DE102004040137A1 - Energy-saving high-performance compressor - Google Patents

Abstract

Swash plate type compressor for compressing liquid and / or gaseous media in which reciprocating pistons controlled by the swash plate act.

Description

compressors or compressors are used in almost all areas of engineering.

It Here are a variety of systems and designs such as turbo compressors, Screw compressors, reciprocating compressors or high pressure compressors.

compressed are mainly liquid and gaseous Supplies.

Nearly all branches of the manufacturing or processing industries put for example compressed air for a variety of applications.

compressed air is an energy form that has a very broad spectrum of potential Offers applications while maintaining speed, power, precision and safe handling connects. The combination of these Properties make compressed air irreplaceable in many applications.

in the upper power range are at continuously high oil-free Compressed air requirement oil-free Compressing screw compressors with frequency control for peak load and turbo compressors for The base load is often summarized as a total solution for large-scale plants.

Especially interesting are the use cases for the Compressed air technology, where they compete with other forms of energy such as the electric Electricity or hydraulics is. Compressed air applications have become in recent years in terms of efficiency in dealing with the primary energy enormously developed.

Of the Use of compressed air has a variety of applications on.

From Active air is for example the speech, if compressed air as a transport medium is used. Current application examples are the bulk material transport, the There and Herschießen of boats in weaving machines, use in air storage or the youngest rediscovered pneumatic tube.

At the Example of air storage can be very nice some advantages of compressed air show. Laser cannons for sighting geosatellites, for example have to accurately aligned and tracked automatically. To get the necessary precision from To reach 1/3600 degrees, the optical system is air-bearing. The air bearings let completely jerk-free and stepless telescopic movements, ensure high measuring accuracy and protect against vibrations. Without compressed air would be such modern methods hardly feasible for earth surveying.

is the compressed air is directly integrated as process medium in certain processes, one speaks of process air. common Areas of application are drying processes, the ventilation of Clarifier or Gärluft for fermentation processes.

different Applications require different Pressures. In the most rare events It is economically justifiable to compress to the highest pressure required and subsequently to reduce the pressure again Therefore, it is necessary to categorize the pressure ranges and to use appropriate generation systems.

Of the Range of vacuum and blower applications ranges from the big vacuum into the overpressure area of about 1 bar. In the area of industrial vacuum, though the possibility to produce this by means of compressed air, the use of special However, vacuum pumps are usually more economical here.

in the Range of 2 to 2.5 bar one speaks of low pressure applications. Mostly rotary positive displacement compressors are used for the production, for extreme size Quantities, turbo compressors.

For standard printing applications, the over one 7 bar - network a wide range of compressors is available. The Determine requirements for air volume and air quality Here, which compressors in which combination is the most economical work.

If it comes to the two- and three-digit bar - range, come oscillating displacement compressors like piston - or Diaphragm compressors are used. With large air quantities can themselves also radial turbochargers expected. Every compressed air consumer needs a certain operating pressure to deliver the best performance. For tools used to Example to be driven only with 5 bar instead of the required 6 bar goes the load speed already back by 25%, although the idle speed only decreases by 5%. Therefore, it is essential to check regularly whether the needed Operating pressure is also available, at full capacity. Pressure losses due to insufficient Line cross sections or bottlenecks can only be noticed when the Compressed air also flows. Excessive operating pressures bring no performance gain. They increase only the compressed air consumption and the wear on the devices.

Besides these aspects in the use of Compressed air, the existing energy savings and cost reduction potentials are still not well known to many companies.

Alone in Germany, the approximately 60,000 installed systems consume every year electricity with a total value of approx. 840 million euros. These 14 billion kWh of electricity is about the same as the annual one Electricity consumption of Deutsche Bahn. Would the compressed air more efficient generated and used, let save on average about 30% of these energy costs.

For example, a German sports car manufacturer has already implemented these findings for themselves. By modernizing its compressed air system and consistently implementing optimization measures in the generation, processing, distribution and application of compressed air, it saves 483,000 kWh of electricity a year and thus avoids the emission of around 280 tonnes of CO ₂ .

In addition exists the aim of the existing facilities according to the technical Development, for example, in terms of efficiency and reliability to improve.

One an integral part of the existing compressors are here the valves used. These should i.a. one possible low flow resistance and one possible high pressure stability exhibit

One specific design principle for Such a valve is already under the number 283656 from the Imperial Patent Office of 21 December 1912 known. This valve is especially for high speed Compressors used and consists of balls that act as valve body and is characterized in that the balls are exposed above their guide and under the influence of a common resilient plate standing as Spring plate for a common charge spring is used (single claim).

From the variety of recent proposals in this field is here on a from the DE 201 02 448 U1 known valve directed,

It this is a compressor valve with one with a Variety of valve openings provided valve seat and with the valve openings closing closing bodies.

When new and inventive is here called that the closing body through wires a net or grid is biased against the valve openings and be held in position with the wires, the net or the grid rest on the closing bodies, but have no firm connection to these.

In Another embodiment is essentially provided here that the valve openings Chamfered holes and the closing body balls are, as well as that over the wires the grid or grid an additional Safety net is arranged.

This Design principle is as in the patent of the Imperial Patent Office It has long been known and contains in the revealed no features that are safe and efficient Ensure operation.

So is for example through the extra Safety net no permanent storage of the closing body guaranteed. The arrangement of the valve openings does not correspond to the fluidic Conditions. In addition, the component disclosed here merely the immediate locking mechanism a valve. The surrounding mechanical support, without the this component is not functional is not shown.

Similarly have been known for a long time swash plate compressor. They count the most pulsating and quietest compressors. They are mainly used as air conditioning compressors used and compact the gaseous medium so that it (at not too much water) becomes liquid again. In this form, it flows through one Capacitor and gives off its heat there. This is sucked refrigerant from the evaporator where there is the heat the inflowing into the work space Has taken in air.

One such air conditioning compressor works mostly on the principle of the axial piston pump.

Uniform on the circumference distributed here are several cylinders arranged, the piston be moved by a rotating swash plate. In the cylinder head Each cylinder usually flutter valves are arranged, depending on the piston movement the way to the suction. or release print page. Piston delivery pumps work well to build up high pressures but have the disadvantage of uneven volume flow.

Of the Device according to the invention Therefore, the object of the invention is to provide a compressor, the known concept of said valve construction in conjunction with a swash plate compressor to a powerful new compressor type represents.

This task is performed by the devices solved according to claims 1 and 2, respectively.

Of the inventive compressor not only characterized by the fact that he has a novel valve assembly having the type described in the prior art, but also in that such a valve assembly to a special way with a specially designed swash plate compressor combined.

For this It should be noted that the mentioned valve arrangement Naturally not only in the compressor according to the invention can be used, but that this valve arrangement particularly characterized in that they can be used very versatile in all devices is where a corresponding valve function is required.

at the valve according to the invention is not just a special form of arrangement of each in a surface arranged valve openings in Composite with the associated Closing bodies chosen, it is also due to a special way of arranging the valve openings achieved that fluidically seen a low flow resistance established.

moreover is due to the special arrangement of several as a valve acting with valve openings provided surfaces achieved that a, the working fluid conveyed, reciprocating piston can act in both directions.

In Connection with a suitable gearbox makes it possible in a tandem arrangement two inventive compressors to be driven by a common drive shaft.

in the The following is the compressor of the invention describe in more detail. They show in detail:

1 : the valve arrangement according to the invention in an operating position

1a : the valve arrangement according to the invention in another operating position

2 : The valve arrangement according to the invention in a detailed section

3 : the detail C off 2

4 a perspective view of the perforated plate ( 12 )

5 : A perspective view of the valve arrangement according to the invention

6 : a perspective view of the collet ( 13 )

7 : A sectional view of the compressor according to the invention

8th : a perspective view of this compressor

9 : A partial perspective view of the grouping of the valves of the compressor according to the invention

10 : a perspective side view of the grouping of the valves

11 : A sectional drawing of a tandem arrangement of the compressor according to the invention

In the 1 the valve assembly according to the invention is shown in an operating position in which the piston ( 4 ), connected to the piston rod ( 6 ) on the cylinder cover ( 2 ) is present. In this case, the entire valve arrangement consists of a cylindrical component which consists of a cylindrical ring ( 1 ), from a so-called cylinder bottom ( 3 ) and a cylinder cover ( 2 ) consists. The terms cylinder bottom ( 3 ), Cylinder cover ( 2 ), or cylinder ring ( 1 ) serve only the distinction of the two top surfaces of the cylindrical member, as well as the area-wise curved cylinder jacket.

The cylinder bottom ( 3 ), the cylinder cover ( 2 ), as well as the cylinder ring ( 1 ) are substantially constructed so that they consist of arranged in a surface valve openings in conjunction with the associated closing bodies. In the case of the cylinder bottom ( 3 ) and the cylinder cover ( 2 ), the surfaces are flat, in the case of the cylinder ring, the surface in question corresponding to the cylinder jacket, or the cylinder ring, curved.

In the case of the cylinder cover ( 2 ) is in the, the valve openings receiving surface in the middle of a surface for receiving the mounting of the piston rod ( 6 ) left out. This storage has a commercial seal. Preferably, for this purpose, a seal is used, which combines a storage and a seal in a design.

The cylinder ring ( 1 ) has an annular area in the middle, which does not contain valve openings. The width of this area corresponds to the height of the piston ( 4 ) coming from the piston rod ( 6 ) is moved back and forth in the valve arrangement according to the invention.

The sealing of the piston ( 4 ) across from the inner wall of the cylindrical valve arrangement takes place via a graphite ring inserted in a corresponding groove.

In the 1a is the valve arrangement according to the invention in another operating position of the piston ( 4 ).

Both operating positions show the extreme positions of the piston ( 4 ). The running in the middle, free of valve openings, strips in the cylinder ring is in both 1 and 1a to recognize.

The operation of the valve arrangement according to the invention is such that, starting from each of the two described positions or working positions of the piston (FIG. 4 ), the operating medium, in the simplest case air, compressed and ejected in the region of the cylinder ring. Each of the direction of movement of the piston opposite cylindrical surface is in this case sealed by the respective closing body.

In this way it is achieved that with each stroke movement of the piston ( 4 ) the energy used to compress the working medium is used.

So in the case of 1 by the movement of the piston ( 4 ) the cylinder bottom ( 3 ) and the valves in the cylinder cover ( 2 ) will be opened. In the case of 1a be by the following movement of the piston ( 4 ) in the opposite direction, the valves of the cylinder cover ( 2 ) and the valves of the cylinder bottom ( 3 ) open and allow the intake air access.

The arrangement of the valves in the corresponding parts of the cylinder ring ensures that the respective areas of the cylinder ring support the desired compression process or suction process. So in the case of 1 by the arrangement of the valves in the cylinder ring ( 1 ) located in the area of the cylinder cover ( 2 ) to the middle of the cylinder ring ( 1 ), ensures that the area of the cylinder cover ( 2 ) sucked air from the described region of the cylinder ring ( 1 ) can flow out.

In the case of 1a It is also ensured that the valves in the cylinder ring located in the area of the cylinder bottom ( 3 ) to the middle of the cylinder ring ( 1 ) ensures that the air drawn in from the area of the cylinder bottom is also from the other area of the cylinder ring ( 1 ) can flow out.

The detailed sectional drawing of the 2 shows the inventive holder of the closing body, or the valve balls used here ( 9 ).

A holder of the closing body solely by wires, a net or a grid, as in the case of DE 201 02 448 U1 described, does not guarantee permanent operation. The mesh used here, through which the balls are pressed against the valve openings. so that they can only be released from the valve openings at a corresponding pressure of the operating medium, for example the air, on the valve, in practice is in need of improvement. It has been found that the bearing clearance of the spherical shooting body is too low.

According to the invention, therefore, the valve ball seat ( 10 ) and the openings of the valve ball seats ( 10 ) each a steel net ( 8th ) to bias the falling out of the valve balls ( 9 ) prevented.

In the case of the cylinder cover ( 2 ) and the cylinder bottom ( 3 ) is the steel net ( 8th ) a perforated plate ( 12 ) upstream. The relevant item C is in ( 3 ) shown separately.

In the ( 3 ) is the position and design of the valve ball seat ( 10 ) in detail. As an essential feature for achieving the desired function, it should be pointed out here that the angle below that of the lower, ball-receiving, part of a valve ball seat ( 10 ) is chamfered at an angle of 118 degrees. This is known to correspond to the angle to be optimally ground under the drill. This drill angle results in an optimum between good chip removal and tool life.

It has been found that a valve ball seat designed in this way ( 10 ) after a short period of operation ensures that a valve ball ( 9 ) their respective valve ball seat ( 10 ) optimally adapts itself and creates its own seal virtually by the seen from the material harder ball is in the valve ball seat ( 10 ) incorporated. This ensures a high degree of safety of the seal.

In 4 is a perforated plate ( 12 ), as in the area of the cylinder cover ( 2 ) and the cylinder bottom ( 3 ) is used, shown in perspective. As a special feature can be seen here that the diameter of the holes of the holes increase from the middle to the edge. This measure takes into account the fact that at the edge of the valve arrangement according to the invention larger air velocities occur and pass greater amounts of air than in the middle.

In 5 is the valve assembly according to the invention from the outside in perspective view posed.

In the area of the cylinder jacket, the corresponding steel net ( 11 ) in conjunction with the outer fabric via a collet ( 7 ) on the cylinder ring ( 1 ) spanned.

In 6 is the collet chuck ( 7 ) is shown in perspective view.

The Valve arrangement according to the invention Can be used in any plant that has the appropriate geometric Dimensions and a drive for the Piston rod has.

It is also possible to use the piston ( 4 ) do not set via a piston rod in oscillating motion, but via an outside of the valve assembly according to the invention oscillating umpolbares magnetic field.

The Choice of manufacturing materials needs to be adjusted for this case.

In the 7 is shown a detailed section through a erfindungemäßen compressor.

Above and below the drive shaft ( 13 ) is in each case a valve according to the invention can be seen in section. On the from the 1 to 6 used reference numerals have been omitted here for the sake of clarity. The drive shaft ( 13 ) runs in an inclined stub shaft ( 14 ) out. This stub shaft ( 14 ) ensures by its, in relation to the drive shaft ( 13 ), oblique position for the drive disc ( 15 ) in conjunction with the driving ring ( 16 ) and the cover ( 17 ) during the rotation of the drive shaft ( 13 ) performs a tumbling motion.

A on the stub shaft ( 14 ) mounted cylindrical roller bearing transmits in this case upon rotation of the drive shaft ( 13 ) the inclination of the stub shaft ( 14 ) on these adjacent components. The securing of these components is achieved by a secured nut or equivalent machine elements.

This tumbling movement is in each case by the, in the driving ring ( 16 ) recessed, piston bearing shell ( 18 ), the piston bearing ring ( 19 ) and the piston bearing back ( 20 ) on the respective piston rod ( 6 ) transfer.

These Components that interact with the effect of a tumbling disc have, force the float around the circumference of the compressor distributed pistons.

The corresponding valves are thus also by the movement of the swash plate upon rotation of the drive shaft ( 13 ).

The actuated pistons ( 4 ) suck with each movement the appropriate working fluid either on the cylinder cover ( 2 ) or the cylinder bottom ( 3 ) and push it over the cylinder ring ( 1 ) out.

Of the Air outlet is separated in the figure using the example of the lower valve designated.

In the 8th is the one in the 7 shown in section arrangement shown in a perspective overall view.

When in the 9 In the perspective view shown, the arrangement of the various disks and rings forming the swash plate is omitted. It is only the piston bearing shells ( 18 ) of the 8 circumferentially distributed valves and associated pistons ( 4 ), or piston rods ( 6 ).

In the 10 the perspective view of the compressor according to the invention is shown in side view. In addition, the piston bearing shells ( 18 ) omitted. To recognize are now in the piston bearing shells ( 18 ) via the piston bearing rings ( 19 ) and the piston bearing backs ( 20 ) guided piston rods ( 6 ).

In the 11 a section through a tandem arrangement of a compressor according to the invention is shown.

in this connection be two compressors, as described above, from a driven common drive shaft. The drive shaft itself learns their Drive over an angular gear. With this arrangement, a special results compact design.

 1

cylinder ring

2

cylinder cover

 3

cylinder base

 4

piston

 5

graphite ring

 6

piston rod

 7

hole ring (Collet)

 8th

Stahlnetz

 9

valve ball

 10

Valve ball seat

 11

Stahlnetz

 12

perforated sheet

 13

drive shaft

14

stub shaft

15

sheave

 16

driver ring

 17

cover plate

 18

Piston bush

 19

Piston bearing ring

 20

Piston bearing backing

Claims (15)

Swashplate compressor for compressing liquid and / or gaseous media, comprising the following features: a) a drive shaft extending from the longitudinal axis of a cylindrical housing ( 13 ) driven, swash plate actuates the reciprocating pistons ( 4 ) of a plurality of distributed on the circumference of the housing cylindrical valve assemblies, b) the reciprocating piston ( 4 ) oscillate in the respective valve arrangements, c) the cylinder bottom ( 3 ), the cylinder cover ( 2 ) and the cylinder ring ( 1 ) of the valve assemblies comprise a multiplicity of valve seats ( 10 ), each via closing body ( 9 ) are closable, d) the influx of media takes place alternately via the cylinder bottom ( 3 ) or the cylinder cover ( 2 ), whereby the compressed media via the cylinder ring ( 1 ) are ejected. Swash plate type compressor for compressing liquid and / or gaseous media, comprising the following features: a) two drive shafts extending in the longitudinal axis of a cylindrical housing ( 13 ) driven, swash plates actuate the reciprocating piston ( 4 ) of a plurality of circumferentially distributed on the circumference of the housing cylindrical valve assemblies, wherein the swash plates on the two ends of the drive shaft ( 13 ) are mounted and the drive of the drive shaft ( 13 ) even one in the middle of the drive shaft ( 13 ) force-introducing angular gear, b) the reciprocating piston ( 4 ) oscillate in the respective valve arrangements, c) the cylinder bottom ( 3 ), the cylinder cover ( 2 ) and the cylinder ring ( 1 ) of the valve assemblies comprise a multiplicity of valve seats ( 10 ), each via closing body ( 9 ) are closable, d) the influx of media takes place alternately via the cylinder bottom ( 3 ) or the cylinder cover ( 2 ), whereby the compressed media via the cylinder ring ( 1 ) are ejected. Swash plate compressor according to one of claims 1 or 2, characterized in that the cylindrical valve arrangements a circular Have cross-section. Swash plate compressor according to one of claims 1 or 2, characterized in that the cylindrical valve arrangements a Cross section of the form of a vesica piscis (fish bladder) Has. Swash plate compressor according to one of claims 1 or 2, characterized in that the cylindrical valve arrangements a Have cross section of any shape Swash plate compressor according to one of claims 1 to 5, characterized in that the cylindrical valve arrangements a Cross-section which is different from each other. Swash plate compressor according to one of claims 1 to 6, characterized in that the whole compressor or parts thereof made of aluminum and / or magnesium and / or carbon are. Swash plate compressor according to one of claims 1 to 7, characterized in that the valve seats ( 10 ) and the closing bodies ( 9 ) are designed so that the closing body ( 9 ) in the valve seats ( 10 ) have a free movement space. Swash plate compressor according to one of claims 1 to 8, characterized in that the closing body ( 9 ) in the valve seats ( 10 ) over an overstretched steel net ( 8th ), respectively. ( 12 ) are secured. Swash plate compressor according to one of claims 1 to 9, characterized in that the closing body ( 9 ) in the valve seats ( 10 ) additionally via a perforated plate ( 12 ) are secured. Swash plate compressor according to one of claims 1 to 10, characterized in that the perforated plate ( 12 ) Has bores whose diameter from the center of the perforated plate ( 12 ) increases to the outside. Swash plate compressor according to one of claims 1 to 11, characterized in that the valve seats ( 10 ) as valve ball seats ( 10 ) and the closing bodies ( 9 ) as valve balls ( 9 ) are formed. Swash plate compressor according to one of claims 1 to 12, characterized in that each valve ball seat ( 10 ) at the bottom has a drill angle of 118 degrees. Swash plate compressor according to one of claims 1 to 13, characterized in that the over the cylinder ring ( 1 ) tensioned steel net ( 11 ) via a collet ( 7 ) is fixed. Swash plate compressor according to one of claims 1 to 14, characterized in that the reciprocating piston ( 4 ) is moved magnetically.