US20130280095A1 - Method and system for reciprocating compressor starting - Google Patents

Method and system for reciprocating compressor starting Download PDF

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Publication number
US20130280095A1
US20130280095A1 US13/857,334 US201313857334A US2013280095A1 US 20130280095 A1 US20130280095 A1 US 20130280095A1 US 201313857334 A US201313857334 A US 201313857334A US 2013280095 A1 US2013280095 A1 US 2013280095A1
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United States
Prior art keywords
compressor
motor
torque
reciprocating
piston
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Abandoned
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US13/857,334
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English (en)
Inventor
Bret Dwayne Worden
Richard C. Peoples
Jayaprakash Shreeshailappa SABARAD
Jason M. STRODE
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General Electric Co
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General Electric Co
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Publication date
Application filed by General Electric Co filed Critical General Electric Co
Priority to US13/857,334 priority Critical patent/US20130280095A1/en
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PEOPLES, RICHARD C., SABARAD, JAYAPRAKASH SHREESHAILAPPA, STRODE, JASON M., WORDEN, BRET DWAYNE
Priority to DE112013006838.9T priority patent/DE112013006838T5/de
Priority to PCT/US2013/036527 priority patent/WO2013158518A2/en
Publication of US20130280095A1 publication Critical patent/US20130280095A1/en
Abandoned legal-status Critical Current

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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06Control using electricity
    • F04B49/065Control using electricity and making use of computers
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B23/00Pumping installations or systems
    • F04B23/02Pumping installations or systems having reservoirs
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B25/00Multi-stage pumps
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B41/00Pumping installations or systems specially adapted for elastic fluids
    • F04B41/02Pumping installations or systems specially adapted for elastic fluids having reservoirs
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/02Stopping, starting, unloading or idling control
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/02Stopping, starting, unloading or idling control
    • F04B49/022Stopping, starting, unloading or idling control by means of pressure
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/10Other safety measures
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B51/00Testing machines, pumps, or pumping installations
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16KVALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K37/00Special means in or on valves or other cut-off apparatus for indicating or recording operation thereof, or for enabling an alarm to be given
    • F16K37/0075For recording or indicating the functioning of a valve in combination with test equipment
    • F16K37/0091For recording or indicating the functioning of a valve in combination with test equipment by measuring fluid parameters
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2201/00Pump parameters
    • F04B2201/06Valve parameters
    • F04B2201/0605Leakage over a valve
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2205/00Fluid parameters
    • F04B2205/06Pressure in a (hydraulic) circuit
    • F04B2205/063Pressure in a (hydraulic) circuit in a reservoir linked to the pump outlet
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F15FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
    • F15BSYSTEMS ACTING BY MEANS OF FLUIDS IN GENERAL; FLUID-PRESSURE ACTUATORS, e.g. SERVOMOTORS; DETAILS OF FLUID-PRESSURE SYSTEMS, NOT OTHERWISE PROVIDED FOR
    • F15B19/00Testing; Calibrating; Fault detection or monitoring; Simulation or modelling of fluid-pressure systems or apparatus not otherwise provided for
    • F15B19/005Fault detection or monitoring
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01MTESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M3/00Investigating fluid-tightness of structures
    • G01M3/02Investigating fluid-tightness of structures by using fluid or vacuum
    • G01M3/26Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors
    • G01M3/28Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for pipes, cables or tubes; for pipe joints or seals; for valves ; for welds
    • G01M3/2876Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors for pipes, cables or tubes; for pipe joints or seals; for valves ; for welds for valves

Definitions

  • Embodiments of the subject matter disclosed herein relate to facilitating starting a reciprocating compressor having a loaded start condition.
  • Compressors compress gas, such as air.
  • An air compressor can include three cylinders with two stages and can be air cooled and driven by an electric motor.
  • the compressor can have two low pressure cylinders which deliver an intermediate pressure air supply to a single high pressure cylinder for further compression for final delivery to an air reservoir. Compressors may sometimes have difficulty in starting.
  • a method includes detecting a compressor start failure (e.g., stall) condition for a reciprocating compressor based on a force from compressed air being compressed into a reservoir of the reciprocating compressor.
  • Power may be removed from or reduced to a motor of the reciprocating compressor.
  • a phase sequence of the motor e.g., a three (3) phase AC motor
  • a reverse stall or a start of the reciprocating compressor may be detected while in a reverse direction as the piston moves toward a Top-Dead-Center (TDC) position.
  • TDC Top-Dead-Center
  • a compressor can be started by employing a high starting torque due to, for instance, wear or a failure.
  • a vehicle in an embodiment, includes an engine, a compressor operatively connected to the engine, wherein the compressor includes a reservoir configured to store compressed air, a detector component that is configured to detect a stall condition of the compressor, and a controller.
  • the controller can be configured to control at least one of removal power from the motor of the compressor, reversal a phase sequence of the motor to force a recompression of a piston of the compressor, and detection of at least one of a reverse stall or a start of the compressor while in a reverse direction as the piston moves to a Top-Dead-Center (TDC) position.
  • TDC Top-Dead-Center
  • a system in an embodiment, includes means for detecting a stall-when-starting condition for a reciprocating bidirectional based on a speed signal, a measured current signal, or a measured pressure signal.
  • the system further includes means for removing power from a motor of the reciprocating bidirectional compressor and means for reversing a phase sequence to the motor to force a recompression of a piston of the reciprocating bidirectional compressor.
  • the system includes means for detecting at least one of a reverse stall or a start of the reciprocating bidirectional compressor while in a reverse direction as the piston moves toward a Top-Dead-Center (TDC) position.
  • TDC Top-Dead-Center
  • FIG. 1 is an illustration of an embodiment of a vehicle system with a compressor
  • FIG. 2 is an illustration of an embodiment of system that includes a compressor
  • FIG. 3 is an illustration of an embodiment of a system that controls a motor based upon a detection component for a compressor
  • FIG. 4 is an illustration of an embodiment of a system that includes a compressor
  • FIG. 5 is an illustration of an embodiment of a system that includes a compressor
  • FIG. 6 is an illustration of an embodiment of a system that includes a compressor
  • FIG. 7 is an illustration of an embodiment of a valve that has a leak to cause a loading sat for a compressor
  • FIG. 8 is an illustration of an embodiment of a system for a system that includes a compressor
  • FIG. 9 is an illustration of a reverse direction mode in response to a stall when starting condition of a compressor
  • FIG. 10 illustrates a flow chart of an embodiment of a method for detecting a stall
  • FIG. 11 illustrates a flow chart of an embodiment of a method for increasing torque for a compressor motor in response to a detected stall condition
  • FIG. 12 illustrates a flow chart of an embodiment of a method for increasing torque for a compressor motor and reversing a phase sequence of the motor in response to a detected stall-when starting
  • Embodiments of the subject matter disclosed herein relate to systems and methods that overcome a higher than normal starting torque for in a reciprocating, electric motor driven air compressor for a vehicle.
  • a detection component can be configured to detect a stall condition for a reciprocating compressor based on a force from compressed air being compressed into a reservoir of the reciprocating compressor.
  • a controller can be configured to control at least one of a reverse direction mode (also referred to as reverse phase mode) or a torque increase mode in order to alleviate the stall condition.
  • the controller component can be configured to change a direction of a crankshaft rotation in order to allow a gain in momentum during a subsequent start attempt to overcome a high starting torque requirement.
  • the controller can be configured to increase at least one of a number of poles for the motor, a line voltage, or a volt/hertz (e.g., motor flux).
  • the controller component can utilize the reverse direction mode alone, or in combination with the torque increase mode.
  • the controller component can utilize the torque increase mode alone, or in combination with the reverse direction mode.
  • the term “component” as used herein can be defined as a portion of hardware, a portion of software, or a combination thereof.
  • a portion of hardware can include at least a processor and a portion of memory, wherein the memory includes an instruction to execute.
  • vehicle as used herein can be defined as an asset that is a mobile machine or a moveable transportation asset that transports at least one of a person, people, or a cargo.
  • a vehicle can be, but is not limited to being, a rail car, an intermodal container, a locomotive, a marine vessel, mining equipment, a stationary power generation equipment, industrial equipment, construction equipment, and the like.
  • the term “loaded” as used herein can be defined as a compressor system mode where air is being compressed into the reservoir.
  • loaded start as used herein can be defined as a compressor system mode in a loaded condition during a starting phase of the compressor.
  • a compressor compresses gas, such as air.
  • the compressed gas is supplied to operate pneumatic or other equipment powered by compressed gas.
  • a compressor may be used for mobile applications, such as vehicles.
  • vehicles utilizing compressors include locomotives, on-highway vehicles, off-highway vehicles, mining equipment, and marine vessels.
  • a compressor may be used for stationary applications, such as in manufacturing or industrial applications requiring compressed air for pneumatic equipment among other uses.
  • the compressor depicted in the below figures is one which utilizes spring return inlet and discharge valves for each cylinder, wherein the movement of these valves is caused by the differential pressure across each cylinder as opposed to a mechanical coupling to the compressor crank shaft.
  • the subject invention can be applicable to machines with either type of valve (e.g., spring return valves, mechanical coupled valves, among others) and the spring return valve is depicted solely for example and not to be limiting on the subject innovation.
  • FIG. 1 illustrates a block diagram of an embodiment of a vehicle system 100 (e.g., a locomotive system, a system, among others).
  • vehicle system 100 is depicted as a rail vehicle 106 configured to run on a rail 102 via a plurality of wheels 108 .
  • the rail vehicle includes a compressor system with a compressor 110 .
  • the compressor is a reciprocating compressor that delivers air at high pressure.
  • the compressor is a reciprocating compressor with a bi-directional drive system that drives a piston in a forward direction and the reverse direction.
  • the compressor receives air from an ambient air intake 114 .
  • the compressor is a two-stage compressor (such as illustrated in FIG. 2 ) in which ambient air is compressed in a first stage to a first pressure level and delivered to a second stage, which further compresses the air to a second pressure level that is higher than the first pressure level.
  • the compressed air at the second pressure level is stored in a reservoir.
  • the compressed air may then be provided to one or more pneumatic devices as needed.
  • the compressor 110 may be a single stage or multi-stage compressor.
  • the compressor includes a crankcase 160 .
  • the crankcase is an enclosure for a crankshaft (not shown in FIG. 1 ) connected to cylinders (not shown in FIG. 1 ) of the compressor.
  • a motor 104 is employed to rotate the crankshaft to drive the pistons within the cylinders.
  • the motor 104 may be an electric or non-electric motor.
  • the crankshaft may be coupled to a drive shaft of an engine or other power source configured to rotate the crankshaft of the compressor.
  • the crankshaft may be lubricated with compressor oil that is pumped by an oil pump (not shown) and sprayed onto the crankshaft.
  • the crankshaft is mechanically coupled to a plurality of pistons via respective connecting rods. The pistons are drawn and pushed within their respective cylinders as the crankshaft is rotated to compress a gas in one or more stages.
  • the rail vehicle further includes a controller 130 for controlling various components related to the vehicle system.
  • the controller is a computerized control system with a processor 132 and a memory 134 .
  • the memory may be computer readable storage media, and may include volatile and/or non-volatile memory storage.
  • the controller includes multiple control units and the control system may be distributed among each of the control units.
  • a plurality of controllers may cooperate as a single controller interfacing with multiple compressors distributed across a plurality of vehicles.
  • the controller may include instructions for enabling on-board monitoring and control of vehicle operation.
  • Stationary applications may also include a controller for managing the operation of one or more compressors and related equipment or machinery.
  • the controller receives signals from one or more sensors 150 to monitor operating parameters and operating conditions, and correspondingly adjust actuators 152 to control operation of the rail vehicle and the compressor.
  • the controller receives signals from one or more sensors corresponding to compressor speed, compressor load, boost pressure, exhaust pressure, ambient pressure, exhaust temperature, or other parameters relating to the operation of the compressor or surrounding system.
  • the controller receives a signal from a crankcase pressure sensor 170 that corresponds to the pressure within the crankcase.
  • the controller receives a signal from a crankshaft position sensor 172 that indicates a position of the crankshaft.
  • the position of the crankshaft may be identified by the angular displacement of the crankshaft relative to a known location such that the controller is able to determine the position of each piston within its respective cylinder based upon the position of the crankshaft.
  • the controller controls the vehicle system by sending commands to various components. On a locomotive, for example, such components may include traction motors, alternators, cylinder valves, and throttle controls among others.
  • the controller may be connected to the sensors and actuators through wires that may be bundled together into one or more wiring harnesses to reduce space in vehicle system devoted to wiring and to protect the signal wires from abrasion and vibration.
  • the controller communicates over a wired or wireless network that may allow for the addition of components without dedicated wiring.
  • the controller may include onboard electronic diagnostics for recording operational characteristics of the compressor.
  • Operational characteristics may include measurements from sensors associated with the compressor or other components of the system. These measurements may include motor currents, compressor rotational speed, air pressure and/or temperature at various locations. Such operational characteristics may be stored in a database in memory. In one embodiment, current operational characteristics may be compared to past operational characteristics to determine trends of compressor performance.
  • the controller may include onboard electronic diagnostics for identifying and recording potential degradation and failures of components of vehicle system. For example, when a potentially degraded component is identified, a diagnostic code may be stored in memory. In one embodiment, a unique diagnostic code may correspond to each type of degradation that may be identified by the controller. For example, a first diagnostic code may indicate a malfunctioning exhaust valve of a cylinder, a second diagnostic code may indicate a malfunctioning intake valve of a cylinder, a third diagnostic code may indicate deterioration of a piston or cylinder resulting in a blow-by condition. Additional diagnostic codes may be defined to indicate other deteriorations or failure modes. In yet other embodiments, diagnostic codes may be generated dynamically to provide information about a detected problem that does not correspond to a predetermined diagnostic code. In some embodiments, the controller modifies the output of charged air from the compressor, such as by reducing the duty cycle of the compressor, based on parameters such as the condition or availability of other compressor systems (such as on adjacent locomotive engines), environmental conditions, and overall pneumatic supply demand.
  • the controller may be further linked to display 140 , such as a diagnostic interface display, providing a user interface to the operating crew and/or a maintenance crew.
  • the controller may control the compressor, in response to operator input via user input controls 142 , by sending a command to correspondingly adjust various compressor actuators.
  • user input controls may include a throttle control, a braking control, a keyboard, and a power switch.
  • operational characteristics of the compressor such as diagnostic codes corresponding to degraded components, may be reported via display to the operator and/or the maintenance crew.
  • the vehicle system may include a communications system 144 linked to the controller.
  • communications system may include a radio and an antenna for transmitting and receiving voice and data messages.
  • data communications may be between vehicle system and a control center of a railroad, another locomotive, a satellite, and/or a wayside device, such as a railroad switch.
  • the controller may estimate geographic coordinates of a vehicle system using signals from a GPS receiver.
  • the controller may transmit operational characteristics of the compressor to the control center via a message transmitted from communications system.
  • a message may be transmitted to the command center by communications system when a degraded component of the compressor is detected and the vehicle system may be scheduled for maintenance.
  • the system can include a detection component 128 that is configured to detect a stall condition for the compressor.
  • the detection component can ascertain whether a failure detected corresponds to a loaded start condition.
  • the controller can be configured to employ at least one of a reverse direction mode or a torque increase mode.
  • the controller can employ the reverse direction mode in order to reverse a direction of the compressor crankshaft temporarily, to be followed by another start attempt in the forward direction in order to overcome a high starting torque required to start the compressor.
  • the controller can employ the torque increase mode that increases at least one of a number of poles for the motor, a line voltage, or a volt/hertz (e.g., motor flux).
  • the controller utilizes the reverse direction mode alone, or in combination with the torque increase mode.
  • the controller utilize one of the reverse direction mode or the torque increase mode for a duration of time and then utilize the both the reverse direction mode or the torque increase mode in combination.
  • a suitable combination of the modes can be employed by the controller and either mode alone or in combination can be selected with sound engineering judgment.
  • the controller communicates to the motor to remove power therefrom.
  • the controller can communicate with the motor to reverse the phase sequence to the motor, wherein the reversed direction sequence forces a recompression.
  • the compressor can either stall again or run in the reverse direction. If the compressor runs in the reverse direction, the controller can be configured to run in a reverse direction (if the compressor can function in such reverse direction). If the compressor is not capable of reverse direction running, the compressor can change to the forward directions after a duration of time after a rotation is detected.
  • a stuck loaded Control Mag Valve (CMV) (not shown but discussed below) or unloader valves can return to a normal operation (e.g., not stuck, not loaded condition, and the like) when the reservoir pressure elevates or the compressor is able to run again (e.g., in a reverse direction for a duration of time, in a forward direction after the reverse direction, among others).
  • CMV Control Mag Valve
  • the controller can reverse the motor to the forward direction to accelerate the compressor.
  • the stall in the reverse direction can be detected as pistons move to a Top-Dead-Center (TDC) and the motor can be reversed to accelerate pistons past Bottom-Dead-Center (BDC) with a combination of motor torque and pneumatic force on the piston(s).
  • TDC Top-Dead-Center
  • BDC Bottom-Dead-Center
  • the motor torque and pneumatic forces build enough momentum to overcome the compressed air forces.
  • the recovery of the compressor after rotation at a running speed is based upon at the following: unloader valve differential pressure reduces or even changes direction to the unload direction during high speed piston down-strokes which allows opening of an unloader valve when the CMV provides compressed control air to drive the unload mode; or CMV valves transition to an unloaded state as control air pressure is elevated by the loaded compressor cycle.
  • the term “loaded” refers a compressor mode where air is being compressed into the reservoir.
  • the compressor depicted is one which utilizes spring return inlet and discharge valves for each cylinder in which the movement of these valves is caused by the differential pressure across them as opposed to a mechanical coupling to the compressor crank shaft.
  • the subject disclosure may be applicable to machines with either type of valve, but the spring return type will be illustrated here for the sake of brevity. For instance, an unloaded condition or unloaded compressor mode is illustrated in FIG. 4 .
  • the detection component can be a stand-alone component (as depicted), incorporated into the controller component, or a combination thereof.
  • the controller component can be a stand-alone component (as depicted), incorporated into the repair component, or a combination thereof.
  • FIG. 2 illustrates a detailed view of the compressor set forth in FIG. 1 above.
  • the compressor includes three cylinders 210 , 220 , 230 .
  • Each cylinder contains a piston 218 , 228 , 238 that is coupled to a crankshaft 250 via connecting rods 240 , 242 , 244 .
  • the crankshaft is driven by the motor to cyclically pull the respective pistons to a Bottom-Dead-Center (BDC) and push the pistons to a Top-Dead-Center (TDC) to output charged air, which is delivered to the reservoir via air lines 280 , 282 , 284 , 286 .
  • BDC Bottom-Dead-Center
  • TDC Top-Dead-Center
  • the compressor is divided into two stages: a low pressure stage and a high pressure stage to produce charged air in a stepwise approach.
  • the low pressure stage compresses air to a first pressure level which is further compressed by the high pressure stage to a second pressure level.
  • the low pressure stage includes cylinders 220 , 230 and the high pressure stage includes cylinder 210 .
  • air from the ambient air intake is first drawn into the low pressure cylinders via intake valves 222 , 232 , which open and close within intake ports 223 , 233 .
  • the ambient air is drawn in as the low pressure cylinders are pulled towards BDC and the intake valves 222 , 232 separate from intake ports 223 , 233 to allow air to enter each cylinder 220 , 230 .
  • the intake valves 222 , 232 close the intake ports 223 , 233 to contain air within each cylinder.
  • pistons 228 , 238 are pushed toward TDC, thereby compressing the ambient air initially drawn into the cylinders.
  • exhaust valves 224 , 234 within exhaust ports 225 , 235 are opened to release the low pressure air into low pressure lines 280 , 282 .
  • the air compressed to a first pressure level is routed to an intermediate stage reservoir 260 .
  • the intermediate stage reservoir 260 received air from one stage of a multistage compressor and provides the compressed air to a subsequent stage of a multistage compressor.
  • the intermediate stage reservoir 260 is a tank or other volume connected between successive stages by air lines.
  • the air lines, such as low pressure lines 280 , 282 provide sufficient volume to function as an intermediate stage reservoir without the need for a tank or other structure.
  • the compressor system also includes an intercooler 264 that removes the heat of compression through a substantially constant pressure cooling process.
  • One or more intercoolers may be provided along with one or more intercooler controllers 262 .
  • the intercooler 264 is integrated with the intermediate stage reservoir 260 .
  • a decrease in the temperature of the compressed air increases the air density allowing a greater mass to be drawn into the high pressure stage increasing the efficiency of the compressor.
  • the operation of the intercooler is controlled by the intercooler controller 262 to manage the cooling operation.
  • the intercooler controller 262 employs a thermostatic control through mechanical means such as via thermal expansion of metal.
  • an intercooler may be provided at each intermediate stage.
  • the air at a first pressure level (e.g., low pressure air) is exhausted from the intercooler into low pressure air line 284 and subsequently drawn into the high pressure cylinder 210 . More particularly, as piston 218 is pulled toward BDC, the intake valve 212 opens, thereby allowing the low pressure air to be drawn into the cylinder 210 via intake port 213 . Once the piston 218 reaches BDC, the intake valve 212 closes to seal the low pressure air within the cylinder 210 . The piston is then pushed upward thereby compressing the low pressure air into high pressure air. High pressure air is air at a second pressure level greater than the first pressure level, however the amount of compression will vary based upon the requirements of the application.
  • a first pressure level e.g., low pressure air
  • the exhaust valve 214 is opened to allow the high pressure air to exhaust into high pressure line 286 via exhaust port 215 .
  • An aftercooler 270 cools the high pressure air to facilitate a greater density to be delivered to the reservoir via high pressure air line 288 .
  • the above process is repeated cyclically as the crankshaft 250 rotates to provide high pressure air to the reservoir 180 , which is monitored by the reservoir pressure sensor 185 . Once the reservoir reaches a particular pressure level (e.g., 140 psi), the compressor operation is discontinued.
  • a particular pressure level e.g. 140 psi
  • the compressor includes one or more valves configured to vent compressed air from intermediate stages of the compressor system.
  • the unloader valves and/or relief valves may be operated after compressor operations are discontinued, or may be operated during compressor operations to relieve pressure in the compressor system.
  • an unloader valve 268 is provided in the intermediate stage reservoir 260 and configured to vent the low pressure compressed air from the intermediate stage reservoir, low pressure air lines 280 , 282 and intercooler 264 . Venting compressed air reduces stress on system components during periods when the compressor is not in use and may extend the life of the system.
  • the unloader valve 268 operates as a relief valve to limit the buildup of pressure in the intermediate stage reservoir 260 .
  • intake valves 222 , 232 operate as unloader valves for the cylinders 220 , 230 allowing compressed air in the cylinders to vent back to the ambient air intake 114 .
  • the system 200 can include relief valves such as breather valve 174 , a relieve valve on the intercooler 264 (shown in FIG. 4 ), a relieve valve for air line 286 , a rapid unloader valve on the intercooler 264 (shown in FIG. 4 )
  • a compressor such as the compressor illustrated in FIG. 2 , operates to charge the reservoir 180 with compressed air or other gas. Once the compressor charges the reservoir to a determined pressure value the compressor operation is discontinued. In some embodiments, when compressor operations are discontinued, one or more unloader valves are opened to vent intermediate stages of the compressor to the atmosphere. The intake valves of the cylinders as well as unloader valves of the intermediate stage reservoirs may all operate as unloader valves to vent the cylinders of the compressor to the atmosphere. Once the unloader valves are actuated and the cylinders and intermediate stages of the compressor have been vented to the atmosphere the pressure within the reservoir is expected to remain constant as previously discussed.
  • the controller can be configured to employ at least one of a torque increase mode or a phase reverse mode or a combination thereof.
  • This mode implementation by the controller can be based upon, but not limited to, the detection component identifying at least one of a failure mode, a stall condition, a loaded start condition, a combination thereof, among others.
  • FIG. 3 illustrates a system 300 that controls a motor based upon a detection component for a compressor, wherein the control relates to the increase torque mode.
  • the system 300 can include the detection component (e.g., detection can be embedded within the controller) that is configured to identify a stall condition for a reciprocating compressor based at least one of compressor speed, compressor motor current, compressor output, and/or reservoir pressure.
  • the controller can be configured to manage an increase in torque (e.g., torque increase mode) based upon such detection.
  • the increase in torque can be an increase in a pole mode for the motor, a line voltage increase, or a volt/hertz increase.
  • the motor can include a number of poles 310 such as pole 1 to pole N , where N is a positive integer.
  • N can be an even positive integer.
  • the motor can further include a pole mode that includes use of a set number of poles.
  • the motor can include a suitable number of pole modes in which each pole mode includes a specific amount of poles.
  • a pole mode can include a first number of poles and a second pole mode can include a second number of poles.
  • the first number of poles can be less than the second number of poles.
  • the motor can increase a number of poles such that the motor updates from the first pole mode to a second pole mode (e.g., where the second pole mode includes more poles than the first pole mode).
  • a motor can include a six (6) pole mode and a twelve (12) pole mode.
  • FIG. 4 illustrates a system 400 that depicts a compressor in an unloaded condition. The system illustrates additional features and/or components that can be included in FIGS. 1 , 2 , and 3 .
  • the system includes a Control Mag Valve (CMV) 402 , a Thermostatically Controlled Intercooler System (TCIS) bypass 404 , a rapid unloader valve 406 , an unloader valve 408 for cylinder 230 , an unloader valve 410 for cylinder 220 , a relief valve 420 , a relief valve 430 , and relief valve 440 (e.g., substantially similar to breather valve 174 in FIG. 2 ).
  • CMV Control Mag Valve
  • TCIS Thermostatically Controlled Intercooler System
  • Crankshaft can include a first end opposite a second end in which the first end is coupled to one or more connecting rods for each respective cylinder.
  • the crankshaft, cylinders, and pistons are illustrated in BDC position based upon the location of the first end.
  • BDC position is a location of the first end at approximately negative ninety degrees ( ⁇ 90 degrees) or 270 degrees.
  • a TDC position is a location of the first end at approximately ninety degrees (90 degrees) or ⁇ 270 degrees.
  • the controller implements one or more modes based upon the detection component identifying a stall condition. For instance, failure modes for the compressor can result in a fully or partially loaded start condition.
  • the detection component can utilize suitable sensor(s) within the system to identify a loaded start condition.
  • FIGS. 5-8 examples of failures for stall conditions are described in which such stall conditions can be detected by the detection component and, in turn, utilized by the controller to employ at least one of the torque increase mode or the reverse direction mode. The below is solely for exemplary purposes and not to be limiting on the subject innovation.
  • a CMV stuck loaded (e.g., CMV 402 in FIG. 4 ) failure can relate to a CMV being stuck in the “loaded” position which closes all un-loader valves.
  • the effect of the CMV stuck loaded failure is to strap air within each cylinder which will need to be compressed on the subsequent “start.” This amount of air mass and the pressure of the trapped air depend on the final position of the pistons and the reservoir pressure both when the compressor was stopped and after.
  • the trapped air in the high pressure cylinder results in increased starting torque and may stall. This is illustrated in FIG. 5 , wherein FIG. 5 illustrates a system 500 that depicts a compressor in a CMV stuck loaded failure.
  • a CMV stuck loaded failure and leakage on a high pressure cylinder discharge valve can be a failure.
  • the high pressure cylinder discharge valve can be exhaust valve 214 .
  • This failure can be related to the CMV stuck in the loaded position which closes all unloader valves except the main reservoir air leaks back into the high pressure cylinder via a faulty exhaust valve.
  • the effect of this failure e.g., leaking valve
  • the trapped air in the High Pressure Cylinder results in increased starting torque and may stall. This is illustrated in FIG. 6 , wherein FIG.
  • FIG. 6 illustrates a system 600 that depicts a compressor in a CMV stuck loaded failure and leakage on a high pressure cylinder discharge valve.
  • FIG. 7 a valve 700 that is a high pressure cylinder discharge valve is depicted.
  • the valve 700 can be from a compressor and include a leak source 702 which relates to the a compressor for a CMV stuck loaded failure and leakage on a high pressure cylinder discharge valve failure.
  • a high pressure cylinder unloader valve stuck loaded failure can relate to the high pressure cylinder being not able to release to atmosphere.
  • the effect of this failure is that trapped air in the high pressure cylinder results in increased starting torque and may stall.
  • FIG. 8 illustrates a system 800 that depicts a compressor in a high pressure cylinder unloader valve stuck failure in which unloader valve 268 is unable to release to atmosphere.
  • a high pressure cylinder unloader valve stuck loaded and leakage on the high pressure cylinder discharge valve can be a failure related to the high pressure cylinder not being able to release to atmosphere except the main reservoir leaks back into the main pressure cylinder.
  • the effect of this failure is the discharge valve leak can result in increased air mass and pressure in the high pressure cylinder. Larger leaks may cause the high pressure piston to move to BDC.
  • the trapped air in the high pressure cylinder results in increased starting torque and may stall.
  • a low pressure cylinder unloader valve stuck loaded can be a failure.
  • This failure relates to a low pressure cylinder not being able to release to atmosphere. The effect of this failure is the trapped air in the low pressure cylinder results in increased starting torque and may stall.
  • Another failure can be leakage on the high pressure cylinder discharge valve. This failure can lead to starting issues if the CMV is at a point in time put in the loaded state even transiently. This can be caused by the fact that when the high pressure cylinder contains pressurized air, the unloader valve actuator may not have enough force capability to overcome the differential pressure across the inlet valve. This can lead to a latched unloader state of closed.
  • the controller and the detection component facilitate overcoming the above stall conditions and/or failures. Moreover, the above referenced failures are not to be limiting on the subject disclosure and a suitable combination or amount of failures related to a stall condition for a loaded start condition can be mitigated by the controller and the detection component.
  • FIG. 9 illustrates a reverse direction mode 900 in response to a stall condition of a compressor.
  • the controller can employ a reverse direction mode based upon an identified stall condition from the detection component.
  • the reverse direction mode 900 is illustrated in a series of images for a cylinder of a reciprocating compressor as described above.
  • the reverse direction mode 900 depicts cylinder 210 but is to be appreciated that the depiction can apply to each cylinder of the compressor and the subject innovation is not limited to a single cylinder.
  • the cylinder 210 includes the unloader valve 268 and is coupled to the crankshaft via the connecting rod. Once a stall condition is detected by the detection component, power can be removed and the cylinder can settle at Bottom-Dead-Center. Once detection of the cylinder being at BDC, power can be reversed (e.g., reverse direction of the motor) and compressed air can enter the cylinder.
  • a reverse stall can be detected.
  • a reverse stall can be detected or the compressor can run in reverse.
  • a reverse stall is detected.
  • the power is applied in the forward direction (e.g., forward power, not reversed power) and forward momentum is built (e.g., motor torque and/or pneumatic force).
  • the torque increase mode can be employed as well to increase torque and momentum. This forward momentum built and applied increased torque (e.g., if the increase torque mode is employed) can result in a start of the compressor.
  • FIGS. 10-12 methodologies that may be implemented in accordance with the disclosed subject matter will be better appreciated with reference to the flow charts of FIGS. 10-12 .
  • the methodologies are shown and described as a series of blocks, the claimed subject matter is not limited by the order of the blocks, as some blocks may occur in different orders and/or concurrently with other blocks from what is depicted and described herein. Moreover, not all illustrated blocks may be required to implement the methods described hereinafter.
  • the methodologies can be implemented by a component or a portion of a component that includes at least a processor, a memory, and an instruction stored on the memory for the processor to execute.
  • FIG. 10 illustrates a flow chart of a method 1000 for detecting a stall condition related to a force from compressed air being compressed into a reservoir of the reciprocating compressor.
  • a stall condition can be detected for a reciprocating compressor based on measured speed, motor current, or air pressure.
  • the stall condition can be detected based on a a force from compressed air being compressed into a reservoir of the reciprocating compressor, wherein a detection component can be used to detect such force.
  • a portion of power from a motor of the reciprocating compressor can be removed.
  • a phase sequence of the motor can be reversed to force a recompression of a piston of the reciprocating compressor.
  • at least one of a reverse stall or a start of the reciprocating compressor can be detected while in a reverse direction as the piston moves to a Top-Dead-Center (TDC) position.
  • TDC Top-Dead-Center
  • FIG. 11 illustrates a flow chart of a method 1100 for increasing torque for a compressor motor in response to a detected stall condition related to a force from compressed air being compressed into a reservoir of the reciprocating compressor.
  • a stall condition can be detected for a reciprocating compressor based on a force from compressed air being compressed into a reservoir of the reciprocating compressor.
  • a torque to start the motor of the compressor can be increased with at least one of a pole switching, a line voltage increase, or a voltz/hertz increase.
  • the torque can be increased with a selection from a first pole mode to a second pole mode, wherein the first pole mode includes a first number of poles that is less than a second number of poles for a second pole mode.
  • FIG. 12 illustrates a flow chart of a method 1200 for increasing torque for a compressor motor and reversing a phase sequence of the motor in response to a detected stall condition related to a force from compressed air being compressed into a reservoir of the reciprocating compressor.
  • a stall condition for a reciprocating compressor can be detected based on a force from compressed air being compressed into a reservoir of the reciprocating compressor.
  • a portion of power can be removed from a motor of the reciprocating compressor.
  • a phase sequence to the motor can be reversed which forces a recompression of a piston of the reciprocating compressor.
  • At reference numeral 1240 at least one of a reverse stall or a start of the reciprocating compressor can be detected while in a reverse direction as the piston moves to a Top-Dead-Center (TDC) position.
  • TDC Top-Dead-Center
  • a torque to start the engine of the reciprocating bidirectional compressor can be increased by selecting a number of poles used by the motor from a first number to a second number, wherein the second number is greater than the first number.
  • the method includes reversing a phase direction of the motor to accelerate the piston past a Bottom-Dead-Center (BDC) position based on the detected reverse stall.
  • the method further includes accelerating the compressor past the BDC with at least one of a torque of the motor or a pneumatic force on the piston to overcome the force.
  • the method can include driving the compressor in the reverse direction for a duration of time based on the detection of the start of the compressor.
  • the method can include reversing a phase direction of the motor after the start of the compressor for a duration of time.
  • the method includes returning a stuck loaded control magnet valve (CMV) or an un-loader valve based on the start of the compressor. In still another embodiment, the method includes returning a stuck loaded control magnet valve (CMV) or an un-loader valve based on elevation of a pressure of the reservoir due to the start of the compressor.
  • CMV stuck loaded control magnet valve
  • the stall condition can be based on at least one of a control magnet valve stuck failure, a leakage on a high pressure cylinder discharge valve of the compressor, a high pressure cylinder un-loader valve stuck failure, or a low pressure cylinder un-loader valve stuck failure.
  • the method includes increasing a torque to start the motor of the compressor with at least one of a pole switching, a line voltage increase, or a volt/hertz increase.
  • the torque used to start the motor can be increased in a forward direction of the piston or the reverse direction of the piston.
  • the torque is increased with a selection of a first pole mode to a second pole mode, wherein the first pole mode includes a first number of poles and the second pole mode includes a second number of poles in which the second number of poles is greater than the first number of poles.
  • a vehicle can be provided with a detector component and a controller as discussed above. Also, the detector may be embedded within the controller component.
  • the vehicle can include an engine in which a compressor can be operatively connected to the engine, wherein the compressor includes a reservoir configured to store compressed air.
  • the controller can provide at least one of a removal power from the motor of the compressor, a reversal a phase sequence of the motor to force a recompression of a piston of the compressor, and a detection of at least one of a reverse stall or a start of the compressor while in a reverse direction as the piston moves to a Top-Dead-Center (TDC) position.
  • the compressor is a reciprocating compressor with a bi-directional drive system that drives a piston in a forward direction and the reverse direction.
  • the controller is configured to reverse a phase direction of the motor to accelerate the piston past a Bottom-Dead-Center (BDC) position based on the detected reverse stall and accelerate the compressor past the BDC position with at least one of a torque of the motor or a pneumatic force on the piston to overcome the force.
  • BDC Bottom-Dead-Center
  • the controller can be further configured to control at least one of the following: a drive of the compressor in the reverse direction for a duration of time based on the detection of the start of the compressor; or a reversal of a phase direction of the motor after the start of the compressor for a duration of time.
  • the controller can be further configured to increase a torque to start the engine of the compressor by selecting a number of poles used by the motor from a first number to a second number, wherein the second number is greater than the first number.
  • the controller can be configured to control an increase to at least one of a line voltage or a volt/hertz to change a torque for an engine start of the compressor.
  • a system in an embodiment, includes means for increasing a torque to start the engine of the reciprocating bidirectional compressor by selecting a number of poles used by the motor from a first number to a second number, wherein the second number is greater than the first number.
  • a method is provided to accommodate a failure to start a reciprocating air compressor due to a high starting torque associated with wear or failure of a component or system that includes the steps of: detecting a stall condition for a reciprocating compressor based on at least one of a compressor speed, a motor current, or a measured pressure signal; and increasing a torque to start the motor of the compressor with at least one of a pole switching, a line voltage increase, or a volt/hertz increase.
  • the torque to start the motor is increased in at least one of a forward direction of a piston of the motor or a reverse direction of the piston of the motor.
  • the torque is increased with a selection of a first pole mode to a second pole mode.
  • the first pole mode includes a first number of poles and the second pole mode includes a second number of poles in which the second number of poles is greater than the first number of poles.
  • the method can respond to a stall during a compressor start sequence by increasing the line voltage to above-normal levels to facilitate extra starting torque for the compressor.
  • the method can respond to a stall during a compressor start sequence by increasing the motor flux to above-normal levels to facilitate providing extra starting torque for the compressor.
  • the motor control is returned to normal except the compressor motor run duration is extended in order to avoid troubled re-starts.
  • the method can include regulating reservoir air pressure using a controllable loading valve to load and unloading the compressor while it maintains rotation.
  • the method can include regulating reservoir air pressure using a hardware relief valve.
  • a method can be provided to accommodate a failure to start a reciprocating air compressor due to a high starting torque associated with wear or failure of a component or system that includes the steps of: detecting a stall condition for a compressor based on at least one of a compressor speed, a motor current, or a measured pressure signal; and reversing the compressor rotation transiently to accommodate the failure.
  • a reverse rotation is driven by reversing a phase sequence to a three (3) phase induction motor driving the compressor.
  • an induction motor is powered by a variable frequency inverter drive.
  • a reverse rotation is limited to a position from which momentum is obtained on a subsequent forward restart.
  • this rotation is maintained if the compressor can pump air in either direction. In the embodiment, if during reverse rotation, the compressor successfully starts in a reverse direction, this rotation is maintained only for a short period of time after which the compressor is stopped and restarted in a forward direction.
  • a system in an embodiment, includes means for detecting a stall condition for a reciprocating bidirectional compressor based on a force from compressed air being compressed into a reservoir of the reciprocating bidirectional compressor, wherein the means for detecting can be the detection component, the controller component, a sensor, a component, or a combination thereof.
  • the system can include means for removing power from a motor of the reciprocating bidirectional compressor, wherein the means for removing can be the controller, the motor, the compressor, a component, among others.
  • the system can include means for reversing a phase sequence to the motor to force a recompression of a piston of the reciprocating bidirectional compressor, wherein the means for reversing can be the controller component, the compressor, the motor, a component, among others.
  • the system can include means for detecting at least one of a reverse stall or a start of the reciprocating bidirectional compressor while in a reverse direction as the piston moves to a Top-Dead-Center (TDC) position, wherein the means for detecting is the detector component, a sensor, a compressor, a controller component, a component, among others.
  • TDC Top-Dead-Center
  • the terms “may” and “may be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur—this distinction is captured by the terms “may” and “may be.”

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Computer Hardware Design (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
  • Compressor (AREA)
  • Valves And Accessory Devices For Braking Systems (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
US13/857,334 2012-04-20 2013-04-05 Method and system for reciprocating compressor starting Abandoned US20130280095A1 (en)

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US13/857,334 US20130280095A1 (en) 2012-04-20 2013-04-05 Method and system for reciprocating compressor starting
DE112013006838.9T DE112013006838T5 (de) 2012-04-20 2013-04-15 Verfahren und System zum Starten eines Kolbenkompressors
PCT/US2013/036527 WO2013158518A2 (en) 2012-04-20 2013-04-15 Method and system for reciprocating compressor starting

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US13/866,573 Abandoned US20130294937A1 (en) 2012-04-20 2013-04-19 System and method for a compressor
US13/866,471 Active 2036-05-29 US9771933B2 (en) 2011-09-15 2013-04-19 System and method for a compressor
US13/866,499 Abandoned US20130294936A1 (en) 2012-04-20 2013-04-19 System and method for a compressor
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US13/866,471 Active 2036-05-29 US9771933B2 (en) 2011-09-15 2013-04-19 System and method for a compressor
US13/866,499 Abandoned US20130294936A1 (en) 2012-04-20 2013-04-19 System and method for a compressor
US13/866,435 Active 2034-02-08 US10233920B2 (en) 2012-04-20 2013-04-19 System and method for a compressor

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US9677556B2 (en) 2017-06-13
US20130294935A1 (en) 2013-11-07
US20130294937A1 (en) 2013-11-07
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WO2013158518A2 (en) 2013-10-24
ZA201407992B (en) 2016-05-25
DE112013006838T5 (de) 2016-06-09
US20130294934A1 (en) 2013-11-07
US10233920B2 (en) 2019-03-19
CN104364523A (zh) 2015-02-18
DE112013002118T5 (de) 2015-01-15
AU2013248977A1 (en) 2014-11-06
US20130294936A1 (en) 2013-11-07
WO2013159087A2 (en) 2013-10-24
WO2013158518A3 (en) 2014-10-23
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AU2013248977B2 (en) 2017-01-12
WO2013159087A3 (en) 2014-10-16

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