a flow chart of the step of detecting a leaking exhaust valve or a plethora of exhaust valves between stages on the multi-stage reciprocating air compressor according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor;

(19) FIG. 16 is a flow chart of the step of testing the head unloader valve and head unloaders according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor; and

(20) FIG. 17 is a flow chart of the step of testing the blowdown valve according to select embodiments of the instant disclosure for the disclosed method of intelligently extending life of a reciprocating air compressor and reducing energy consumption of the reciprocating air compressor.

(21) It is to be noted that the drawings presented are intended solely for the purpose of illustration and that they are, therefore, neither desired nor intended to limit the disclosure to any or all of the exact details of construction shown, except insofar as they may be deemed essential to the claimed disclosure.

DETAILED DESCRIPTION

(22) Referring now to FIGS. 1-17, in describing the exemplary embodiments of the present disclosure, specific terminology is employed for the sake of clarity. The present disclosure, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions. Embodiments of the claims may, however, be embodied in many different forms and should not be construed to be limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.

(23) Referring first to FIG. 1, a typically known reciprocating air compressor 12 of the prior art is shown. As shown, this prior art reciprocating air compressor 12 includes tank 14, air compressor pump 16, motor 18, motor starter 20, check valve 22, ball valve 23, head unloader valve 50, blowdown valve 54, gauge 90, pressure relief valve 92, switch 107 and relay 108. The motor starter 20 is configured to control power of the reciprocating air compressor 12. Mechanical pressure switch 107 and blowdown valve 54 are used. Wherein, the tank pressure in tank 14 acts against a diaphragm and spring to open/close the electrical circuit of the switch 107 and blowdown valve 54. Pressure relief valve 92 is a pressure activated safety relief valve. Head unloader valve 50 is also pressure activated. Motor starter 20 is a motor main power circuit/magnetic starter. Currently, the known current controls and/or control logic for reciprocating air compressor 12 lacks the ability to alter operating parameters to improve efficiency, reliability, or to diagnose components of reciprocating air compressor 12 that are not operating correctly and require service.

(24) Referring to FIGS. 2-17, the present disclosure may solve the aforementioned limitations of the currently available reciprocating air compressors and controls thereof by providing the disclosed intelligent controller 10 for reciprocating air compressor 12 and methods 200 of use thereof.

(25) Referring now specifically to FIGS. 2-4, intelligent controller 10 for reciprocating air compressor 12 may generally include processor 24, plurality of sensors 26, and plurality of peripheral devices 30. The plurality of sensors 26 may be in communication with processor 24. The plurality of sensors 26 may be configured to read operating data 28 of reciprocating air compressor 12 and send that operating data 28 to processor 24. The plurality of peripheral devices 30 may be in communication with processor 24. Each of the plurality of peripheral devices 30 may be configured to be controlled by processor 24. The plurality of peripheral devices 30 may be configured to operatively control reciprocating air compressor 12. Wherein, processor 24 may be configured to read data from the plurality of sensors 26 and control the plurality of peripheral devices 30 to intelligently extend life of reciprocating air compressor 12 and reduce energy consumption of reciprocating air compressor 12.

(26) One feature of intelligent controller 10 may be that it can be configured to calculate an optimum start and stop pressure value to maximize compressor efficiency and minimize heat buildup without stressing motor 18 or air compressor pump 16 based on an entered minimum required pressure.

(27) Another feature of intelligent controller 10 may be that it can detect a failure of check valve 22 and communicate the failure of check valve 22 and alter operation to protect reciprocating air compressor 12 from damage.

(28) Another feature of intelligent controller 10 may be that it can detect a failure of an exhaust valve (not shown in the Figures) and communicate the failure of the exhaust valve.

(29) Another feature of intelligent controller 10 may be that it can utilize operating data 28 of reciprocating air compressor 12 from sensors 26 to diagnose subassembly or component degradation or failure and communicate the component failure to a user, and if required, limiting air compressor operation to prevent a catastrophic failure.

(30) Another feature of intelligent controller 10 may be that it can control reciprocating air compressor 12 to extend the life of the reciprocating air compressor by identifying hazardous operating conditions and warning the user, and if required, limiting compressor function to protect reciprocating air compressor 12 from the catastrophic failure.

(31) Another feature of intelligent controller 10 may be that it can improve efficiency and reliability of reciprocating air compressor 12 by adjusting control methods via processor 24 based on contextual decisions to deliver a desired pressure without over pressurizing reciprocating air compressor 12 or cycling motor 18 and air compressor pump 16 excessively.

(32) Processor 24 may be included with intelligent controller 10. See FIGS. 2-4. Processor 24 may be used for reading data from plurality of sensors 26 and controlling reciprocating air compressor 12 through peripheral devices 30 based off of the data read from sensors 26. Processor 24 may include any computers, circuit boards, processors, the like, etc. configured for reading data from plurality of sensors 26 and controlling reciprocating air compressor 12 through peripheral devices 30 based off of the data read from sensors 26. As an example, processor 24 may include a control board (printed circuit board) with many components to handle inputs and outputs from the connected components, i.e., sensors 26 and peripheral devices 30. This control board of processor 24 may contain a processor and other components for communicating with and controlling the I/O sensors and relays. Processor 24 may be a microcontroller or other computer that makes logic decisions. It is part of a larger control board, that connects to peripheral devices to change the state of the compressor. The control board could be customized to control all of the other components for intelligent controller 10; the I/O of the control board will match the components configured for intelligent controller 10. The way that the control board transmits usage data and alerts may be unique. The possibilities here are basically endless; e.g., Oil pressure low.fwdarw.send alert to cloud.fwdarw.cloud alerts user. In select embodiments of intelligent controller 10, processor 24 may be configured to use a number of networking protocols to obtain network connection 34. See FIGS. 2-4. Network connection 34 may be made via wired or wireless communication 36. Network connection 34 may be used to communicate the operating data of reciprocating air compressor 12 from any of the plurality of sensors 26. In select embodiments, processor 24 may be configured to make decisions to control reciprocating air compressor 12 with or without network connection 34. Network connection 34 may be used to communicate with a user or operator of reciprocating air compressor 12, like for communicating any failures, starts, stops, leaks, etc. This communication may be made with or without owner's approval, where the ability is provided to communicate compressor operating and fault data to the manufacturer or to an authorized service provider to expedite ordering service and/or parts.

(33) Another feature of intelligent controller 10 may be that operating data 28 from the plurality of sensors 26 can be displayed by processor 24 to the user or operator through graphical interface 38. Graphical interface 38 may be any gauge(s), lights, screen(s), or web or mobile application(s) used to communicate to the user or operator the operating data 28 of reciprocating air compressor 12. As such, data from processor 24 can be displayed to the users through a number of graphical interfaces, including screens, status lights, or by representing data presented via a web or mobile application.

(34) As best shown in FIGS. 2-4, in select embodiments of intelligent controller 10, processor 24 can be configured to communicate with the plurality of sensors 26 and the plurality of peripheral devices 30 via wired communication lines 40 and/or wireless communication lines 42. As such, intelligent controller 10 can be housed on reciprocating air compressor 12, or it may be remotely located.

(35) Sensors 26 may be included with intelligent controller 10. See FIGS. 2-4. Sensors 26 may be for reading various operating data 28 from reciprocating air compressor 12. Sensors 26 may include any type or quantity of sensors configured for reading any operating data 28 of reciprocating air compressor 12. In select embodiments of intelligent controller 10, the plurality of sensors 26 may include at least one interstage pressure sensor 44. Each of the at least one interstage pressure sensors 44 may be configured to monitor pressure between stages of compression. In other select embodiments of intelligent controller 10, the plurality of sensors 26 may include first tank pressure sensor 46. First tank pressure sensor 46 may be configured to monitor pressure of air in tank 14. In other select embodiments of intelligent controller 10, the plurality of sensors 26 may include final discharge pressure sensor 48. Final discharge pressure sensor 48 may be configured to monitor pressure after an exhaust valve of a final stage, but before check valve 22. In select possibly preferred embodiments, plurality of sensors 26 of intelligent controller 10 may include a combination of interstage pressure sensor 44, first tank pressure sensor 46, and final discharge pressure sensor 48. In select optional embodiments, the plurality of sensors 26 may further include, but is not limited to: an oil pressure sensor configured to monitor oil pressure, like in a pressure lubricated compressor; 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 the surface temperature of the exhaust valve or the 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 the level of oil in the air compressor pump to protect from low oil levels; the like; and/or combinations thereof.

(36) Peripheral devices 30 may be included with intelligent controller 10. See FIGS. 2-4. Peripheral devices 30 may be for controlling various valves, switches, the like, etc. of reciprocating air compressor 12. Peripheral devices 30 may include any type or quantity of peripheral devices configured for controlling any various valves, switches, the like, etc. of reciprocating air compressor 12. In select embodiments of intelligent controller 10, the plurality of peripheral devices 30 may include head unloader valve 50. Head unloader valve 50 may be configured to energize or de-energize head unloaders 52 for unloaded operation. Head unloader valve 50 may be digitally activated by processor 24. In select embodiments of intelligent controller 10, the plurality of peripheral devices 30 may include blowdown valve 54. Blowdown valve 54 may be configured to discharge air between the exhaust valve of the final stage and check valve 22 going into tank 14. Blowdown valve 54 may be digitally activated by processor 24. In select possibly preferred embodiments, plurality of peripheral devices 30 of intelligent controller 10 may include a combination of head unloader valve 50, blowdown valve 54. In select optional embodiments, the plurality of peripheral devices 30 may further include: the tank pressure regulator configured to control pressure exiting tank 14, the tank pressure regulator may be configured to be manually controlled or digitally controlled; a tank drain valve configured to drain condensate from tank 14; 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; relay 78 being an electronic on-off switch configured to control power to starter 20; the like; and/or combinations thereof.

(37) Still referring to FIGS. 2-4, in select embodiments, intelligent controller 10 may include housing 80. Housing 80 may be configured to house processor 24. Housing 80 may include any components and/or members configured to house processor 24. Housing 80 may be designed and configured to protect and conceal the electronic components of intelligent controller 10. In select embodiments, housing 80 may be configured to further house any of the plurality of sensors 26 and/or any of the plurality of peripheral devices 30. As shown in FIGS. 3-4, in select embodiments, housing 80 may be sized similar to conventional pressure switch size 82 (as understood by one skilled in the art). This may provide a form factor to intelligent controller 10 with any of the plurality of sensors 26 and/or plurality of peripheral devices 30 built therein. As such, in select embodiments, only processor 24 may be housed inside of housing 80 of intelligent controller 10, like as shown in FIG. 2, or on the sides of housing 80, like as shown in FIGS. 4. And in other select embodiments, some or all of sensors 26 and/or peripheral devices 30 may be housed inside of housing 80 of intelligent controller 10, like as shown in FIGS. 3-4. As best shown in FIGS. 4, in select embodiments, housing 80 may include manifold assembly 84. Manifold assembly 84 may include internal passage 86 configured to support multiple ports 88 all connected to tank 14. In select embodiments, multiple ports 88 may connect processor 24 to head unloader valve 50, gauge 90, pressure relief valve 92, a discharge port, the like, and/or combinations thereof. Threaded connection point 96 may be on bottom 98 or side 100 of housing 80. Bottom 98 may serve as a mounting platform for housing 80 of intelligent controller 10 that also serves as a pneumatic manifold, certified/or designed for required working pressure and local codes. Threaded connection point 96 may be standard pipe thread 101 configured to mount to pipe nipple 102 on tank 14. Wherein, manifold assembly 84 may be configured to supply air to tank 14 and head unloader valve 50 through head unloader solenoid valve 50. A separate circuit of the manifold may connect the final discharge line ahead of check valve 22 to the pressure transducers/sensors and blowdown valve 54. All other pneumatic and digital signals may be contained or supported by this single enclosure of housing 80. In select embodiments, manifold assembly 84 may include second passage 103. Second passage 103 may be connected to a compressor side of check valve 22. Second passage 103 may be configured to connect processor 24 with a pressure transducer and blowdown valve 54.

(38) In select embodiments, intelligent controller 10 may be powered by a dedicated power supply 105 or from a compressor supply power 106. Wherein, switch 107 may incorporate relay 108 with main power being supplied to motor 18 through intelligent controller 10 or may have an electronic signal or a power supply to turn the motor on and off using magnetic starter 109.

(39) Another feature of intelligent controller 10 may be that it can be configured to detect a faulty check valve 22 on reciprocating air compressor 12.

(40) Another feature of intelligent controller 10 may be that it can be configured to detect a leaking exhaust valve or a plethora of exhaust valves on reciprocating air compressor 12.

(41) Another feature of intelligent controller 10 may be that it can be configured to protect reciprocating air compressor motor 18 from failing prematurely.

(42) Another feature of intelligent controller 10 may be that it can be configured to autonomously adjust start and stop pressures on reciprocating air compressor 12 to reduce energy and heat.

(43) Another feature of intelligent controller 10 may be that it can be configured to record a new capacity baseline for a new compressor when it is started for the first time at the factory after being assembled.

(44) Another feature of intelligent controller 10 may be that it can be configured to record a current capacity baseline and calculate a current system capacitance for an installation during field commissioning or any time after reciprocating air compressor 12 is installed in a system.

(45) Another feature of intelligent controller 10 may be that it can be configured to identify a catastrophic leak or an excessive demand on reciprocating air compressor 12.

(46) Another feature of intelligent controller 10 may be that it can be configured to detect a leaking intake valve or a plethora of intake valves between stages on a multi-stage reciprocating air compressor 12.

(47) Another feature of intelligent controller 10 may be that it can be configured to detect a leaking exhaust valve or a plethora of exhaust valves between stages on the multi-stage reciprocating air compressor 12.

(48) Referring now specifically to FIGS. 5-17, in another aspect, the instant disclosure embraces method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12 utilizing intelligent controller 10 in any embodiment and/or combination of embodiments shown and/or described herein. As such, in general, referring to FIG. 5, method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12 may include the steps of: step 201 of providing intelligent controller 10 for reciprocating air compressor 12 in any embodiment and/or combination of embodiments shown and/or described herein; step 202 of installing intelligent controller 10 on reciprocating air compressor 12; step 203 of reading data from the plurality of sensors 26 via processor 24; and step 204 of controlling the plurality of peripheral devices 30 via processor 24 to intelligently extend life of reciprocating air compressor 12 and reduce energy consumption of reciprocating air compressor 12.

(49) Still referring specifically to FIG. 5, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 204 of controlling the plurality of peripheral devices 30 to intelligently extend life of reciprocating air compressor 12 and reduce energy consumption of reciprocating air compressor 12 may include the steps of: step 205 of calculating 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; step 206 of detecting a failure of the check valve and communicating the failure of the check valve and alter operation to protect the reciprocating air compressor from damage; step 207 of detecting a failure of an exhaust valve and communicating the failure of the exhaust valve; step 208 of utilizing the operating data 28 of reciprocating air compressor 12 to diagnose subassembly or component degradation or failure and communicating the component failure to a user, and if required, limiting air compressor operation to prevent a catastrophic failure; step 209 of controlling reciprocating air compressor 12 to extend the life of reciprocating air compressor 12 by identifying hazardous operating conditions and warning the user, and if required, limiting compressor function to protect reciprocating air compressor 12 from the catastrophic failure; step 210 of improving efficiency and reliability of reciprocating air compressor 12 by adjusting control methods via processor 24 based on contextual decisions to deliver a desired pressure without over pressurizing reciprocating air compressor 12 or cycling motor 18 and air compressor pump 16 excessively; the like; and/or combinations thereof. These control methods, may include the use of stop start control or use of head unloaders.

(50) Referring now specifically to FIG. 6, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 204 of controlling the plurality of peripheral devices 30 to intelligently extend life of reciprocating air compressor 12 and/or reduce energy consumption of reciprocating air compressor 12 may include the steps of: step 211 of detecting a faulty check valve 22 on reciprocating air compressor 12; step 220 of detecting a leaking exhaust valve or a plethora of exhaust valves on reciprocating air compressor 12; step 230 of protecting reciprocating air compressor motor 18 from failing prematurely; step 240 autonomously adjust start and stop pressures on reciprocating air compressor 12 to reduce energy and heat; step 250 of recording a new capacity baseline for a new compressor when it is started for the first time at the factory after being assembled; step 260 of recording a current capacity baseline and calculating a current system capacitance for an installation during field commissioning or any time after the reciprocating air compressor is installed in a system; step 270 of identifying a catastrophic leak or an excessive demand on reciprocating air compressor 12; step 280 of detecting a leaking intake valve or a plethora of intake valves between stages on a multi-stage reciprocating air compressor 12; step 290 of detecting a leaking exhaust valve or a plethora of exhaust valves between stages on the multi-stage reciprocating air compressor; the like; and/or combinations thereof.

(51) Referring now specifically to FIG. 7, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 211 of detecting the faulty check valve 22 on reciprocating air compressor 12 may include the steps of: step 212 of stopping or unloading reciprocating air compressor 12; step 213 of opening an electronically controlled valve to exhaust air from the discharge of the air compressor ahead of check valve 22; step 214 of analyzing data from a pressure sensor installed on the line between the air compressor discharge and check valve 22, calculate and save time required to reduce pressure in the line to a safe start pressure for the air compressor, wherein this data may be used to determine when to initiate the compressor start sequence; step 215 of closing the electronically controlled valve after a predetermined or calculated period of time; step 216 of analyzing data from a pressure sensor installed on the line between the air compressor discharge and check valve 22 to identify air leaking past check valve 22; step 217 of communicating a check valve failure if the analysis determines check valve 22 is leaking, which may also include recording or saving the failure event for summary which may include statistics of frequency of check valve leak relative to unload/stop in case it is intermittent and/or trending changes in severity based on blowdown rate, all potentially to be used for severity evaluation for rate level of urgency for correcting fault (this may be a separate action applicable to all fault detections and performance evaluations or may be added to each one); step 218 of keeping the electronically controlled valve closed to prevent the compressed air leaking past check valve 22 from exhausting to the atmosphere saving energy by not wasting stored compressed air; and step 219 of analyzing data from a pressure sensor installed on the tank circuit to calculate when to initiate a compressor start sequence so the compressor can safely start before pressure decays to a value less than a defined minimum pressure setting. As examples, blowdown time may be used to calculate when to open blowdown valve 54 to achieve safe start pressure before starting the motor while ensuring compressor achieves fully loaded state before pressure drops to calculated minimum pressure value.

(52) Referring now specifically to FIG. 8, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 220 of detecting the leaking exhaust valve or the plethora of exhaust valves on reciprocating air compressor 12 may include the steps of: step 221 of stopping or unloading reciprocating air compressor 12; step 222 of keeping an electronically controlled valve in a closed state to not evacuate air from a discharge line of the air compressor; step 223 of analyzing data from a pressure sensor installed on the line between the air compressor discharge and check valve 22 to identify a leaking exhaust valve; step 224 of communicating an air compressor exhaust valve failure if the analysis determines one or more exhaust valves are leaking; step 225 of if pressure decays to a value close to zero or less than the tank pressure this indicates check valve 22 is holding but the air has leaked past the exhaust valves and out through the crank case vent or intake valves if they are also leaking; step 226 of evaluating exhaust valve leakage including trending compressor capacity by rate of pressure change with respect to time and also by monitoring discharge temperature, thereby increasing confidence in the failure diagnosis or evaluating severity; and step 227 of if pressure tracks with the tank pressure, communicating the exhaust valves are holding and working fine.

(53) Referring now specifically to FIG. 9, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 230 of protecting reciprocating air compressor motor 18 from failing prematurely may include the steps of: step 231 of analyzing data from a pressure sensor while reciprocating air compressor 12 is loaded to estimate the time motor 18 will be off after reaching the stop pressure target; step 232 of analyzing the reciprocating air compressor motor design data, loaded time, possibly pressure, possibly temperature, and possibly motor age to estimate a minimum safe motor off duration; step 233 of deciding to unload reciprocating air compressor 12 or stop motor 18 by comparing the estimated time motor 18 will be off after reaching the stop pressure target with the calculated minimum safe motor off duration; and step 234 of deciding to temporarily raise the motor stop pressure setting to extend the calculated off time to protect motor 18 if the air compressor is not capable of unloading the compressor pump 16 while keeping motor 18 on.

(54) Referring now specifically to FIG. 10, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 240 of autonomously adjusting the start and stop pressures on reciprocating air compressor 12 to reduce energy and heat may include the steps of: step 241 of analyzing data from a single or plethora of pressure sensors while the compressor is loaded and off to estimate loaded and off duration as a function of the loaded rate of change; step 242 of analyzing the change in pressure with respect to time while the reciprocating air compressor is loaded, calculate the stop-unload pressure required to satisfy the minimum threshold loaded time and off time to reliably cycle the reciprocating air compressor; and step 243 of stopping or unloading the reciprocating air compressor using the calculated pressure value.

(55) Referring now specifically to FIG. 11, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 250 of recording the new capacity baseline for the new compressor when it is started for the first time at the factory after being assembled may include the steps of: step 251 of upon the first startup of the new compressor at the factory, measuring and recording pressure rate of change as part of the initial controller registration and commissioning, wherein this value of pressure rate of change is used for quality verification by the supplier and future performance verification; and step 252 as part of the controller commissioning during the initial factory registration, the compressor model information can be validated by associating the compressor factory capacity rating, tank volume and other factory settings allocated to the model for future control and calculator purposes may be included with step 251. Since tank volume and compressor performance data based on model is required for baseline and quality evaluation and should be entered at the factory, the information can be validated or possibly edited during commissioning after installation or any time after.

(56) Referring now specifically to FIG. 12, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 260 of recording the current capacity baseline and calculate the current system capacitance for the installation during field commissioning or any time after the reciprocating air compressor is installed in the system may include the steps of: step 261 of in the field, isolating the tank and conducting a performance verification test to compare and quantify compressor performance against the factory new baseline value; and step 262 of upon field installation startup, measuring and recording running pressure rate of change and off pressure rate of change, wherein the intelligent controller using this information and the factory commissioning data to calculate capacitance of the installation system, wherein this data is used to calculate volume flow rate, leak rate and as a baseline to detect degradation in compressor performance.

(57) Referring now specifically to FIG. 13, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 270 of identifying a catastrophic leak or an excessive demand on reciprocating air compressor 12 may include the steps of: step 271 of while reciprocating air compressor 12 is running fully loaded and encounters a negative pressure rate of change, reducing pressure to a defined value below the start pressure and after a calculated period of time the compressor is stopped; step 272 of if pressure stops dropping or the negative rate of change is less than or equal to the normal leak value or continues to decay to a value close to zero, automatically restarting reciprocating air compressor 12; step 273 of if pressure builds in the system to some defined value above the start pressure, documenting the excessive demand event with start time, duration, and estimated volume flow rate and communicating as an exceeded capacity event warning (this event data can be logged for statistical analysis, summary communication of these events, etc.); step 274 of if pressure will not recover when the compressor is turned back on, turning off reciprocating air compressor 12 and communicating a catastrophic leak message, wherein it is determined to be a catastrophic leak because the excessive demand event did not stop after pressure decreased to an unproductive level implying the event was not monitored or intentional (A leak will not fix itself after the compressor turns off, then back on again. In the case of an excessive demand, the practical application, e.g., sandblaster, will stop working. The operator will then stop using the compressed air. When the compressor turns back on again, the pressure will increase normally because the excessive demand is no longer on.); and step 275 of communicating events along with an estimated volume, time of day and duration thereby helping the compressor owner determine if they can modify their compressed air usage or consider upgrading their compressed air system.

(58) Referring now specifically to FIG. 14, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 280 of detecting a leaking intake valve or a plethora of intake valves between stages on a multi-stage reciprocating air compressor 12 may include the steps of: step 281 of analyzing data from a plethora of pressure sensors installed between stages of the multi-stage reciprocating air compressor 12, wherein a faulty or failing intake valve will cause interstage pressure to increase above an operating baseline value or pressure will increase after reciprocating air compressor 12 stops or operates in an unloaded state; step 282 of communicating an air compressor intake valve failure if the analysis determines one or more intake valves are leaking; and step 283 of communicating the specific stage of the multi-stage reciprocating air compressor intake valve failure if the analysis determines one or more intake valves are leaking.

(59) Referring now specifically to FIG. 15, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 290 of detecting a leaking exhaust valve or a plethora of exhaust valves between stages on the multi-stage reciprocating air compressor 12 may include the steps of: step 291 of analyzing data from a plethora of pressure sensors installed between stages of the multi-stage reciprocating air compressor 12, wherein a faulty or failing exhaust valve will cause interstage pressure to decrease below an operating baseline value or pressure will decrease after the compressor stops or operates in an unloaded state; step 292 of communicating an air compressor exhaust valve failure if the analysis determines one or more exhaust valves are leaking; and step 293 of communicating the specific stage of the multi-stage reciprocating air compressor exhaust valve failure if the analysis determines one or more exhaust valves are leaking.

(60) Referring now specifically to FIG. 16, in select embodiments of method 200 of intelligently extending life of a reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 300 of testing head unloader valve 50 and head unloaders 52 may include the steps of: step 301 of when the controller logic sends a command to energize head unloader valve 50, valve 50 opens and air at pressure is applied to head unloaders 52, wherein one of head unloaders 52 is mounted on each first stage intake valve, and compressor pump 16 has one or a plethora of intake valves; step 302 of after the unload command has been sent, pressurizing head unloaders 52 will hold the first stage intake valves open and compressor 12 will not be able to compress air and the mass flow of air from compressor 12 will become zero, wherein: step 303 of if all of the head unloaders do not function, the compressor output may only be partially reduced, whereby controller 10 can analyze the change in tank pressure over time and if activating the head unloader circuit does not reduce the calculated output of compressor 12, a head unloader fault will be identified and communicated; step 304 of if the change in capacity output is only reduced but indicates compressor 12 is still pumping a percentage of air, compressor motor 18 is turned off using the motor stop control sequence; step 305 of if the change in pressure is zero or drops over time this indicates a head unloader failure; step 306 of if energizing the head unloaders 52 does not change the rate of pressure increase over time in tank 14, the issue is a failure of head unloader valve 50, wherein if this occurs compressor 12 will operate using the motor stop/start control method until the head unloader fault has been corrected; and step 307 of wherein the testing of head unloader valve 50 and head unloaders 52 is configured to be manually initiated or executed at some calculated interval or when it is a utilized control mode.

(61) Referring now specifically to FIG. 17, in select embodiments of method 200 of intelligently extending life of reciprocating air compressor 12 and/or reducing energy consumption of reciprocating air compressor 12, step 310 of testing blowdown valve 54 may include the steps of: step 311 of manually initiating or autonomously executing the testing of blowdown valve 54 every time blowdown valve 54 is commanded to open or close; wherein: step 312 of if compressor 12 is running and motor 18 is turned off where blowdown valve 54 is signaled/commanded to open and pressure in the line between check valve 22 and pump 16 does not drop at all this is an indication that blowdown valve 54 will not open and a blowdown valve closed valve fault shall be communicated; step 313 of if the compressor pressure in this line cannot be exhausted compressor 12 using head unloaders 52 to start; step 314 of if head unloaders 52 are not available compressor 12 is configured to not initiate a motor start command until the pressure drops to a predetermined acceptable value which is configured to include pressure dropping to that value in tank 14; step 315 of when compressor 12 is off and compressor 12 is commanded to start and load, the command is given to close blowdown valve 54, wherein: step 316 of if the pressure ahead of check valve 22 does not increase to a value greater than or equal to the tank pressure in a predetermined or calculated amount of time, this indicates blowdown valve 54 is open and all air from compressor pump 16 is exhausted through blowdown valve 54, and a blowdown valve open failure is communicated and compressor 12 turned off since it cannot charge tank 14 and will run for no purpose; step 317 of if the pressure increases ahead of check valve 22 to a value greater than or equal to the tank pressure but pressure rate of change indicates compressor 12 is operating under capacity, the next time compressor 12 turns off, blowdown valve open command will be postponed and a decreasing or no pressure in the line ahead of check valve 22 will indicate a blowdown valve open valve fault.

(62) In sum, the disclosed intelligent controller 10 and disclosed method 200 of use thereof are designed and configured to provide a new electronic controller and method for reciprocating air compressors that will extend the life and reduce the energy consumption of such reciprocating air compressors. The disclosed intelligent controller 10 may include unique logic and an electronic control device that has the ability to process input data from connected sensors and external sources. Intelligent controller 10 may have processing capabilities and may be capable of communicating to external sources using wired or wireless methods. Intelligent controller 10 may have output capabilities to control valves, switches, and other devices with an electronic signal. To simplify the installation of intelligent controller 10 on an existing or new reciprocating air compressor 12, intelligent controller 10 and pneumatic inputs (sensors 26) may be incorporated into a single component that is dimensionally similar to a conventional pressure switch (see FIGS. 3-4).

(63) In use, as examples, and clearly not limited thereto: by entering a minimum required pressure, intelligent controller 10 can calculate an optimum start and stop pressure value to maximize compressor efficiency, minimize heat build-up without stressing the motor or compressor; when a check valve fails, intelligent controller will detect the failure, communicate the failure and alter operation to protect the compressor from damage; when an exhaust valve fails, intelligent controller 10 can detect the failure, and communicate the failure; the like; and/or combinations thereof.

(64) In the specification and/or figures, typical embodiments of the disclosure have been disclosed. The present disclosure is not limited to such exemplary embodiments. The use of the term and/or includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.

(65) The foregoing description and drawings comprise illustrative embodiments. Having thus described exemplary embodiments, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present disclosure. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Accordingly, the present disclosure is not limited to the specific embodiments illustrated herein but is limited only by the following claims.