Prevention of air compressor overload can be started from the following aspects:

First, equipment selection and installation

Reasonable selection

According to the actual demand for air to accurately select the model and specifications of the air compressor. If the selection is too large, in the low load operation is prone to overload phenomenon; selection is too small can not meet the production demand, long-term high load operation is also easy to overload. For example, it is necessary to accurately calculate the air consumption, pressure and other parameters, and select the air compressor that matches them.

Correct installation

Ensure that the air compressor is installed on a stable foundation to avoid excessive vibration affecting the normal operation of the equipment. When installing, make sure that all components are firmly connected, such as intake piping, exhaust piping, cooling water piping, etc. are tightly connected and not distorted, to prevent piping problems from causing resistance to increase, which in turn leads to overloading.

Second, operation and management

Monitoring of operating parameters

Real-time monitoring of key operating parameters of the air compressor, such as exhaust pressure, exhaust temperature, current, etc.. When the exhaust pressure is close to the rated value, we should adjust the load or check whether there is a pipe blockage and other problems; high exhaust temperature may mean cooling system failure or load is too large, need to be investigated in time; current is also an important signal of overload, pay close attention.

Avoid frequent starting and stopping

Frequent startup of the compressor will make the motor instantly withstand a large current impact, easy to cause overload. Reasonable arrangement of production plan, minimise unnecessary start-stop operation. If you need to stop for a period of time and then start again, you can extend the interval appropriately.

Regular maintenance

Maintain the air compressor according to the specified period. Clean the air filter to ensure smooth air intake and prevent overloading due to insufficient air intake causing the air compressor to work hard; change the lubricating oil regularly to ensure good lubrication and reduce mechanical friction resistance; check and tighten the connecting bolts of each component to avoid vibration and extra load caused by loosening.

Third, the control system

Setting protection device

In the air compressor control system set overload protection devices, such as thermal relays, overcurrent protector. When there is an overload situation, these protection devices can cut off the power supply in time to protect the motor and other key components from damage.

Intelligent control system application

An intelligent control system is used to manage the air compressor. The system can automatically adjust the operating frequency and load of the air compressor according to the demand for gas, avoiding a long time in the high load operating state. For example, soft start and energy-saving operation of the air compressor can be realised through frequency conversion technology to effectively prevent overloading.

IV. Operator Training

Professional training

Professional training for air compressor operators, so that they are familiar with the performance of the air compressor, operating procedures and common fault handling methods. Operators can correctly judge the operating status of the equipment, take correct measures in time when problems occur, and avoid overloading due to misoperation.

Cultivation of Safety Awareness

Cultivate the safety awareness of the operators, let them realise the danger of overloading to the equipment and production, strictly abide by the operating procedures in daily operation, and do not use the air compressor overloaded.