U.S. patent application number 14/614346 was filed with the patent office on 2015-08-06 for system and method for modeling, simulation, optimization, and/or quote creation.
The applicant listed for this patent is Ingersoll-Rand Company. Invention is credited to Nicholas Able, Kelly Glenn Campbell, Ryan D. Hartman, John J. Linehan, Eric W. Seidel, Chun Jian Tang.
Application Number | 20150220669 14/614346 |
Document ID | / |
Family ID | 52465224 |
Filed Date | 2015-08-06 |
United States Patent
Application |
20150220669 |
Kind Code |
A1 |
Linehan; John J. ; et
al. |
August 6, 2015 |
System and Method for Modeling, Simulation, Optimization, and/or
Quote Creation
Abstract
A computer may display on a graphical user interface (GUI) a
component library including a set of components relating to a
compressed air system. The GUI may have a modeling interface for
configuring a virtual model using the set of components. The
computer may simulate the virtual model to determine one or more
optimizations to the compressed air system. The computer may also
determine the cost of implementing the compressor system
optimization.
Inventors: |
Linehan; John J.; (Jamison,
PA) ; Campbell; Kelly Glenn; (Davidson, NC) ;
Hartman; Ryan D.; (Huntersville, NC) ; Able;
Nicholas; (Huntersville, NC) ; Seidel; Eric W.;
(Davidson, NC) ; Tang; Chun Jian; (Annandale,
NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ingersoll-Rand Company |
Davidson |
NC |
US |
|
|
Family ID: |
52465224 |
Appl. No.: |
14/614346 |
Filed: |
February 4, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61935807 |
Feb 4, 2014 |
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61943131 |
Feb 21, 2014 |
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61943146 |
Feb 21, 2014 |
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61943152 |
Feb 21, 2014 |
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61943149 |
Feb 21, 2014 |
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Current U.S.
Class: |
703/1 |
Current CPC
Class: |
G06F 30/20 20200101;
G05B 13/04 20130101; G06Q 30/0627 20130101; G06F 17/10 20130101;
G06F 2111/06 20200101; G06Q 30/0631 20130101; G05B 13/042 20130101;
G06Q 30/0641 20130101; G06Q 10/20 20130101; G05D 16/20
20130101 |
International
Class: |
G06F 17/50 20060101
G06F017/50 |
Claims
1. A method, comprising: displaying, with a computer having a
graphical user interface (GUI), a component library including a set
of components relating to a compressed air system in a first
portion of the GUI and a modeling interface for configuring a
virtual model using the set of components in a second portion of
the GUI; receiving, through the GUI, a component add request to add
at least one of the set of components to the second portion of the
GUI; adding the at least one of the set of components to the second
portion of the GUI in response to the component add request;
determining whether the component add request includes adding the
at least one of the set of components to the virtual model;
interconnecting the at least one of the set of components with the
virtual model when the component add request includes adding the at
least one of the set of components to the virtual model; receiving
and storing, with the computer, real-time monitoring data of an
in-use compressed air system; and simulating the virtual model with
the real-time monitoring data.
2. The method of claim 1, further comprising: receiving, through
the GUI, a rule at least partially defining the at least one of the
set of components added to the second portion of the GUI and the
virtual model; performing a rules check for at least partially
validating the at least one of the set of components added to the
second portion of the GUI and the virtual model based on the rule;
and generating a notification when the set of components added to
the second portion being connected to the virtual model violates
the rules check.
3. The method of claim 1, further comprising: establishing a
communication link between the computer and a server; requesting
the component library from a database on the server; and receiving
the component library from the server.
4. The method of claim 1, wherein the GUI further includes a third
portion including a settings interface for adjusting one or more
settings.
5. The method of claim 4, further comprising: receiving, through
the GUI, an adjustment request to adjust one or more settings of a
selected component in the virtual model; adjusting one or more
settings based on the adjustment request; and configuring a
compressed air system model on the second portion of the GUI based
on the set of components added to the second portion of the GUI and
the one or more settings adjusted on the third portion.
6. The method of claim 5, wherein the one or more settings includes
one or more component settings for each of the set of components on
a first sub-portion of the third portion of the GUI, and the one or
more component settings includes at least one of a compressor
pressure set point, a dryer dew point, a flow demand, and a
component operating condition.
7. The method of claim 5, wherein the one or more settings includes
one or more system settings for the compressed air system on a
second sub-portion of the third portion of the GUI, and the one or
more system settings includes at least one of a pressure, a flow, a
relative humidity, a temperature, an energy consumption, an energy
cost, and a system operating condition.
8. The method of claim 1, further comprising: receiving, through
the GUI, a template add request to add one or more templates from a
fourth portion of the GUI including a template library of
selectable templates relating to a compressed air system; adding
the one or more templates onto the second portion of the GUI;
determining whether the template add request includes adding the
one or more templates the virtual model; and interconnecting the
one or more templates with the virtual model when the template add
request includes adding the one or more templates to the virtual
model.
9. The method of claim 8, wherein the one or more templates
includes at least one of a pre-built compressor room, a factory
floor layout, a header network, and a compressed air system
component combination.
10. The method of claim 1, wherein the set of components includes
at least one of a compressor, a dryer, a filter, a regulator, a
pipe, a pipe fitting, a point-of-use tool, a hose, a valve, a
drain, an air receiver, a separator, a lubricator, a cooler, a
safety device, a treatment component, and a customizable
component.
11. The method of claim 1, wherein the component add request
includes at least one of a user selecting one of the set of
components, and dragging and dropping one of the set of components
on the second portion of the GUI.
12. The method of claim 1, further comprising: scanning a barcode
of an in-operation compressed air system; determining, with the
computer, a virtual component based on the barcode; and
interconnecting the virtual component to the virtual model.
13. A computing device, comprising: a graphical user interface
including a first portion and second portion, wherein the first
portion is configured to display a component library including a
set of components relating to a compressed air system, wherein the
second portion includes a modeling interface to configure a virtual
model using the set of components; and one or more processors
configured with non-transitory computer executable instructions to
receive a component add request to add at least one of the set of
components to the second portion of the GUI, to add the at least
one of the set of components to the second portion in response to
the component add request, to determine whether the component add
request includes adding the at least one of the set of components
to the virtual model, to interconnect the at least one of the set
of components with the virtual model when the component add request
includes adding the at least one of the set of components to the
virtual model, to store real-time monitoring data of a currently
used compressed air system, and to simulate the virtual model with
the real-time monitoring data.
14. The computing device of claim 13, wherein the one or more
processors are further configured to receive, through the graphical
user interface, a rule at least partially defining the at least one
of the set of components added to the second portion and the
virtual model, to perform a rules check for at least partially
validating the at least one of the set of components added to the
second portion and the virtual model based on the rule, and
generate a notification when the set of components added to the
second portion being connected to the virtual model violates the
rules check.
15. The computing device of claim 13, wherein the graphical user
interface further includes a third portion including a settings
interface for adjusting one or more settings.
16. The computing device of claim 15, wherein the one or more
processors are further configured to receive, through the graphical
user interface, an adjustment request to adjust one or more
settings of a selected component in the virtual model, to adjust
one or more settings based on the adjustment request, and configure
a compressed air system model on the second portion of the
graphical user interface based on the set of components added to
the second portion of the graphical user interface and the one or
more settings adjusted on the third portion.
17. The computing device of claim 16, wherein the one or more
settings includes one or more component settings for each of the
set of components on a first sub-portion of the third portion, and
the one or more component settings includes at least one of a
compressor pressure set point, a dryer dew point, a flow demand,
and a component operating condition.
18. The computing device of claim 17, wherein the one or more
settings includes one or more system settings for the compressed
air system on a second sub-portion of the third portion, and the
one or more system settings includes at least one of a pressure, a
flow, a relative humidity, a temperature, an energy consumption, an
energy cost, and a system operating condition.
19. The computing device of claim 13, wherein the one or more
processors are further configured to receive, through the graphical
user interface, a template add request to add one or more templates
from a fourth portion of the graphical user interface including a
template library of selectable templates relating to a compressed
air system, to add the one or more templates onto the second
portion, and to determine whether the template add request includes
adding the one or more templates the virtual model, and to
interconnect the one or more templates with the virtual model when
the template add request includes adding the one or more templates
to the virtual model.
20. The computing device of claim 20, wherein the computing device
is one of a laptop computer, a desktop computer, and tablet
computer.
21. A system, comprising: a server configured to store a component
library; a barcode scanner structured to scan a barcode of an
in-operation compressed air system; and a computing device
comprising: a graphical user interface including a first portion
and second portion, wherein the first portion is configured to
display the component library including a set of components
relating to a compressed air system, wherein the second portion
includes a modeling interface to configure a virtual model using
the set of components; and one or more processors configured with
non-transitory computer executable instructions to receive a
component add request to add at least one of the set of components
to the second portion of the GUI, to add the at least one of the
set of components to the second portion in response to the
component add request, to determine whether the component add
request includes adding the at least one of the set of components
to the virtual model, to interconnect the at least one of the set
of components with the virtual model when the component add request
includes adding the at least one of the set of components to the
virtual model, to determine a virtual component based on the
barcode, to interconnect the virtual component to the virtual
model, to store real-time monitoring data of a currently used
compressed air system, and to simulate the virtual model with the
real-time monitoring data.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Patent Application No. 61/935,807, filed on Feb. 4,
2014, U.S. Provisional Patent Application No. 61/943,131, filed on
Feb. 21, 2014, U.S. Provisional Patent Application No. 61/943,146,
filed on Feb. 21, 2014, U.S. Provisional Patent Application No.
61/943,152, filed on Feb. 21, 2014, and U.S. Provisional Patent
Application No. 61/943,149, filed on Feb. 21, 2014, all of which
are hereby incorporated by reference in their entirety.
BACKGROUND
[0002] The present invention generally relates to modeling,
simulating, optimizing, and/or generating a quote for a system such
as a compressed air system. A compressed air system in a facility
typically includes many components, such as one or more
compressors, dryers, tanks, pipes, and/or regulators. Compressed
air systems are typically designed to provide compressed air at a
desired flow rate, pressure, temperature, and quality at a high
efficiency to minimize energy consumption. Some existing systems
have various shortcomings relative to certain applications.
Accordingly, there remains a need for further contributions in this
area of technology.
SUMMARY
[0003] One embodiment of the present invention is a unique system
and method for modeling, simulation, optimization, and/or quote
creation. Other embodiments include apparatuses, systems, devices,
hardware, methods, and combinations for modeling, simulation,
optimization, and/or quote creation. Further embodiments, forms,
features, aspects, benefits, and advantages of the present
application shall become apparent from the description and figures
provided herewith.
BRIEF DESCRIPTION OF THE FIGURES
[0004] The description herein makes reference to the accompanying
figures wherein like reference numerals refer to like parts
throughout the several views, and wherein:
[0005] FIG. 1 is a schematic block diagram of an exemplary
system;
[0006] FIG. 1A is an exemplary GUI for adjusting solution control
settings;
[0007] FIG. 1B is another exemplary GUI for adjusting solution
control settings;
[0008] FIG. 2 is a schematic block diagram of an exemplary
computing device;
[0009] FIG. 3 is a schematic flow diagram of an exemplary process
for determining and providing a recommendation and sales quote;
[0010] FIG. 4 is a schematic block diagram of an exemplary modeling
GUI; and
[0011] FIG. 5 is a schematic block diagram of an exemplary feedback
GUI.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0012] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to the
embodiments illustrated in the drawings and specific language will
be used to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended, any alterations and further modifications in the
illustrated embodiments, and any further applications of the
principles of the invention as illustrated therein as would
normally occur to one skilled in the art to which the invention
relates are contemplated herein.
[0013] With reference to FIG. 1, there is illustrated an exemplary
system 100, which includes a computer 102, a model server 104, and
a sales quote server 106. Each of the model server 104 and the
sales quote server 106 in operable conjunction with a sales quote
database 107 may communicate with the computer 102 remotely over
the Internet and/or other data networks known in the art. It is
contemplated that the model server 104 and the sales quote server
106 may be of any server type configurable to communicate with the
computer 102. While the model server 104 and the sales quote server
106 are each shown as separate single servers in FIG. 1, it is
contemplated that in certain embodiments the model server 104 and
the sales quote server 106 may each be combined into a single
server or may each be comprised of multiple servers.
[0014] The system 100 is directed to a compressed air system.
However, it is contemplated that the embodiments and/or features of
the present application may be applied to any other type of system
other than compressed air systems.
[0015] The computer 102 may be any type of computer such as a
desktop computer, laptop computer, server, tablet computer,
smartphone, and the like. The computer 102 may include a number of
modules providing a number of functionalities. A module may be
implemented as operations by software, hardware, artificial
intelligence, fuzzy logic, or any combination thereof, or at least
partially performed by a user or operator. In certain embodiments,
modules represent software elements as a computer program encoded
on a computer readable medium, wherein a computer performs the
described operations when executing the computer program. A module
may be a single device, distributed across devices, and/or a module
may be grouped in whole or in part with other modules or devices.
The operations of any module may be performed wholly or partially
in hardware/software or by other modules. The presented
organization of the modules is exemplary only, and other
organizations, configurations and arrangements are
contemplated.
[0016] The model server 104 is structured to store information in a
database 105 at the model server 104 or other remote database
server. The database 105 may store a compressed air system
component library that may include digital representations or
computer model definitions of compressed air system components,
such as one or more compressors, dryers, tanks, pipes, regulators,
and the like. It is contemplated that in certain embodiments the
compressed air system component library may be maintained in a
secure environment, the secure environment only allowing access,
for example, when credentials have been input and validated. The
computer 102 may include an application which, upon start-up of
computer 102, will log into the model server 104 using, for
example, an administrator name, location, contact information,
password, and/or any other information. The database 105 may
further include but are not limited to system generation,
automation, and/or instructions, performance or fluid dynamic maps,
data curves, parameter lookup tables, flow rates, temperatures,
pressure control settings, speeds, efficiencies, and/or other
parameters for each of the compressed air system components. The
set of parameters may include proportional-integral-derivative
(PID) controller settings and/or various control algorithms for
each of the compressed air system components, when applicable.
[0017] The computer 102 includes a modeling module 108 configured
to request and receive at least a portion of the compressed air
system component library from the database 105 at the model server
104 via the Internet, for example. The compressed air system
component library may be requested automatically by the computer
102 or when requested or selected by a user of the computer 102.
The modeling module 108 may be further configured to communicate
with a graphical user interface (GUI) that allows a user to
configure a compressed air system model using the compressed air
system components from the compressed air system component library,
such as a modeling GUI 402, which is discussed in further detail in
the description of FIG. 4.
[0018] The computer 102 includes a simulation module 110 configured
to receive and interpret the compressed air system model including
component parameters from the modeling module 108 and perform one
or more simulations on the compressed air system model based on one
or more system parameters. The system parameters may include a
pressure, a flow, a relative humidity, a temperature, an energy
consumption, and/or other parameters.
[0019] In certain embodiments, the simulation module 110 may be
further configured to predict and/or diagnose compressed air system
component failures by comparing real-time monitoring data to a
real-time simulation, which may allow for preventive maintenance
troubleshooting, root-cause analysis, and/or back solving for
desired system parameters. The computer 102 may receive the
real-time monitoring data from various sources such as being input
from a user manually or via a portable storage drive, download the
real-time monitoring data from the server 104, or receive the
real-time monitoring data electronically from a remote location. In
certain other embodiments, the simulation may be performed using
one or more geometrical and/or performance parameters from each
component in the compressed air system model to model transient and
dynamic pressure, flow, moisture content, energy consumption,
and/or the like through the compressed air system model. The
computer 102 may provide the results of any preventive maintenance
troubleshooting, root-cause analysis, and/or back solving to a
customer or third party in a report via email, stored in the model
server 104 or the sales quote server 106, displayed on a GUI 400 of
the computer 102, and/or communicated by any other electronic means
as known by those skilled in the art. Furthermore, it is
contemplated that the real-time monitoring data from a previous
installation or other facility may be used in a different
installation or facility.
[0020] The simulation module 110 may be further configured to
determine reliability. In certain embodiments, the reliability may
include installation reliability and/or design reliability. The
installation reliability may use real-time data, historical data,
and/or predictive simulation to determine the reliability of an
existing compressed air system. The design reliability may use
historical data from like compressed air systems to determine the
reliability of a virtual compressed air system and/or known
performance parameters derived from the simulation, like cycle
rate, pressure, moisture content which influence reliability. In
certain embodiments an acceptable reliability setting may be set by
the user, such as by a GUI, for example. The acceptable reliability
may be based on a total cost of ownership (TCO), a performance
metric, and/or other costs. In one non-limiting example, the
reliability would be based on having minimized up-front costs which
may allow the user to improve the system based on the reliability
by changing the control strategy and/or adding or replacing
equipment in the system.
[0021] The simulation module 110 may also include an intelligent
solution or convergence control to prevent the user and/or customer
from experiencing problems when running simulations of varying
complexity. In particular, there are at least two types of
parameters that are referred to as solution control. Those are the
time step and the convergence criteria which in one embodiment can
include a group of 15 individual settings. Solution control
settings may impact the accuracy, stability, and computation time
of simulations. The way in which solution control is handled in the
system generally should be user friendly and intuitive, but also
flexible to handle a wide range of use cases. A modeling program
such as Flowmaster may be used with the system 100; however, other
modeling programs are contemplated.
[0022] The time step is the increment in which the simulation
proceeds through time. For example, if a time step of 0.1 seconds
is selected, a calculation generally will occur every 10th of a
second until the simulation runs to completion. The smaller the
time step generally the more accurate and more stable a given
simulation will be but the cost generally will be computation time.
The opposite is generally true for a larger time step. In one
embodiment, to conserve computation time when a smaller time step
is used, the results may be written only once per second. To make
setting the time step easier for the user, four time steps and
corresponding write intervals have been identified for conducting
analyses as shown in table 1 below.
TABLE-US-00001 TABLE 1 Time Step & Results File Write Interval
Table Time Step & Results File Write Interval TS1 TS2 TS3 TS4
Time Step (S) 0.5 0.25 0.1 0.05 Results file Write Interval 2 4 10
20
[0023] The convergence criteria, which is a combination of various
parameters such as the ones shown below in table 2, also may affect
the simulation accuracy, stability, and computation time. To make
selecting these parameters easier for the user, predefined values
for all parameters have been broken out into four "buckets". As
buckets increase from one to four, the convergence criteria
generally moves from loose to tight.
TABLE-US-00002 TABLE 2 Convergence Criteria Table Convergence
Criteria Property Bucket 1 Bucket 2 Bucket 3 Bucket 4 Units
Pressure Loose Slightly Tighter Tightest Tolerance Tolerance
Tigether Tolerance Tolerance Flow Tolerance Tolerance Weighting
Factor Controller Tolerance Controller Weighting Factor
[0024] A combination of time step and convergence criteria
(specifically a convergence criteria bucket) includes what is being
referred to as a "solution control setting." These solution control
settings are shown in Table 3. Computation time generally increases
from solution control setting 1 to solution control setting 16.
Simulation accuracy and stability generally increase from solution
control setting 1 to solution control setting 16.
TABLE-US-00003 TABLE 3 Solution Control Setting Table Solution
Control Convergence Criteria Setting Time Step Bucket 1 TS1 Bucket
1 2 TS1 Bucket 2 3 TS1 Bucket 3 4 TS1 Bucket 4 5 TS2 Bucket 1 6 TS2
Bucket 2 7 TS2 Bucket 3 8 TS2 Bucket 4 9 TS3 Bucket 1 10 TS3 Bucket
2 11 TS3 Bucket 3 12 TS3 Bucket 4 13 TS4 Bucket 1 14 TS4 Bucket 2
15 TS4 Bucket 3 16 TS4 Bucket 4
[0025] It should be noted that the values shown in all of the
tables are exemplary in nature and not to be construed as limiting
in any way. The values will vary depending on the system to be
analyzed.
[0026] The simulation module 110 may provide a solution control
method to the user as a default setting in which the user does not
have to adjust any of the previously discussed time step or
convergence criteria settings. Generally, with the solution control
setting should be adjusted (i.e., moving from solution control
setting 1 to solution control setting 16) in an iterative loop
until a successful simulation is reached.
[0027] To determine the initial solution control setting, the logic
in Table 4 may be applied by the simulation module 110. If the
answer to any of the questions is yes, the corresponding setting
generally should be used as the initial setting. If more than one
question in Table 4 is answered yes, then the highest corresponding
starting solution control setting generally should be used
TABLE-US-00004 TABLE 4 Determining Initial Simulation Control
Setting Determining Initial Simulation Control Setting Max Starting
Scenario (if the answer is yes apply the specified Solution
Simulation Control Setting) Control Setting Is there a VSD
compressor in the system? 5 Is there more than 1 compressor of any
type in the 5 system? Is there an Intelliflow Valve in the system?
5 Does the flow demand vary? 5 Is this an advanced simulation?
(header network 9 included) Is there more than 1 VSD compressors in
the system? 9 Is there a centac compressor in the system? 9 Is
there a two arm tank in the system? 9 IF ALL QUESTIONS ARE ANSWERED
"NO" THE SOLUTION CONTROL SETTING SHOULD BE 1
[0028] A successful solution generally is one that runs to
completion with no errors (often warnings may be present, but are
typically okay). An unsuccessful simulation occurs anytime the
solution fails to initiate or fails to complete. In both cases some
form of error message generally should be communicated from the
system. Another way in which a simulation can be unsuccessful is
when a monitored pressure gauge such as one denoted as P3 by the
user (which may be a mandatory requirement) goes above a threshold
pressure of 3447379 Pa (500 psi) in one example. If this occurs the
simulation should be stopped and the next solution control setting
in the loop should be set and the simulation re-run.
[0029] The simulation module 110 may also include an advanced
solution control mode in which the user may have the ability to
manually specify the time step and the convergence criteria. As
seen in FIG. 1A, a GUI 120 provides a user two slider bars 122, 124
to adjust. The first slider bar 122 may have four settings and
allow for adjustment of the time step. The second slider bar 124
may have four settings and allow for adjustment between the four
convergence criteria buckets.
[0030] In another embodiment, another advanced solution control
mode may allow the user to have the ability to specify the time
step and certain convergence criteria parameters manually as seen
in FIG. 1B, which illustrates a GUI 126 with a time step slide bar
128, a convergence criteria slide bar 130, and various other inputs
for time step, weighting factor, pressure tolerance, flow
tolerance, controller weighting factor, and/or controller
tolerance.
[0031] The range for manual time step setting may be from TS1 and
TS4 shown in Table 1 and the ranges for manual convergence criteria
may be from defaults to Bucket 4 shown in Table 2.
[0032] The simulation module 110 may also include a variable speed
drive (VSD) performance curve generator to simulate competitor or
generic VSD rotary compressor. To simulate a compressor model,
typically flow and power surfaces as well as maximum and minimum
speed lines must be created. The following are examples variables
of these surfaces and curves. Flow Surface: Independent Variables:
Discharge Pressure (Pa) & Percent of Max Motor Speed (ratio);
Dependent Variable: Volumetric Flow Rate (m 3/s). Power Surface:
Independent Variables: Discharge Pressure (Pa) & Percent of Max
Motor Speed (ratio); Dependent Variable: Volumetric Flow Rate (m
3/s). Max Speed Line: Independent Variable: Pressure (Pa);
Dependent Variable: Percent of Max Motor Speed (ratio). Min Speed
Line: Independent Variable: Pressure (Pa Dependent Variable:
Percent of Max Motor Speed (ratio). The Percent of Max Motor Speed
may be assumed to be proportional to flow rate such that the max
flow rate of the machine will equal 100% motor speed; a flow rate
of 80% of the max flow will be 80% motor speed and so on.
[0033] There are two scenarios in which flow and power surfaces can
be created based on the different levels of information the user
has regarding the compressor: advanced method and a basic method
depending on the amount of data a user has about the machine and/or
system. Calculations shown are in SI units, but may be in other
units.
[0034] The inputs for the advanced method may include data for flow
and power at a specified pressure, the maximum capacity of the
compressor, the maximum operating pressure, and the minimum
operating pressure as seen in Tables 5 and 6 below.
TABLE-US-00005 TABLE 5 Advanced Method Inputs Pressure Pressure
689464.9752 792884.7215 Flow Speed Power Flow Speed Power
m{circumflex over ( )}3/s ratio W m{circumflex over ( )}3/s ratio W
0.31385 1.000 114400.0 0.28600 0.911 115200.0 0.28208 0.899
104300.0 0.26165 0.834 104900.0 0.25400 0.809 93800.0 0.23744 0.757
95400.0 0.22559 0.719 83400.0 0.21389 0.682 86500.0 0.19713 0.628
73500.0 0.19034 0.606 77900.0 0.16834 0.535 63900.0 0.16664 0.531
69700.0 0.14111 0.450 55400.0 0.14394 0.459 62000.0
TABLE-US-00006 TABLE 6 Advanced Method Inputs Max Volumetric Flow
Rate of Compressor (m{circumflex over ( )}3/s) 0.31385 Max
Operating Pressure (Pa) 1137617.2090 Min Operating Pressure (Pa)
448152.2339
[0035] The first step in the advanced method may be to extrapolate
the flow and power to the max and min operating pressures as seen
in Table 7.
TABLE-US-00007 TABLE 7 Flow & Power Extrapolated Values
Pressure Pressure Pressure Pressure 448152.2339 689464.9752
792884.7215 1137617.209 Flow Speed Power Flow Speed Power Flow
Speed Power Flow Speed Power m{circumflex over ( )}3/s ratio W
m{circumflex over ( )}3/s ratio W m{circumflex over ( )}3/s ratio W
m{circumflex over ( )}3/s ratio W 0.37882 1.207 112533.3 0.31385
1.000 114400.0 0.28600 0.911 115200.0 0.19318 0.616 117866.7
0.32977 1.051 102900.0 0.28208 0.899 104300.0 0.26165 0.834
104900.0 0.19353 0.617 106900.0 0.29265 0.932 90066.7 0.25400 0.809
93800.0 0.23744 0.757 95400.0 0.18222 0.581 100733.3 0.25290 0.806
76166.7 0.22559 0.719 83400.0 0.21389 0.682 86500.0 0.17487 0.557
96833.3 0.21299 0.679 63233.3 0.19713 0.628 73500.0 0.19034 0.606
77900.0 0.16768 0.534 92566.7 0.17231 0.549 50366.7 0.16834 0.536
63900.0 0.16664 0.531 69700.0 0.16098 0.513 89033.3 0.13451 0.429
40000.0 0.14111 0.450 55400.0 0.14394 0.459 62000.0 0.15338 0.489
84000.0
[0036] The first step is implemented using the equation for linear
interpolation/extrapolation where pressure is the "x" variable and
flow or power is the "y" variable. An example of this calculation
is done for a flow of 0.29265 as shown below.
y = y 0 + ( y 1 - y 0 ) * ( x - x 0 x 1 - x 0 ) y = 0.25400 + (
0.23744 - 0.25400 ) * ( 448152.2339 - 689464.9752 792884.7215 -
689464.9752 ) y = 0.29264 ( 1 ) ##EQU00001##
[0037] This process should be repeated moving up and down the
columns until all values for flow and power are calculated. The "y"
variable in the above equation is a flow value when extrapolating
for flow and the "y" variable is a power value when extrapolating
power, however, the same equation is to be used.
[0038] The second step of the advanced method is to calculate the
speed as a percentage of max speed at every flow point. To
calculate, simply take a given flow rate in Table 7 and divide it
by the "Max Volumetric Flow Rate of Compressor" shown in Table 6.
An example of this calculation for a speed of 0.581 is show
below.
Speed = Flow Rate Max Flow Rate Speed = 0.18222 0.31385 Speed =
0.581 ( 2 ) ##EQU00002##
[0039] This process should be repeated until all speeds shown in
Table 7 are calculated.
[0040] Once Table 7 is completely calculated, the simulation module
110 may calculate the max and min speed line points shown below in
Tables 8 and 9, respectively.
TABLE-US-00008 TABLE 8 Max Speed Line Max Speed Line Pressure (Pa)
Speed (ratio) 448152.2339 1.000 689464.9752 1.000 792884.7215 0.911
1137617.2090 0.617
TABLE-US-00009 TABLE 9 Min Speed Line Min Speed Line Pressure (Pa)
Speed (ratio) 448152.2339 0.429 689464.9752 0.450 792884.7215 0.459
1137617.2090 0.489
[0041] The speeds are the maximum and minimum speeds calculated in
step 2 for each given pressure. By using a "max" and "min" approach
instead of using the value in row 1 and row 7 it allows for
flexibility if the user only specifies 5 rows of data. However, if
a speed calculated in step 2 exceeds a value of 1 it typically
should be clipped down to 1 when defining the speed lines. This
will typically happen at lower pressures such as 448152.2339 Pa in
the case of this example where in Table the max speed at
448152.2339 Pa is 1.207 but when calculating the max speed line in
Table 8 this value is clipped to 1.
[0042] Next the data calculated in the previous steps may be used
by a modeling program to create the desired curves and/or surfaces.
There may be an automation process for creating the curves and/or
surfaces. The following are notes or settings for each
curve/surface. Max Speed Line: 2D Curve, x-axis: Pressure (Pa);
y-axis: Speed (as a ratio); Degree fit: Linear. Min Speed Line: 2D
Curve; x-axis: Pressure (Pa); y-axis: Speed (as a ratio); Degree
fit: Linear. Flow Surface: 3D surface; x-axis: Pressure (Pa);
y-axis: Speed (as a ratio); z-axis: Volumetric Flow Rate (m 3/s);
Degree fit: Linear. Power Surface: 3D surface; x-axis: Pressure
(Pa); y-axis: Speed (as a ratio); z-axis: Power (W); Degree fit:
2nd Degree.
[0043] Turning to the basic method, typically the required inputs
include pressure, max flow, and min flow. The optional inputs may
include max power and min power. It is the combination of these
optional inputs that make up the three different calculation
options discussed below. Tables 10 and 11 illustrate these
values.
TABLE-US-00010 TABLE 10 Inputs Pressure 792884.7215 Flow Speed
Power m{circumflex over ( )}3/s ratio W 0.28600 0.911 115200.0
0.23865 0.760 97466.7 0.19130 0.610 79733.3 0.14394 0.459
62000.0
TABLE-US-00011 TABLE 11 Max and Min Inputs Max Volumetric Flow Rate
of Compressor (m{circumflex over ( )}3/s) 0.31385 Max Operating
Pressure (Pa) 1137617.2090 Min Operating Pressure (Pa) 448152.2339
Turn Down Percent (ratio) 0.497
[0044] Under option 1, the user specifies all mandatory inputs and
the optional flow and power input for the specified pressure shown
in Table 10. Under option 2, the user specifies all mandatory
inputs and only the optional flow input for the specified pressure
shown in Table 10. Under option 3, the user specifies all of the
mandatory inputs and only the optional turn down percent in Table
11.
[0045] The first step of the process is to ensure all of the
inputs, both mandatory and optional, are obtained. Since two of the
values are optional they will need to be calculated if the user
does not specify them. This step will now be broken out into the
different options.
[0046] Under option 1, the user will have specified all of the
highlighted inputs in Table 10 and no further calculations are
needed. This step is complete.
[0047] Under option 2, the user has specified all of the inputs
discussed above except the minimum power. The calculation for this
and an example is shown below.
Min Power = Max Power * [ ( Min Flow Max Flow ) + 0.04 ] Min Power
= 115200.0 * [ ( 0.14394 0.28600 ) + 0.04 ] Min Power = 625866 ( 3
) ##EQU00003##
[0048] Under option 3, the user has not specified the minimum flow
or the minimum power but did specify the turn down percent. The
first step will be to calculate the minimum flow. The calculation
to do this is shown below.
Min Flow=(1-Turn Down Percent)*Max Flow
Min Flow=(1-0.497)*0.28600
Min Flow=0.14386 (4)
[0049] Next, the minimum power is calculated. With the knowledge of
the minimum flow, the calculation used in option 2 can now be used
here.
[0050] The remaining steps in the basic method are the same for all
three options. In step 2 of the basic method, the maximum and
minimum flow at the maximum and minimum specified pressures will be
calculated.
TABLE-US-00012 TABLE 12 Pressure & Power Value Calculation
Pressure Pressure Pressure 448252.2339 792884.7215 1137517.2090
Flow Speed Power Flow Speed Power Flow Speed Power m{circumflex
over ( )}3/s ratio W m{circumflex over ( )}3/s ratio W m{circumflex
over ( )}3/s ratio W 0.35439 1.129 115200.0 0.28000 0.911 115200.0
0.21761 0.693 115200.0 0.27997 0.892 92349.1 0.23865 0.760 97466.7
0.19732 0.629 105800.7 0.20555 0.655 69408.5 0.19130 0.618 79733.3
0.17704 0.564 96901.4 0.13114 0.418 46647.8 0.14384 0.459 62000.0
0.15675 0.499 87002.1
[0051] For calculating the max flow values the following equation
with example may be used:
Flow 1 , max = Flow 2 , max * [ ( - 0.00000064488882 * Pressure 1 +
1.44100755353019 ) ( - 0.00000064488882 * Pressure 2 +
1.44100755353019 ) ] Flow 1 , max = 0.28600 * [ ( -
0.00000064488882 * 448152.2239 + 1.44100755353019 ) ( -
0.00000064488882 * 792884.7215 + 1.44100755353019 ) ] Flow 1 , max
= 0.35439 ( 5 ) ##EQU00004##
[0052] For calculating the min flow values the following equation
with example may be used:
Flow 1 , min = Flow 2 , min * [ ( 0.000000264166015 * Pressure 1 +
0.814079058709771 ) ( 0.000000264166015 * Pressure 2 +
0.814079058709771 ) ] Flow 1 , min = 0.14394 * [ (
0.000000264166015 * 448152.2239 + 0.814079058709771 ) (
0.000000264166015 * 792884.7215 + 0.814079058709771 ) ] Flow 1 ,
min = 0.13114 ( 6 ) ##EQU00005##
[0053] Step 4 of the basic method will be to calculate the maximum
and minimum power at the maximum and minimum specified pressures.
There is no calculation needed for the max power as should be the
same for all specified pressures. The calculation for minimum power
does require a calculation of which the equation and an example are
shown below.
Power 1 , min = Power 1 , max * [ ( Flow 1 , min Flow 1 , max ) + (
Power 2 , min Power 2 , max ) - ( Flow 2 , min Flow 2 , max ) ]
Power 1 , min = 115200.0 * [ ( 0.13106 0.35439 ) + ( 62553.6 115200
) - ( 0.14386 0.28600 ) ] Power 1 , min = 47210.5 ( 7 )
##EQU00006##
[0054] Step 5 of the basic method includes calculating the even
linear spacing between the max and min flow and power,
respectively, using equations known by those of ordinary skill in
the art. The rest of the steps in the basic method are the same as
those in the advanced method discussed above.
[0055] The simulation module 110 may be further configured to
predict a centrifugal compressor transient surge. In simulating
centrifugal compressors, the simulation module 110 may be
configured to use models to predict a compressor's performance at
any point in time and accounting for its interactions with the
system it is installed in, which allows the user and customer to
know where the compressor is on the performance map as it is
installed in the compressed air system and how close the compressor
is to surge. The tool also allows for prediction of these
characteristics at different geographical locations (e.g., varying
altitudes and temperatures) as well as seasonal changes (e.g.,
varying temperatures).
[0056] Generally, in centrifugal compressors, there are two
phenomena that may limit the operating flow and pressure of the
particular machine. One is choke, where at a particular operating
pressure mass flow cannot be increased by increasing compressor
speed. The other phenomena is surge, wherein at a defined operating
pressure and flow rate the air does not have enough momentum to
continue to overcome the pressure gradient at the compressor
discharge and a flow reversal occurs. Both of these compressor
phenomena may be modeled and predicted by the system defined
herein. Other types of compressors may also be also be modeled by
the system disclosed herein.
[0057] The simulation module 110 may be configured to model the
entire compressor system including installation configuration and
components upstream and downstream of the compressor. These
components can include but are not limited to fluid conduits, heat
exchangers, filters, valves, air/oil separators, fluid separators,
dryers, etc. Because of the interaction between the compressor and
system components, performance will change depending on the type
and location of the compressor and variations of the system
components. The simulation module 110 may be configured to predict
the transient effects of the compressor on the system and the
transient effects of the system on the compressor. This allows the
simulation module 110 to determine where the compressor is
operating relative to surge and choke at any point in time and
allow certain operating parameters to be changed to keep the
compressor out of surge and operating as efficiently as
possible.
[0058] The computer further includes an analytics module 112
configured to receive and process the results of the one or more
simulations on the compressed air system model from the simulation
module 110. The analytics module 112 is further configured to
request a demand profile of the compressed air system model from
the user, such as by a GUI, for example, if the user has not
already input the demand profile via the modeling GUI 400. The
demand profile may include one or more usage parameters and/or load
requirements demanded of the compressed air system, such as a
storage capacity, an air demand amount, an energy cost rate, a
power source type, an application type, and/or one or more schedule
factors.
[0059] The analytics module 112 identifies one or more compressed
air system optimization gaps or opportunities based on the demand
profile and simulation results from the simulation module 110. The
compressed air system optimization gaps may include an insufficient
pressure, a high energy consumption, an undesired system
condensation, and/or other identified compressed air system
optimization gaps. It is contemplated that other optimization gaps
may be identified. In certain embodiments, the database 105 at the
model server 104 may further store iterations of previously saved
simulation results and demand profiles. The analytics module 112
may be further configured to predict compressed air system
optimization gaps based on the previously saved simulation results
and demand profiles. The analytics module 112 may be used to
perform preventive maintenance troubleshooting, root-cause
analysis, and/or back solving for an air compression system.
[0060] The computer also includes a recommendations module 114
configured to receive and process the compressed air system
optimization gaps from the analytics module 112. The
recommendations module 114 identifies one or more recommendations,
intended to improve or optimize the compressed air system model
based on the optimization gaps. The recommendations may include an
compressed air system pressure increase, a compressor duty cycle
decrease, adding a dryer to the compressed air system, and/or
adding a tank to the compressed air system. It is contemplated that
other recommendations may be identified.
[0061] The recommendations module 114 is further configured to
transmit the one or more recommendations to the sales quote server
106 and receive from the sales quote server 106 one or more sales
quotes corresponding to the recommendations. The sales quotes may
include, for example, a product list and a price corresponding to
each product in the product list, each of which may be stored in
the database 107 at the sales quote server 106. In certain
embodiments, the recommendations module 114 is further configured
to output the one or more recommendations and corresponding sales
quotes to the user, such as by a GUI, for example. The
recommendations module 114 may be further configured to retrieve
and interpret previously saved simulation results, virtual models,
and/or real time data from the database 105 at the model server 104
to recommend solutions to virtual and/or existing compressed air
systems. The recommendations module 114 may be further configured
to communicate with a GUI that communicates the simulation results,
virtual models, real time data, recommendations, and/or sales
quotes to the user, such as via a feedback GUI 502, which is
discussed in further detail in the description of FIG. 5.
[0062] The analytics module 112 and/or the recommendations module
114 may have the ability to link into a manufacturing execution
system (MES) to predict failures or poor quality. For example, the
MES may be used to control compressed air equipment in a
manufacturing plant. The analytics module 112 and/or the
recommendations module 114 may be configured to determine how
current equipment at the plant could be controlled differently to
improve efficiency, performance, energy consumption, and/or
reliability of the compressed air system in addition to quality,
delivery, and cost of the user's final product. The analytics
module 112 and/or the recommendations module 114 may also be
configured to determine how new or different equipment could be
used at the plant to improve efficiency, performance, energy
consumption, and/or reliability of the compressed air system and
thus the user's metrics of their final product.
[0063] The simulation module 110, the analytics module 112 and/or
the recommendations module 114 may be configured to model, analyze,
and recommend control(s) of individual components and/or compressed
air systems and system controllers in order to improve performance
and/or energy consumption. For example, the simulation module 110,
the analytics module 112 and/or the recommendations module 114 may
be used to determine a new or different set of control settings or
control strategy that would improve the efficiency, performance,
energy consumption, and/or reliability of one or more components of
a compressed air system. For example, the simulation module 110,
the analytics module 112 and/or the recommendations module 114 may
be used to determine adjustments of interactions between equipment
that would improve the efficiency, performance, energy consumption,
and/or reliability of one or more components of a compressed air
system. For example, the simulation module 110, the analytics
module 112 and/or the recommendations module 114 may be used to
determine performance predictions that may be used to improve the
efficiency, performance, energy consumption, and/or reliability of
one or more components of a compressed air system. Furthermore, the
analytics module 112 and/or the recommendations module 114 may have
the ability to learn as the number of simulations in the database
grows and better predict or recommend system optimization
techniques.
[0064] The computer 102 generally maintains a database 116. The
database 116 may include one or more saved compressed air system
models, real-time monitoring results, and/or compressed air system
model simulation results. The saved compressed air system models,
real-time monitoring results, and/or compressed air system model
simulation results may be used by the analytics module 112 and/or
the recommendations module 114 to predict compressed air system
optimization gaps, opportunities, and/or recommend compressed air
system solutions. It is contemplated that the database 116 may also
contain a cached compressed air system component library for use
when the computer 102 may be offline and/or unable to communicate
with the model server 104.
[0065] FIG. 2 is a schematic block diagram of a computing device
200. The computing device 200 is one example of a computer or
server that may be utilized in connection with the computer 102,
the model server 104, and/or the sales quote server 106 shown in
FIG. 1. Computing device 200 includes a processing device 202, an
input/output device 204, memory 206, and operating logic 208.
Furthermore, computing device 200 communicates with one or more
external devices 210.
[0066] The input/output device 204 allows the computing device 200
to communicate with the external device 210. For example, the
input/output device 204 may be a transceiver, network adapter,
network card, interface, or a port (e.g., a USB port, serial port,
parallel port, an analog port, a digital port, VGA, DVI, HDMI,
FireWire, CAT 5, or any other type of port or interface). The
input/output device 204 may be comprised of hardware, software,
and/or firmware. It is contemplated that the input/output device
204 will include more than one of these adapters, cards, or
ports.
[0067] The external device 210 may be any type of device that
allows data to be inputted or outputted from the computing device
200. For example, the external device 210 may be a mobile device, a
reader device, equipment, a handheld computer, a diagnostic tool, a
controller, a computer, a server, a processing system, a printer, a
display, an alarm, an illuminated indicator such as a status
indicator, a keyboard, a mouse, or a touch screen display.
Furthermore, it is contemplated that the external device 210 may be
integrated into the computing device 200. It is further
contemplated that there may be more than one external device in
communication with the computing device 200.
[0068] Processing device 202 can be a programmable type, a
dedicated, hardwired state machine; or a combination of these; and
it can further include multiple processors, Arithmetic-Logic Units
(ALUs), Central Processing Units (CPUs), Digital Signal Processors
(DSPs), or the like. Processing devices 202 with multiple
processing units may utilize distributed, pipelined, and/or
parallel processing. Processing device 202 may be dedicated to
performance of just the operations described herein or may be
utilized in one or more additional applications. In the depicted
form, processing device 202 is of a programmable variety that
executes algorithms and processes data in accordance with operating
logic 208 as defined by programming instructions (such as software
or firmware) stored in memory 206. Alternatively or additionally,
operating logic 208 for processing device 202 is at least partially
defined by hardwired logic or other hardware. Processing device 202
can be comprised of one or more components of any type suitable to
process the signals received from input/output device 204 or
elsewhere, and provide desired output signals. Such components may
include digital circuitry, analog circuitry, or a combination of
both.
[0069] Memory 206 may be of one or more types, such as a
solid-state variety, electromagnetic variety, optical variety, or a
combination of these forms. Furthermore, memory 206 can be
volatile, nonvolatile, or a combination of these types, and some or
all of memory 206 can be of a portable variety, such as a disk,
tape, memory stick, cartridge, or the like. In addition, memory 206
can store data that is manipulated by the operating logic 208 of
processing device 202, such as data representative of signals
received from and/or sent to input/output device 204 in addition to
or in lieu of storing programming instructions defining operating
logic 208, just to name one example. As shown in FIG. 2, memory 206
may be included with processing device 202 and/or coupled to the
processing device 202.
[0070] FIG. 3 illustrates a schematic flow diagram of an exemplary
process 300 for providing recommendations and corresponding sales
quotes for a system such as a compressed air system via a computer,
such as the computer 102 discussed in FIG. 1. Operations
illustrated for all of the processes in the present application are
understood to be examples only, and operations may be combined or
divided, and added or removed, as well as re-ordered in whole or in
part, unless explicitly stated to the contrary.
[0071] It is contemplated that in certain embodiments process 300
may be started by a user initiated trigger, such as by the user
starting an application and/or visiting a website. Process 300
starts at operation 302, where a computer (e.g., computer 102)
receives data from a first server, such as the model server 104
discussed in FIG. 1. In certain embodiments, the data may be a
library of compressed air system components, such as one or more
compressors, dryers, tanks, pipes, regulators, and the like. After
the computer 102 receives the data from the model server 104,
process 300 continues to operation 304, where a user generates a
compressed air system model based on the data from the model server
104 using the modeling module 108. In certain embodiments, the user
may be presented with a GUI for selecting components to include in
the compressed air system model. It is contemplated that in certain
embodiments, where the computer 102 is not in communication with
the first server (e.g., model server 104), the library of
compressed air system components may be cached in a local storage
116 on the computer 102.
[0072] From operation 304, process 300 then continues to operation
306, where the simulation module 110 of the computer 102 runs a
simulation of the compressed air system model based on the selected
compressed air system model components selected from the library of
compressed air system components by the user in operation 304. The
simulation may be performed on system parameters, including
pressure, flow, relative humidity, temperature, energy consumption,
and/or other parameters. It is contemplated that one or more
simulations may be run on the compressed air system model to
simulate the behavior of the compressed air system model over a
period of time and/or under certain conditions, for example various
geographical locations, altitudes, pressures, and/or temperatures.
Process 300 continues to operation 308, where the computer 102
processes the compressed air system model simulation results.
[0073] Process 300 continues to operation 310, where the computer
102 requests the user enter a demand profile of the compressed air
system model generated at operation 304. In certain embodiments,
the demand profile may be entered by the user via a GUI presented
by the computer.
[0074] After receiving the demand profile, process 300 continues to
operation 312, where the analytics module 112 of the computer 102
performs a series of analytic comparisons between the simulation
results and the demand profile to determine a set of optimization
gaps for the compressed air system model. The compressed air system
optimization gaps based on the compressed air system model may
include an insufficient pressure, a high energy consumption, an
undesired condensation amount in the compressed air system, and/or
other optimization gaps.
[0075] Process 300 then proceeds from operation 312 to 314, in
which the recommendations module 114 of the computer 102 determines
recommendations based on the optimization gaps. In certain
embodiments, the set of recommendations may include an increase in
the compressed air system pressure, a decrease in compressor duty
cycle, adding a dryer to the compressed air system, adding a tank
to the compressed air system, and/or other recommendations.
[0076] From operation 314, process 300 continues to operation 316,
where the recommendations module 114 of the computer 102 requests
data from a second server, such as the sales quote server 106
discussed in FIG. 1. In certain embodiments, the second server may
provide sales quote data corresponding to the components in the set
of recommendations determined in operation 312. It is contemplated
that in certain embodiments the operations performed on the first
and second server may be performed on a single server.
[0077] Process 300 then continues from operation 316 to operation
318, where the recommendations module 114 of the computer 102
provides the set of recommendations and the corresponding sales
quote data to the user or another computer or server, such as via a
GUI presented by the computer, email, and/or a printout, for
example.
[0078] The various aspects of the process 300 in the present
application may be implemented in operating logic 208 as operations
by software, hardware, artificial intelligence, fuzzy logic, or any
combination thereof, or at least partially performed by a user or
operator. In certain embodiments, operations represent software
elements as a computer program encoded on a computer readable
medium, wherein the computer 102, model server 104, and/or sales
quote server 106 performs the described operations when executing
the computer program.
[0079] The GUI embodiments illustrated in FIGS. 4 and 5 are
exemplary only, and other organizations, configurations, and
arrangements of the elements illustrated and/or discussed are
contemplated.
[0080] With reference to FIG. 4, there is illustrated an embodiment
400 of the modeling GUI 402 for modeling a virtual compressed air
system 403 (i.e. a graphical depiction of a network of compressed
air system components representative of a physical compressed air
system). The modeling GUI 402 includes a compressed air system
component library 404 including a set of component graphics 406.
The components 406 may include compressors, dryers, tanks, pipes,
regulators and/or other compressed air system components. It is
contemplated that the compressed air system component library 404
may be received from the database 105 at the model server 104
and/or from the database 116 at the computer 102.
[0081] The modeling GUI 402 further includes a modeling canvas 408
in which to construct the virtual compressed air system 403 and a
settings adjustment interface 410 for adjusting component and/or
system settings. The modeling GUI 402 includes a template selection
interface 416 including one or more predefined templates 418. The
predefined templates may include component combination templates,
such as a compressor and a pipe size, and/or system level
templates, such as a pre-built common compressor room, a factory
floor layout, and/or a header network, for example. It is
contemplated that in certain embodiments the set of component
graphics 406 and/or predefined templates 418 may be represented as
icons, buttons, or any other type of textual and/or graphical
representation configured to be user interfaceable.
[0082] The user can select one or more components from the
component graphics 406 in the compressed air system component
library 404 and place them onto the modeling canvas 408, where they
can be moved around the modeling canvas 408 and inter-connected to
form the virtual compressed air system 403. To select a component
from the set of component graphics 406, the user may click on a
component graphic 406. In one embodiment, the user may place the
selected component onto the modeling canvas 408 by dragging the
selected component graphic(s) 406 from the compressed air system
component library 404 and dropping it onto the modeling canvas 408.
In another embodiment, the user there may bring up a context menu,
such as by right-clicking on the component graphic 406, for
example, and selecting a context menu option to add the component
to the modeling canvas 408. In still another embodiment, selecting
a component may enable a button that, when clicked, adds the
selected component to the modeling canvas 408. It is contemplated
that multiple components may be modeled in parallel (i.e. multiple
tanks, dryers, filters, etc.) that allow for a real time
side-by-side comparison. It is further contemplated that any or all
of the component placement embodiments herein described may be
combined in a single embodiment. In certain embodiments, the
virtual compressed air system 403 may only be simulated when the
components are inter-connected to form a network representative of
a physical compressed air system.
[0083] The settings adjustment interface 410 may include a system
settings interface 412 and a selected component settings interface
414. Each compressed air system component may include component
settings, such as one or more geometrical and/or performance
parameters, that may be set using the selected component settings
interface 414 of the settings adjustment interface 410. The
component settings may include a compressor pressure set point, a
dryer dew point, a flow demand, a humidity, a temperature, and/or
other component specific settings. In certain embodiments, the
component settings interface may be a dynamically changing
interface, where only specific settings for the selected component
are displayed and/or enabled.
[0084] The system settings for the virtual compressed air system
403 may be set using the system settings interface 412. The system
settings may include pressure, flow, relative humidity,
temperature, energy consumption, energy cost, atmospheric pressure,
altitude, and the like. The system settings may further include a
demand profile, which may include one or more usage parameters
and/or load requirements demanded of the compressed air system,
such as a storage capacity, an air demand amount, an energy cost
rate, a power source type, an application type, a flow demand,
and/or one or more schedule factors. The system settings may also
include real-time settings data from an installation or
facility.
[0085] The system and/or component settings may further include
setting an operating condition for the system and/or component
(e.g., a set of varying demand and transition settings for the
system and/or components). The operating conditions may include
varying demand from process equipment, compressors going from
online at full flow to offline at zero flow, compressors going from
offline at zero flow to online at full flow, desiccant dryer
changeover, and/or other system and/or component level operating
points and/or conditions.
[0086] In certain embodiments, the system and/or component settings
may be input via real data from a compressed air system monitoring
method, which may provide real-time settings or a historic set of
demand data from the user's system and/or a like system, from a
manual/offline user input method, by identifying air system
components, such as scanning component specific barcodes of current
air system components (e.g., on a plant floor), to automatically
build the virtual compressed air system 403 as components are
identified, and/or based on the demand profile and/or user
specified requirements. The user specified requirements may
include, but are not limited to, system layout, reliability,
performance, and financial settings, such as a return on
investment. It is contemplated that a user may use a barcode
scanner to scan the current air system components. The barcode
scanner may decode the barcode or send the barcode to a computer or
server to be decoded. In some embodiments, the barcode scanner may
be a smartphone with a barcode scanning app. The computer 102 may
receive the barcode or the decoded barcode from the barcode scanner
or from a server. The computer 102 may look up the compressed air
system component(s) that corresponds to the barcode and include the
corresponding virtual component into a virtual model that is being
built for simulation.
[0087] In certain embodiments, when components are added to the
virtual compressed air system 403, a rules check may be performed
to ensure the user does not produce a potentially dangerous and/or
unreliable compressed air system model. It is further contemplated
that a rules check may be performed additionally or alternatively
on a user initiated event, such as clicking a test button, for
example, and/or on a non-user initiated event where the rules check
is performed periodically and/or after a predetermined period of
time has passed. In certain embodiments, the user may be notified
of a rules check failure by being presented with an error message
warning the user if the potentially dangerous and/or unreliable
compressed air system model, for example.
[0088] Additional and/or alternative user controls for use in the
modeling GUI 402 are contemplated. Such user controls include, but
are not limited to, a Start/Stop button for starting and stopping a
simulation of the virtual compressed air system 403, a clear button
for clearing the virtual compressed air system components from the
modeling canvas 408, one or more save buttons for saving the system
settings interface 412 settings, the selected component settings
interface 414 settings, and/or the virtual compressed air system
403. In certain embodiments, the user may be able to introduce
faults into the virtual compressed air system 403 to show the
effects thereof. Such faults may include dirty filters, faulty
drain valves, rusted pipe, and/or the like. In certain other
embodiments, the user may be able to model how moisture is brought
back into the virtual compressed air system 403 from external
sources and/or introduce seasonal and environmental effects. In
still other embodiments, the user may be able to include any
Newtonian fluid, such as for a virtual compressed air system that
uses pneumatic power to operate pumps and/or other hydraulic
equipment, for example.
[0089] In certain embodiments, the modeling GUI 402 may have a
portion that receives a demand side performance from the user. The
desired output performance may include a torque output, a force
output, etc., such that the demand side performance may be used to
determine flow and pressure requirements of the compressed air
system, to which the virtual compressed air system 403 may be
constructed by the modeling GUI 402 without further instruction
from the user. In certain other embodiments, the modeling GUI 402
may have a portion that receives a number of drops from the user.
The number of drops may be used to determine required components of
the compressed air system, to which the virtual compressed air
system 403 may be constructed by the modeling GUI 402 without
further instruction from the user.
[0090] With reference to FIG. 5, there is illustrated an embodiment
500 of the feedback GUI 502 that includes a visual results
interface 504, a financial results interface 506, and a system
simulation results interface 508. The visual results interface 504
may include a visualization of the simulation results (i.e.,
pressure, flow, moisture content, energy consumption, etc. at any
point in the system) in the form of videos, line graphs, bar
graphs, gauges, tabulated data, and/or other data visualization
technique.
[0091] The financial results interface 506 may include a bill of
materials (BOM), a budgetary quote, a total cost of ownership
(TCO), a return on investment (ROI), a sales quote including
pricing details corresponding to each component in the simulated
virtual compressed air system, and/or other financial data
corresponding to the component and/or behavior of the simulated
virtual compressed air system. The total cost of ownership may
include the initial cost of purchase and installation of the
equipment, the operating costs of the equipment, and/or the
maintenance costs of the equipment.
[0092] The system simulation results interface 508 includes a
visual layout of the simulated virtual compressed air system that
may be zoomed in/out in order to identify particular components
and/or arrangements. Compressed air systems include a supply side,
which includes compressors and air treatment systems, and a demand
side, which includes distribution and storage systems, as well as
end-use equipment. In certain embodiments, the visual layout may
provide a visual indicator distinguishing the supply side
components and the demand side components, such as by a first color
indicating the supply side and a second color indicating the demand
side, for example. Further visual indicators may be provided in the
visual layout, such as flow direction indicator, which may be
represented by a series of arrows pointing in the direction of the
flow at a size and/or color indicative of the pressure of the flow,
for example.
[0093] Performance metrics and/or potential issues may be
identified in the system simulation results interface 508.
Performance metrics may include a compressor efficiency, an energy
efficiency, a part load efficiency, a full load efficiency, a no
load efficiency, a supply side efficiency, a demand side
efficiency, and/or an overall system efficiency. The compressor
efficiency may include a volumetric efficiency, an adiabatic
efficiency, an isothermal efficiency, isentropic efficiency and/or
a mechanical efficiency. It is contemplated that the efficiencies
may be theoretical, ideal and/or based on emperical data. A supply
side efficiency may include the system's ability to deliver clean,
dry, and/or stable air at an appropriate pressure and/or in a
cost-effective manner. A demand side efficiency may include the
system's ability to minimize wasted air and use compressed air for
the appropriate end-use applications. Potential issues may include
compressed air lost in the form of unusable air, misuse, friction,
vibration, incorrect capacity, incorrect pressure, maintenance
costs, leakage, and/or noise. In certain embodiments, seasonal
effects, environmental effects, and/or energy usage penalties on
the simulated virtual compressed air system may be identified. It
is contemplated that in certain embodiments a proposed
solution/strategy may be identified in the system simulation
results interface 508 based on the performance metrics, potential
issues, seasonal effects, environmental effects, and/or energy
usage penalties.
[0094] The feedback GUI 502 may include a means to return to the
modeling GUI 402 referenced in FIG. 4, e.g., a button, to modify
the virtual compressed air system. The feedback GUI 502 may further
include a means to save at least a portion the data displayed in
the feedback GUI 502. In certain embodiments, the displayed data
may be saved in local memory on the computer 102 and/or saved
remotely, such as at the model server 104, for example. The
feedback GUI 502 may also include a means to export the data
displayed in the feedback GUI 502. In certain embodiments, the data
displayed in the feedback GUI 502 may be formatted and exported as
a document, an email, and/or the like.
[0095] Various aspects of the systems, apparatus, and methods are
disclosed herein. For example, one aspect involves a method,
comprising: receiving, with a computing device, a component
library; generating, with the computing device, a model of a system
based on the component library; simulating, with the computing
device, the model of the system to generate simulation data;
determining, with the computing device, an optimization gap based
on the simulation data and a demand profile; determining, with the
computing device, a recommendation based on the optimization gap;
and receiving, with the computing device, a sales quote for a
product.
[0096] Features of the aspect may include: displaying the sales
quote and the recommendation on a graphical user interface;
transmitting the sales quote and the recommendation to another
computing device via email; storing at least one of the component
library, the model, and the simulation data in a database in the
computing device; wherein the computing device receives the
component library from a first server and wherein the computing
device receives the sales quote from a second server; wherein the
first server maintains a database of component libraries; wherein
the second server generates the sales quote based on the
recommendation; wherein the computing device receives the component
library and the sales quote from one server; wherein the system is
a compressed air system.
[0097] Another aspect of the present application may include: a
system, comprising: a first computing device configured with
non-transitory computer executable instructions to maintain a
database of component libraries; a second computing device
configured with non-transitory computer executable instructions to
receive one of the component libraries from the first computing
device, generate a model of a system based on the component
library, simulate the model of the system to generate simulation
data, determine an optimization gap based on the simulation data
and a demand profile, determine a recommendation based on the
optimization gap, and receive a sales quote for a product; and a
third computing device configured with non-transitory computer
executable instructions to generate the sales quote based on the
recommendation and transmit the sales quote to the second computing
device.
[0098] Features of the aspect may include: wherein the first
computing device is a model server and the third computing device
is a sales quote server, and wherein the model server and the sales
quote server are part one server; wherein the first computing
device is a model server and the third computing device is a sales
quote server, and wherein the model server and the sales quote
server are separate servers; wherein the second computing device is
further configured to display the sales quote and the
recommendation on a graphical user interface; wherein the second
computing device is further configured to transmit the sales quote
and the recommendation to a fourth computing device via email;
wherein the second computing device further includes a database to
store at least one of the component library, the model, and the
simulation data.
[0099] Yet another aspect of the present application may include a
computing device, comprising: a modeling module configured to
receive a component library and generate a model of a system based
on the component library; a simulation module configured to
simulate the model of the system to generate simulation data; an
analytics module configured to determine an optimization gap based
on the simulation data and a demand profile; and a recommendation
module configured to determine a recommendation based on the
optimization gap and receive a sales quote for a product.
[0100] Features of the aspect of the present application may
include: a graphical user interface to display the sales quote and
the recommendation; wherein the recommendation module is further
configured to transmit the sales quote and the recommendation to
another computing device via email; a database to store at least
one of the component library, the model, and the simulation data;
wherein the system is a compressed air system.
[0101] Another aspect of the present application includes a method,
comprising: receiving, with a computer, a set of library data
relating to a compressed air system from a database at a first
server; displaying, with a first graphical user interface (GUI) on
the computer, a visual representation of each of the set of library
data in a first portion of the GUI, a settings interface in a
second portion of the GUI, and a modeling interface in a third
portion of the GUI; receiving, through the GUI, a user initiated
request to add at least a portion of the set library data to the
second portion of the GUI to form a model of a compressed air
system; receiving a demand profile from a user; receiving, through
the GUI, a user initiated request to simulate the model; simulating
the model of the system to generate simulation data; determining
one or more optimization gaps based on the simulation data and a
demand profile; determining a recommendation based on the one or
more optimization gap; transmitting the recommendation to a second
server; receiving a sales quote for one or more products from the
second server based on the recommendation; displaying, with a
second GUI on the computer, the simulation data, the sales quote,
and the recommendation.
[0102] Features of the aspect may include: wherein the set of
library data includes at least one of a component library and a
template library; wherein the component library comprises a set of
components relating to a compressed air system, wherein the set of
components includes at least one of a compressor, a dryer, a
filter, a regulator, a pipe, a pipe fitting, a point-of-use tool, a
hose, a valve, a drain, an air receiver, a separator, a lubricator,
a cooler, a safety device, a treatment component, and a
customizable component; wherein each component in the set of
components includes one or more settings, and wherein the one or
more settings includes at least one of a compressor pressure set
point, a dryer dew point, a flow demand, a humidity, a temperature,
an energy consumption, a pressure, a flow, a relative humidity, a
temperature, and a component specific setting; wherein the template
library comprises a set of templates relating to a compressed air
system, wherein the set of templates includes at least one of a
component combination template, a compressor room layout template,
a factory floor layout template, and a header network template;
wherein the visual representation includes at least one of an icon,
a button, a textual representation, and a graphical representation;
wherein the simulation data includes at least one of a transient
pressure, a dynamic pressure, a flow, a moisture content, an energy
consumption, and a financial reference; wherein the financial
reference includes at least one of a bill of materials (BOM), a
budget, a return on investment (ROI), and a total cost of ownership
(TCO); further comprising transmitting the sales quote and the
recommendation to another computing device via email; transmitting
at least one of the model and the simulation to be saved on the
first server.
[0103] Yet another aspect of the present application includes a
system, comprising: a first computing device configured with
non-transitory computer executable instructions to receive and
maintain a first database that includes library data relating to a
compressed air system; a second computing device configured with
non-transitory computer executable instructions to receive at least
a portion of the library data from the first computing device,
display the library data in a graphical user interface (GUI),
receive input through the GUI from a user to create a demand
profile and generate a model of a system from the library data,
simulate the model of the system to generate simulation data,
determine one or more optimization gaps based on the simulation
data and the demand profile, determine a recommendation based on
the optimization gap, receive a sales quote for one or more
products, and display the simulation data, the sales quote, and the
recommendation; and a third computing device configured with
non-transitory computer executable instructions to receive the
recommendation, generate the sales quote based on the
recommendation and transmit the sales quote to the second computing
device.
[0104] Features of the aspect may include: wherein the first
computing device is a first server and the third computing device
is a second server, and wherein the first server and the second
server are part of one server; wherein the first computing device
is a first server and the third computing device is a second
server, and wherein the first server and the second server are
separate servers; wherein the first computing device is further
configured receive and maintain at least one of a real-time data
and a historical data; wherein the second computing device is
further configured to receive and display, through the GUI, at
least one of the real-time data and the historical data, and
wherein the one or more optimization gaps are further determined
based on at least one of the real-time data and the historical
data; wherein the third computing device further includes a second
database to store at least one of the component library, the model,
and the simulation data.
[0105] Another aspect of the present application includes a
computing device, comprising: a modeling module configured to
receive a component library relating to a compressed air system and
generate a model of a system based on the component library, the
component library including a set of components relating to the
compressed air system; a simulation module configured to simulate
the model of the system to generate simulation data; an analytics
module configured to determine an optimization gap based on the
simulation data and a demand profile; a recommendation module
configured to determine a recommendation based on the optimization
gap and receive a sales quote for a product; and a first graphical
user interface (GUI) configured to display the component library in
a first portion of the GUI, the model of the system based on the
component library in a second portion of the GUI, and the demand
profile and one or more settings of the each of the set of
components in the component library in a third portion of the
GUI.
[0106] Features of the aspect may include: a second GUI to display
the simulation data, the recommendation, and the sales quote;
wherein the recommendation module is further configured to transmit
the sales quote and the recommendation to another computing device
via email; a database to store at least one of the component
library, the model, and the simulation data; wherein the system is
a compressed air system.
[0107] Another aspect of the present application includes: storing
a component library relating to a compressed air system in a
database at a server; receiving, with the server, a component
library request from the computer to transmit at least a portion of
the component library to the computer; and transmitting, with the
server, at least a portion of the component library to the computer
in response to the component library request.
[0108] Features of the aspect may include: wherein the component
library includes at least one of a set of components relating to a
compressed air system, one or more control settings for each of the
set of components, and a template; wherein the set of components
includes at least one of a compressor, a dryer, a filter, a
regulator, a pipe, a pipe fitting, a point-of-use tool, a hose, a
valve, a drain, an air receiver, a separator, a lubricator, a
cooler, a safety device, a treatment component, and a customizable
component; wherein the one or more control settings includes at
least one of a compressor pressure set point, a dryer dew point, a
flow demand, a humidity, a temperature, an operating condition, and
a component size; wherein the template includes at one of a
component combination template, a pre-built common compressor room,
a factory floor layout, and a header network; receiving, with the
server, a data set from the computer; and storing the data set in
the database at the server; receiving, with the server, a data set
request from the computer to transmit at least a portion of the
data set to the computer; and transmitting, with the server, at
least a portion of the data set to the computer in response to the
data set request; wherein the data set includes at least one of a
simulation result relating to a simulation of a virtual model of a
compressed air system, the virtual model of the compressed air
system, and a real-time monitoring data set of a compressed air
system; wherein the computer and the server communicate via a
secure communication link.
[0109] Yet another aspect of the present application includes a
system, comprising: a server configured with non-transitory
computer executable instructions to store a component library
relating to a compressed air system in a database at the server, to
receive a component library request from a computing device to
transmit at least a portion of the component library to the
computing device, and to transmit at least a portion of the
component library to the computing device in response to the
component library request.
[0110] Features of the aspect may include: wherein the computing
device is configured with non-transitory computer executable
instructions to transmit the component library request to the
server, to receive the component library from the server in
response to the component library request, to simulate a virtual
model of a compressed air system based on the component library, to
generate a simulation result based on the simulating of the virtual
model, and to transmit at least one of a simulation result relating
to the simulating of the virtual model of the compressed air
system, the virtual model of the compressed air system, and a
real-time monitoring data set of the compressed air system to the
server; wherein the component library includes at least one of a
set of components relating to a compressed air system, one or more
control settings for each of the set of components, and a template;
wherein the set of components includes at least one of a
compressor, a dryer, a filter, a regulator, a pipe, a pipe fitting,
a point-of-use tool, a hose, a valve, a drain, an air receiver, a
separator, a lubricator, a cooler, a safety device, a treatment
component, and a customizable component; wherein the one or more
control settings includes at least one of a compressor pressure set
point, a dryer dew point, a flow demand, a humidity, a temperature,
an operating condition, and a component size; wherein the template
includes at one of a component combination template, a pre-built
common compressor room, a factory floor layout, and a header
network.
[0111] Yet another aspect of the present application includes a
method, comprising: transmitting, with a computer, a component
library request to a server; receiving, with the computer, a
component library from the server in response to the component
library request; simulating, with the computer, a virtual model of
a compressed air system based on the component library; generating,
with the computer, a simulation result based on the simulating of
the virtual model; and transmitting, with the computer, at least
one of a simulation result relating to the simulating of the
virtual model of the compressed air system, the virtual model of
the compressed air system, and a real-time monitoring data set of
the compressed air system to the server.
[0112] Another aspect of the present application includes a method,
comprising: displaying, with a computer having a graphical user
interface (GUI), a component library including a set of components
relating to a compressed air system in a first portion of the GUI
and a modeling interface for configuring a virtual model using the
set of components in a second portion of the GUI; receiving,
through the GUI, a component add request to add at least one of the
set of components to the second portion of the GUI; adding the at
least one of the set of components to the second portion of the GUI
in response to the component add request; determining whether the
component add request includes adding the at least one of the set
of components to the virtual model; and interconnecting the at
least one of the set of components with the virtual model when the
component add request includes adding the at least one of the set
of components to the virtual model.
[0113] Features of the aspect may include: receiving, through the
GUI, a rule at least partially defining the at least one of the set
of components added to the second portion of the GUI and the
virtual model; performing a rules check for at least partially
validating the at least one of the set of components added to the
second portion of the GUI and the virtual model based on the rule;
and generating a notification when the set of components added to
the second portion being connected to the virtual model violates
the rules check; establishing a communication link between the
computer and a server; requesting the component library from a
database on the server; and receiving the component library from
the server; wherein the GUI further includes a third portion
including a settings interface for adjusting one or more settings;
receiving, through the GUI, an adjustment request to adjust one or
more settings of a selected component in the virtual model;
adjusting one or more settings based on the adjustment request; and
configuring a compressed air system model on the second portion of
the GUI based on the set of components added to the second portion
of the GUI and the one or more settings adjusted on the third
portion; wherein the one or more settings includes one or more
component settings for each of the set of components on a first
sub-portion of the third portion of the GUI, and the one or more
component settings includes at least one of a compressor pressure
set point, a dryer dew point, a flow demand, and a component
operating condition; wherein the one or more settings includes one
or more system settings for the compressed air system on a second
sub-portion of the third portion of the GUI, and the one or more
system settings includes at least one of a pressure, a flow, a
relative humidity, a temperature, an energy consumption, an energy
cost, and a system operating condition; receiving, through the GUI,
a template add request to add one or more templates from a fourth
portion of the GUI including a template library of selectable
templates relating to a compressed air system; adding the one or
more templates onto the second portion of the GUI; determining
whether the template add request includes adding the one or more
templates the virtual model; and interconnecting the one or more
templates with the virtual model when the template add request
includes adding the one or more templates to the virtual model;
wherein the one or more templates includes at least one of a
pre-built compressor room, a factory floor layout, a header
network, and a compressed air system component combination; wherein
the set of components includes at least one of a compressor, a
dryer, a filter, a regulator, a pipe, a pipe fitting, a
point-of-use tool, a hose, a valve, a drain, an air receiver, a
separator, a lubricator, a cooler, a safety device, a treatment
component, and a customizable component; wherein the component add
request includes at least one of a user selecting one of the set of
components, and dragging and dropping one of the set of components
on the second portion of the GUI.
[0114] Yet another aspect of the present application may include a
computing device, comprising: a graphical user interface including
a first portion and second portion, wherein the first portion is
configured to display a component library including a set of
components relating to a compressed air system, wherein the second
portion includes a modeling interface to configure a virtual model
using the set of components; and one or more processors configured
with non-transitory computer executable instructions to receive a
component add request to add at least one of the set of components
to the second portion of the GUI, to add the at least one of the
set of components to the second portion in response to the
component add request, to determine whether the component add
request includes adding the at least one of the set of components
to the virtual model, and to interconnect the at least one of the
set of components with the virtual model when the component add
request includes adding the at least one of the set of components
to the virtual model.
[0115] Features of the aspect may include: wherein the one or more
processors are further configured to receive, through the graphical
user interface, a rule at least partially defining the at least one
of the set of components added to the second portion and the
virtual model, to perform a rules check for at least partially
validating the at least one of the set of components added to the
second portion and the virtual model based on the rule, and
generate a notification when the set of components added to the
second portion being connected to the virtual model violates the
rules check; wherein the graphical user interface further includes
a third portion including a settings interface for adjusting one or
more settings; wherein the one or more processors are further
configured to receive, through the graphical user interface, an
adjustment request to adjust one or more settings of a selected
component in the virtual model, to adjust one or more settings
based on the adjustment request, and configure a compressed air
system model on the second portion of the graphical user interface
based on the set of components added to the second portion of the
graphical user interface and the one or more settings adjusted on
the third portion; wherein the one or more settings includes one or
more component settings for each of the set of components on a
first sub-portion of the third portion, and the one or more
component settings includes at least one of a compressor pressure
set point, a dryer dew point, a flow demand, and a component
operating condition; wherein the one or more settings includes one
or more system settings for the compressed air system on a second
sub-portion of the third portion, and the one or more system
settings includes at least one of a pressure, a flow, a relative
humidity, a temperature, an energy consumption, an energy cost, and
a system operating condition; wherein the one or more processors
are further configured to receive, through the graphical user
interface, a template add request to add one or more templates from
a fourth portion of the graphical user interface including a
template library of selectable templates relating to a compressed
air system, to add the one or more templates onto the second
portion, and to determine whether the template add request includes
adding the one or more templates the virtual model, and to
interconnect the one or more templates with the virtual model when
the template add request includes adding the one or more templates
to the virtual model; wherein the computing device is one of a
laptop computer, a desktop computer, and tablet computer.
[0116] Yet another aspect of the present application includes a
method, comprising: performing, with a computer, a simulation of a
virtual compressed air system, the virtual compressed air system
including a set of components relating to a compressed air system;
analyzing a simulation result of the simulation based on one or
more settings of the virtual compressed air system and one or more
settings of the set of components; calculating a financial
reference based on the analyzed result; displaying, with a first
portion of a graphical user interface (GUI) on the computer, a
visual reference of the analyzed result; displaying, with a second
portion of the GUI, the financial reference based on the analyzed
result of the simulation; and displaying, with a third portion of
the GUI, a schematic model of the virtual compressed air
system.
[0117] Features of the aspect may include: wherein the result
includes at least one of a pressure, a flow, a moisture content,
and an energy consumption at any point of the simulation; wherein
the visual reference includes at least one of a video, a graph, a
gauge, a tabulated data display, and a flow diagram; wherein the
financial reference includes at least one of a bill of materials
(BOM), a budget, a return on investment (ROI), and a total cost of
ownership (TCO); receiving, from an input device, a user command;
and displaying only a subset of the schematic model of the virtual
compressed air system based on the user command, wherein the user
command includes at least one of a subset location, a subset size,
a dimension, and a zoom magnification level; wherein displaying the
subset of the schematic model comprises displaying the subset of
the schematic model in a rectangular region superimposed on the
third portion of the GUI; establishing a communication link between
the computer and a server; requesting a sales quote from a database
on the server based on the virtual compressed air system; and
receiving the sales quote from the database, wherein the financial
reference further includes the sales quote; establishing a
communication link between the computer and a server; requesting a
historical data set from a database on the server based on one or
more previously saved simulation results; receiving the historical
data set from the database; and wherein analyzing the simulation
result is further based on the historical data; displaying, with a
fourth portion of the GUI, a file menu that includes at least one
of an export option and a save option; receiving, from an input
device, a save command; establishing a communication link between
the computer and a server; and transmitting at least one of the
schematic model of the virtual compressed air system, the
simulation result, and the financial reference to the server;
receiving, from an input device, an export command; and exporting
at least one of the schematic model of the virtual compressed air
system, the simulation result, and the financial reference in an
export format based on the export command; wherein the export
format includes one of a locally saved document, a remotely saved
document, and an email.
[0118] Another aspect of the present application includes a
computing device, comprising: one or more processors configured
with non-transitory computer executable instructions to perform a
simulation of a virtual compressed air system that includes a set
of components relating to a compressed air system, to analyze a
result of the simulation based on one or more settings of the
virtual compressed air system and one or more settings of the set
of components, and to calculate a financial reference based on the
analyzed result; and a graphical user interface including a first
portion, a second portion, and third portion, wherein the first
portion is configured to display a visual reference of the analyzed
result, wherein the second portion is configured to display the
financial reference based on the analyzed result of the simulation,
and wherein the third portion is configured to display a schematic
model of the virtual compressed air system.
[0119] Features of the aspect may include: wherein the graphical
user interface further comprises a fourth portion having a file
menu that includes at least one of an export option and a save
option; wherein the one or more processors are further configured
to establish a communication link between the computing device and
a server in response to receiving a save command from a user input
device, and wherein the processor is further configure to transmit
at least one of the schematic model of the virtual compressed air
system, the simulation result, and the financial reference to the
server; wherein the one or more processors are further configured
to export at least one of the schematic model of the virtual
compressed air system, the simulation result, and the financial
reference in an export format in response to receiving an export
command from a user input device; wherein the export format
includes one of a locally saved document, a remotely saved
document, and an email; wherein the computing device is one of a
laptop computer, a desktop computer, and tablet computer.
[0120] Another aspect of the present application may include a
method, comprising: receiving, with a computer, a set of library
data relating to a compressed air system from a database at a first
server; displaying, with a first graphical user interface (GUI) on
the computer, a visual representation of each of the set of library
data in a first portion of the GUI, a settings interface in a
second portion of the GUI, and a modeling interface in a third
portion of the GUI; receiving, through the GUI, a user initiated
request to add at least a portion of the set library data to the
second portion of the GUI to form a model of a compressed air
system; receiving a demand profile from a user; receiving, through
the GUI, a user initiated request to simulate the model; simulating
the model of the system to generate simulation data; determining
one or more optimization gaps based on the simulation data and the
demand profile; determining a recommendation based on the one or
more optimization gap; transmitting the recommendation to a second
server; receiving a sales quote for one or more products from the
second server based on the recommendation; displaying, with a
second GUI on the computer, the simulation data, the sales quote,
and the recommendation.
[0121] Features of the aspect may include: wherein the set of
library data includes at least one of a component library and a
template library; wherein the component library comprises a set of
components relating to a compressed air system, wherein the set of
components includes at least one of a compressor, a dryer, a
filter, a regulator, a pipe, a pipe fitting, a point-of-use tool, a
hose, a valve, a drain, an air receiver, a separator, a lubricator,
a cooler, a safety device, a treatment component, and a
customizable component; wherein each component in the set of
components includes one or more settings, and wherein the one or
more settings includes at least one of a compressor pressure set
point, a dryer dew point, a flow demand, a humidity, a temperature,
an energy consumption, a pressure, a flow, a relative humidity, a
temperature, and a component specific setting; wherein the template
library comprises a set of templates relating to a compressed air
system, wherein the set of templates includes at least one of a
component combination template, a compressor room layout template,
a factory floor layout template, and a header network template;
wherein the visual representation includes at least one of an icon,
a button, a textual representation, and a graphical representation;
wherein the simulation data includes at least one of a transient
pressure, a dynamic pressure, a flow, a moisture content, an energy
consumption, and a financial reference; wherein the financial
reference includes at least one of a bill of materials (BOM), a
budget, a return on investment (ROI), and a total cost of ownership
(TCO); further comprising transmitting the sales quote and the
recommendation to another computing device via email; transmitting
at least one of the model and the simulation to be saved on the
first server.
[0122] Yet another aspect of the present application may include a
system, comprising: a first computing device configured with
non-transitory computer executable instructions to receive and
maintain a first database that includes library data relating to a
compressed air system; a second computing device configured with
non-transitory computer executable instructions to receive at least
a portion of the library data from the first computing device,
display the library data in a graphical user interface (GUI),
receive input through the GUI from a user to create a demand
profile and generate a model of a system from the library data,
simulate the model of the system to generate simulation data,
determine one or more optimizations based on the simulation data
and the demand profile, determine a recommendation based on the
optimizations, receive a sales quote for one or more products, and
display the simulation data, the sales quote, and the
recommendation; and a third computing device configured with
non-transitory computer executable instructions to receive the
recommendation, generate the sales quote based on the
recommendation and transmit the sales quote to the second computing
device.
[0123] Features of the aspect may include: wherein the first
computing device is a first server and the third computing device
is a second server, and wherein the first server and the second
server are part of one server; wherein the first computing device
is a first server and the third computing device is a second
server, and wherein the first server and the second server are
separate servers; wherein the first computing device is further
configured to receive and maintain at least one of a real-time data
and a historical data; wherein the second computing device is
further configured to receive and display, through the GUI, at
least one of the real-time data and the historical data, and
wherein the one or more optimizations are further determined based
on at least one of the real-time data and the historical data;
wherein the third computing device further includes a second
database to store at least one of the component library, the model,
and the simulation data.
[0124] Another aspect of the present application may include a
computing device, comprising: a processor and a memory including
non-transitory computer executable instructions that when executed
by the processor cause the computing device to: receive a component
library relating to an HVAC system and generate a model of a
customer system based on the component library, the component
library including a set of components relating to the HVAC system;
to simulate the model of the customer system to generate simulation
data; determine an optimization based on the simulation data and a
demand profile; determine a recommendation based on the
optimization and receive a sales quote for a product; and generate
and display a GUI with the component library in a first portion of
the GUI, the model of the customer system based on the component
library in a second portion of the GUI, and the demand profile and
one or more settings of the each of the set of components in the
component library in a third portion of the GUI.
[0125] Features of the aspect may include wherein the computing
device is further structured to generate and display a second GUI
with the simulation data, the recommendation, and the sales quote;
wherein the computing device is further structured to transmit the
sales quote and the recommendation to another computing device via
email; a database to store at least one of the component library,
the model, and the simulation data; wherein the optimization is
based on real-time data and historical data.
[0126] Yet another aspect of the present application may include a
method, comprising: displaying, with a computer having a graphical
user interface (GUI), a component library including a set of
components relating to a compressed air system in a first portion
of the GUI and a modeling interface for configuring a virtual model
using the set of components in a second portion of the GUI;
receiving, through the GUI, a component add request to add at least
one of the set of components to the second portion of the GUI;
adding the at least one of the set of components to the second
portion of the GUI in response to the component add request;
determining whether the component add request includes adding the
at least one of the set of components to the virtual model;
interconnecting the at least one of the set of components with the
virtual model when the component add request includes adding the at
least one of the set of components to the virtual model; receiving
and storing, with the computer, real-time monitoring data of an
in-use compressed air system; and simulating the virtual model with
the real-time monitoring data.
[0127] Features of the aspect may include: receiving, through the
GUI, a rule at least partially defining the at least one of the set
of components added to the second portion of the GUI and the
virtual model; performing a rules check for at least partially
validating the at least one of the set of components added to the
second portion of the GUI and the virtual model based on the rule;
and generating a notification when the set of components added to
the second portion being connected to the virtual model violates
the rules check; establishing a communication link between the
computer and a server; requesting the component library from a
database on the server; and receiving the component library from
the server; wherein the GUI further includes a third portion
including a settings interface for adjusting one or more settings;
receiving, through the GUI, an adjustment request to adjust one or
more settings of a selected component in the virtual model;
adjusting one or more settings based on the adjustment request; and
configuring a compressed air system model on the second portion of
the GUI based on the set of components added to the second portion
of the GUI and the one or more settings adjusted on the third
portion; wherein the one or more settings includes one or more
component settings for each of the set of components on a first
sub-portion of the third portion of the GUI, and the one or more
component settings includes at least one of a compressor pressure
set point, a dryer dew point, a flow demand, and a component
operating condition; wherein the one or more settings includes one
or more system settings for the compressed air system on a second
sub-portion of the third portion of the GUI, and the one or more
system settings includes at least one of a pressure, a flow, a
relative humidity, a temperature, an energy consumption, an energy
cost, and a system operating condition; receiving, through the GUI,
a template add request to add one or more templates from a fourth
portion of the GUI including a template library of selectable
templates relating to a compressed air system; adding the one or
more templates onto the second portion of the GUI; determining
whether the template add request includes adding the one or more
templates the virtual model; and interconnecting the one or more
templates with the virtual model when the template add request
includes adding the one or more templates to the virtual model;
wherein the one or more templates includes at least one of a
pre-built compressor room, a factory floor layout, a header
network, and a compressed air system component combination; wherein
the set of components includes at least one of a compressor, a
dryer, a filter, a regulator, a pipe, a pipe fitting, a
point-of-use tool, a hose, a valve, a drain, an air receiver, a
separator, a lubricator, a cooler, a safety device, a treatment
component, and a customizable component; wherein the component add
request includes at least one of a user selecting one of the set of
components, and dragging and dropping one of the set of components
on the second portion of the GUI; scanning a barcode of an
in-operation compressed air system; determining, with the computer,
a virtual component based on the barcode; and interconnecting the
virtual component to the virtual model.
[0128] Yet another aspect of the present application may include a
method, comprising: performing, with a computer, a simulation of a
virtual compressed air system using real-time monitoring data, the
virtual compressed air system including a set of components
relating to a compressed air system; analyzing a simulation result
of the simulation based on one or more settings of the virtual
compressed air system and one or more settings of the set of
components; predicting component failures in the compressed air
system based on the simulation result; calculating a financial
reference based on the analyzed result; displaying, with a first
portion of a graphical user interface (GUI) on the computer, a
visual reference of the analyzed result; displaying, with a second
portion of the GUI, the financial reference based on the analyzed
result of the simulation; and displaying, with a third portion of
the GUI, a schematic model of the virtual compressed air
system.
[0129] Features of the aspect may include: wherein the simulation
result includes at least one of a pressure, a flow, a moisture
content, and an energy consumption at any point of the simulation;
wherein the visual reference includes at least one of a video, a
graph, a gauge, a tabulated data display, and a flow diagram;
wherein the financial reference includes at least one of a bill of
materials (BOM), a budget, a return on investment (ROI), and a
total cost of ownership (TCO); receiving, from an input device, a
user command; and displaying only a subset of the schematic model
of the virtual compressed air system based on the user command,
wherein the user command includes at least one of a subset
location, a subset size, a dimension, and a zoom magnification
level; wherein displaying the subset of the schematic model
comprises displaying the subset of the schematic model in a
rectangular region superimposed on the third portion of the GUI;
establishing a communication link between the computer and a
server; requesting a sales quote from a database on the server
based on the virtual compressed air system; and receiving the sales
quote from the database, wherein the financial reference further
includes the sales quote; establishing a communication link between
the computer and a server; requesting a historical data set from a
database on the server based on one or more previously saved
simulation results; receiving the historical data set from the
database; and wherein analyzing the simulation result is further
based on the historical data; displaying, with a fourth portion of
the GUI, a file menu that includes at least one of an export option
and a save option; receiving, from an input device, the save
command; establishing a communication link between the computer and
a server; and transmitting at least one of the schematic model of
the virtual compressed air system, the simulation result, and the
financial reference to the server; receiving, from an input device,
the export command; and exporting at least one of the schematic
model of the virtual compressed air system, the simulation result,
and the financial reference in an export format based on the export
command; wherein the export format includes one of a locally saved
document, a remotely saved document, and an email; determining
optimizations for the compressed air system based on the analyzed
simulation result; displaying, with a third portion of the GUI, a
schematic model of the virtual compressed air system and; wherein
the computer is structured to provide better optimizations as the
amount of historical data grows.
[0130] Yet another aspect of the present application may include a
computing device, comprising: one or more processors configured
with non-transitory computer executable instructions to perform a
simulation of a virtual compressed air system that includes a set
of components relating to a compressed air system, to analyze a
result of the simulation based on one or more settings of the
virtual compressed air system and one or more settings of the set
of components, and to calculate a financial reference based on the
analyzed result and to predict component failures; and a graphical
user interface including a first portion, a second portion, and
third portion, wherein the first portion is configured to display a
visual reference of the analyzed result, wherein the second portion
is configured to display the financial reference based on the
analyzed result of the simulation, and wherein the third portion is
configured to display a schematic model of the virtual compressed
air system.
[0131] Features of the aspect may include: wherein the graphical
user interface further comprises a fourth portion having a file
menu that includes at least one of an export option and a save
option; wherein the one or more processors are further configured
to establish a communication link between the computing device and
a server in response to receiving a save command from a user input
device, and wherein the processor is further configure to transmit
at least one of the schematic model of the virtual compressed air
system, the simulation result, and the financial reference to the
server; wherein the one or more processors are further configured
to export at least one of the schematic model of the virtual
compressed air system, the simulation result, and the financial
reference in an export format in response to receiving an export
command from a user input device; wherein the export format
includes one of a locally saved document, a remotely saved
document, and an email; wherein the computing device is one of a
laptop computer, a desktop computer, and tablet computer.
[0132] Another aspect of the present application may include a
computing device, comprising: a graphical user interface including
a first portion and second portion, wherein the first portion is
configured to display a component library including a set of
components relating to a compressed air system, wherein the second
portion includes a modeling interface to configure a virtual model
using the set of components; and one or more processors configured
with non-transitory computer executable instructions to receive a
component add request to add at least one of the set of components
to the second portion of the GUI, to add the at least one of the
set of components to the second portion in response to the
component add request, to determine whether the component add
request includes adding the at least one of the set of components
to the virtual model, to interconnect the at least one of the set
of components with the virtual model when the component add request
includes adding the at least one of the set of components to the
virtual model, to store real-time monitoring data of a currently
used compressed air system, and to simulating the virtual model
with the real-time monitoring data.
[0133] Features of the aspect may include: wherein the one or more
processors are further configured to receive, through the graphical
user interface, a rule at least partially defining the at least one
of the set of components added to the second portion and the
virtual model, to perform a rules check for at least partially
validating the at least one of the set of components added to the
second portion and the virtual model based on the rule, and
generate a notification when the set of components added to the
second portion being connected to the virtual model violates the
rules check; wherein the graphical user interface further includes
a third portion including a settings interface for adjusting one or
more settings; wherein the one or more processors are further
configured to receive, through the graphical user interface, an
adjustment request to adjust one or more settings of a selected
component in the virtual model, to adjust one or more settings
based on the adjustment request, and configure a compressed air
system model on the second portion of the graphical user interface
based on the set of components added to the second portion of the
graphical user interface and the one or more settings adjusted on
the third portion; wherein the one or more settings includes one or
more component settings for each of the set of components on a
first sub-portion of the third portion, and the one or more
component settings includes at least one of a compressor pressure
set point, a dryer dew point, a flow demand, and a component
operating condition; wherein the one or more settings includes one
or more system settings for the compressed air system on a second
sub-portion of the third portion, and the one or more system
settings includes at least one of a pressure, a flow, a relative
humidity, a temperature, an energy consumption, an energy cost, and
a system operating condition; wherein the one or more processors
are further configured to receive, through the graphical user
interface, a template add request to add one or more templates from
a fourth portion of the graphical user interface including a
template library of selectable templates relating to a compressed
air system, to add the one or more templates onto the second
portion, and to determine whether the template add request includes
adding the one or more templates the virtual model, and to
interconnect the one or more templates with the virtual model when
the template add request includes adding the one or more templates
to the virtual model; wherein the computing device is one of a
laptop computer, a desktop computer, and tablet computer.
[0134] Another aspect of the present application may include a
method, comprising: receiving, with a computer, a set of library
data relating to a compressed air system from a database at a first
server; displaying, with a first graphical user interface (GUI) on
the computer, a visual representation of each of the set of library
data in a first portion of the GUI, a settings interface in a
second portion of the GUI, and a modeling interface in a third
portion of the GUI; receiving, through the GUI, a user initiated
request to add at least a portion of the set library data to the
second portion of the GUI to form a model of a compressed air
system; receiving a demand profile from a user; receiving, through
the GUI, a user initiated request to simulate the model; simulating
the model of the system to generate simulation data; determining
one or more optimization gaps based on the simulation data and the
demand profile; and determining a recommendation based on the one
or more optimization gap, wherein the recommendation includes at
least one of recommending new equipment to be used in the
compressed air system and recommending a change in control settings
for the compressed air system.
[0135] Features of the aspect may include: wherein the component
library comprises a set of components relating to a compressed air
system, wherein the set of components includes at least one of a
compressor, a dryer, a filter, a regulator, a pipe, a pipe fitting,
a point-of-use tool, a hose, a valve, a drain, an air receiver, a
separator, a lubricator, a cooler, a safety device, a treatment
component, and a customizable component; wherein each component in
the set of components includes one or more settings, and wherein
the one or more settings includes at least one of a compressor
pressure set point, a dryer dew point, a flow demand, a humidity, a
temperature, an energy consumption, a pressure, a flow, a relative
humidity, a temperature, and a component specific setting; wherein
the visual representation includes at least one of an icon, a
button, a textual representation, and a graphical representation;
wherein the simulation data includes at least one of a transient
pressure, a dynamic pressure, a flow, a moisture content, an energy
consumption, and a financial reference; wherein simulation data
includes at least one of a bill of materials (BOM), a budget, a
return on investment (ROI), and a total cost of ownership (TCO);
wherein the recommendation further includes a sales quote based on
the simulation data; predicting component failures in the
compressed air system based on the simulation data.
[0136] Yet another aspect of the present application may include a
computing device, comprising: a graphical user interface (GUI)
including a first portion and second portion, wherein the first
portion is configured to display a component library including a
set of components relating to a compressed air system, wherein the
second portion includes a modeling interface to configure a virtual
model using the set of components; and one or more processors
configured with non-transitory computer executable instructions to
receive a component add request to add at least one of the set of
components to the second portion of the GUI, to add the at least
one of the set of components to the second portion in response to
the component add request, to determine whether the component add
request includes adding the at least one of the set of components
to the virtual model, to interconnect the at least one of the set
of components with the virtual model when the component add request
includes adding the at least one of the set of components to the
virtual model, to store real-time monitoring data of a currently
used compressed air system, to simulate the virtual model with the
real-time monitoring data to generate simulation data, to determine
one or more optimizations based on the simulation, to determine one
or more recommendations based on the optimizations, wherein the one
or more recommendations include at least one of a change of control
strategy, a redesign of a layout of the compressed air system, and
new equipment to be used in the compressed air system.
[0137] Feature of the aspect of the present application may
include: wherein the simulation data includes at least one of a
transient pressure, a dynamic pressure, a flow, a moisture content,
an energy consumption, and a financial reference; wherein the add
request includes a barcode of component of the compressed air
system scanned by a mobile barcode scanner; wherein the computing
device is one of a laptop computer, a desktop computer, and tablet
computer; predicting component failures in the compressed air
system based on the simulation data; wherein the change of control
strategy includes reprogramming a compressed air system controller;
wherein the recommendation further includes a sales quote based on
the simulation data.
[0138] While the invention has been illustrated and described in
detail in the drawings and foregoing description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only certain exemplary embodiments have been
shown and described and that all changes and modifications that
come within the spirit of the inventions are desired to be
protected.
[0139] It should be understood that while the use of words such as
preferable, preferably, preferred or more preferred utilized in the
description above indicate that the feature so described may be
more desirable, it nonetheless may not be necessary and embodiments
lacking the same may be contemplated as within the scope of the
invention, the scope being defined by the claims that follow. In
reading the claims, it is intended that when words such as "a,"
"an," "at least one," or "at least one portion" are used there is
no intention to limit the claim to only one item unless
specifically stated to the contrary in the claim. When the language
"at least a portion" and/or "a portion" is used the item can
include a portion and/or the entire item unless specifically stated
to the contrary.
* * * * *