WO2023198315A1

WO2023198315A1 - Forced air-cooling of air compressor using suction of compressor

Info

Publication number: WO2023198315A1
Application number: PCT/EP2023/025178
Authority: WO
Inventors: Bhanupratap NIRANJAN; Shahnawaz Khan; Praveen BALEKUNDRI
Original assignee: Eaton Intelligent Power Limited
Priority date: 2022-04-15
Filing date: 2023-04-14
Publication date: 2023-10-19

Abstract

A compression system comprises a compressor (100) configured to receive and compress inlet airflow received by the compressor. The compressor comprises a body (102) having a plurality of ribs (112) extending therefrom. The body comprises an inlet (104) defined in a first side (106) of the body and an outlet (108) defined in a second side (110) of the body. The compression system further comprises a housing (202) configured to contain the compressor, wherein the compressor is disposed within the housing. The housing comprises an inlet port and an outlet port each configured to provide fluid communication between an interior and an exterior of the housing. The housing is configured to reduce a noise level output by the compressor to about 75 decibels.

Description

FORCED AIR-COOLING OF AIR COMPRESSOR USING SUCTION OF COMPRESSOR

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of Indian Patent Application No. 202211022483, filed April 15, 2022, which is hereby incorporated by reference as if reproduced in its entirety

BACKGROUND

The present disclosure relates generally to air compressors and, more particularly, to improved forced air-cooling of an air compressor using the suction of the compressor.

Operation of compressors generate noise, vibrations, and a rise in temperature of nearby structures (i.e., rotors). To reduce the noise and vibrations, the compressor can be isolated with respect to the nearby components, but this may further increase the heat generated by operation of the compressor. For example, an un-isolated compressor may experience convective cooling to reduce its temperature. When isolated, there is a reduction in the heat transfer away from the compressor. There is a need for an improved, isolated compressor.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures are included to illustrate certain aspects of the present disclosure and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications alterations combinations, and equivalents in form and function, without departing from the scope of this disclosure.

FIG. 1 illustrates a perspective view of a compressor, according to one or more aspects of the present disclosure.

FIGs. 2-3 illustrate perspective views of a compression system with the compressor of FIG.

1, according to one or more aspects of the present disclosure.

FIGs. 4-5 illustrate cross-sectional views of a flow of external air during operation of the compression system of FIGs. 2-3, according to one or more aspects of the present disclosure.

DETAILED DESCRIPTION

Illustrative embodiments of the present invention are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions may be made to achieve the specific implementation goals, which may vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.

Throughout this disclosure, a reference numeral followed by an alphabetical character refers to a specific instance of an element and the reference numeral alone refers to the element generically or collectively. Thus, as an example (not shown in the drawings), widget "la" refers to an instance of a widget class, which may be referred to collectively as widgets " 1 " and any one of which may be referred to generically as a widget " 1". In the figures and the description, like numerals are intended to represent like elements.

The terms “couple” or “couples,” as used herein, are intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect electrical connection or a shaft coupling via other devices and connections.

To facilitate a better understanding of the present disclosure, the following examples of certain embodiments are given. In no way should the following examples be read to limit, or define, the scope of the disclosure. Embodiments described below with respect to one implementation are not intended to be limiting.

FIG. 1 illustrates a perspective view of a compressor 100. The compressor 100 may be any suitable component configured to compress and pressurize a gas, such as air. Without limitations, compressor 100 may be a roots-type compressor, centrifugal compressor, piston type, or the like. In embodiments, the compression of air may cause noise, vibrations, and a rise in temperature throughout the structural integrity of compressor 100. This may cause thermal expansion of components, such as a rotor, which may cause reduced clearance and lead to failure. To reduce the generated noise and vibrations, compressor 100 may be isolated and encapsulated, but this may further increase temperature as there is a reduction in natural, convective cooling. As described further below, the compressor 100 may be disposed within a housing or enclosure to reduce the generated noise and vibrations, wherein convective cooling may be initiated through the housing or enclosure to reduce the temperature of the compressor 100 without the need of a separate actuating unit forcing the airflow.

As illustrated, the compressor 100 may comprise a body 102 defined by a plurality of sides. The body 102 may be any suitable size, height, shape, and any combinations thereof. Further, the body 102 may comprise any suitable materials, such as metals, nonmetals, polymers, composites, and any combinations thereof. The body 102 may comprise an inlet 104 defined in a first side 106 of the body 102 and an outlet 108 defined in a second side 110 of the body 102. The first side 106 may be disposed perpendicular to the second side 110. The inlet 104 may be configured to receive an inlet airflow at an initial temperature and pressure. During operations, the compressor 100 may compress the inlet airflow, thereby increasing the temperature and pressure. The outlet 108 may be configured to discharge the compressed airflow, wherein the compressed airflow is at a greater temperature and pressure than the inlet airflow.

The body 102 may further comprise a plurality of ribs 112 extending outwards. The plurality of ribs 112 may be configured to function as a heat sink and may transfer heat, via conduction, away from the body 102. In embodiments, the plurality of ribs 112 may be disposed around at least a portion of the body 102. Each one of the plurality of ribs 112 may comprise approximately the same dimensions (i.e., height, width, etc.). As shown, one or more channels 114 may be defined by the plurality of ribs 112. For example, there may be a singular channel 114 or a portion of the one or more channels 114 disposed between adjacent ribs 112. The one or more channels 114 may additionally be disposed between a first or last rib 112, within a sequence of ribs 112, and the body 102. The one or more channels 114 may be defined by the space defined by the distance between the plurality of ribs 112. In embodiments, there may be a singular, contiguous channel 114 or a plurality of channels 114 disposed around the body 102. The one or more channels 114 may be configured to direct a flow of external air around the body 102 during operation of the compressor 100. As the external air flow around the body 102, the compressor 100 may experience convective cooling and transfer heat away from the compressor 100.

FIGs. 2-3 illustrate perspective views of a compression system 200. In embodiments, the compression system 200 may be used in fuel cell air compressor systems, superchargers, blowers, other air pumps, and the like. A boost controller may be devised to implement the methods herein, such as valve or gate controllers, or an air compressor controller, among other options. The compression system 200 may comprise the compressor 100 of FIG. 1, a housing 202, and an actuation mechanism 204. The actuation mechanism 204 may be any suitable component configured to drive the compressor 100. For example, the actuation mechanism 204 may be a motor, a pulley system, and the like. The actuation mechanism 204 may be coupled to a side of the compressor 100 opposite from the first side 106. In other embodiments, the actuation mechanism 204 may be coupled to the compressor 100 at a different side or other suitable location.

As illustrated, compressor 100 may be disposed within the housing 202. The plurality of ribs 112 may extend outwards from the compressor 100 to abut against the housing 202. In other embodiments, there may be a distance between a top of the plurality of ribs 112 and the housing 202. The housing 202 may be any suitable size, height, shape, and any combinations thereof to contain the compressor 100. Further, the housing 202 may comprise any suitable materials, such as metals, nonmetals, polymers, composites, and any combinations thereof. In embodiments, the housing 202 may be configured to reduce the noise and vibrations generated by the compressor 100 during operations. In embodiments wherein the compressor 100 is not disposed within housing 202, the compressor 100 may operate at a noise level output of about 90 decibels to about 100 decibels. In embodiments wherein the compressor 100 is disposed within the housing 202, the compressor 100 may operate at a noise level output of about 75 decibels.

The housing 202 may comprise an inlet port 206 configured to provide fluid communication between an interior and an exterior of the housing 202. The inlet port 206 may be configured to receive a flow of external air and introduce the flow of external air into the housing 202 and through the one or more channels 114. The inlet port 206 may be defined as an opening through the housing 202 and may be disposed on a side of the housing 202. The inlet port 206 may be disposed about any suitable location along the housing 202. In embodiments, the inlet port 206 may be disposed at a distance from the first side 106 of the compressor 100 to optimize airflow around the compressor 100. For example, the inlet port 206 may be disposed closer to the side of the compressor 100 coupled to the actuation mechanism 204 than the first side 106.

There may be an outlet port 208 disposed in proximity to the inlet 104 of the compressor 100, wherein the outlet port 208 may provide fluid communication between the interior of the housing 202 and the inlet 104 of the compressor 100. The outlet port 208 may be defined as an opening through the body 102 (referring to FIG. 1) of the compressor 100. The compression system 200 may further comprise a filter 210 disposed at the outlet port 208 within the housing 202 configured to remove particles from a flow of external air being discharged through the outlet port 208. Any suitable filtering device may be used as the filter 210.

FIGs. 4-5 illustrate cross-sectional views of a flow of external air 400 during operation of the compression system 200. FIG. 4 illustrates a top, cross-sectional view of compression system 200, and FIG. 5 illustrates a side, cross-sectional view of compression system 200. During operations, inlet airflow 402 may flow into the compressor 100 via the inlet 104 (referring to FIG. 1). In one or more embodiments, an inlet adapter 404 may be coupled to the inlet 104 and configured to direct an incoming flow of fluid to the inlet 104. A pressure differential may be created between the inlet port 206 and the outlet port 208 as the outlet port 208 is in fluid communication with the inlet 104. In certain embodiments, the outlet port 208 may be disposed on the inlet adapter 404. In other embodiments, the outlet port 208 may be disposed along the body 102 (referring to FIG. 1) of the compressor 100. The inlet airflow 402 flowing into the compressor 100 may comprise a higher velocity compared to the external, ambient air proximate to the inlet port 206. The suction of operating compressor 100 may introduce the flow of external air 400 into the housing 202 through the inlet port 206, wherein the external air 400 may be subsequently discharged by the outlet port 208 to the inlet 104 of compressor 100.

In one or more embodiments, the external air 400 may be directed to flow through the one or more channels 114 between the plurality of ribs 112 to reach the outlet port 208. In these embodiments, the plurality of ribs 112 may restrict the space within the interior of the housing 202 and limit potential flow paths to the one or more channels 114. The external air 400 may further be filtered, wherein the filter 210 (referring to FIG. 3) may remove particles from the flow of external air 400 as the external air 40 discharges from the outlet port 208. As the external air 400 flows through the housing 202, heat may be transferred from the compressor 100 to the external air 400. For example, convective heat transfer may occur as the external air 400 flows around the body 102 of the compressor 100, and conductive heat transfer may occur between the external air 400 and the plurality of ribs 112. Compression system 200 thereby may employ passive cooling to reduce the temperature of the compressor 100 during operations. Further, as compressor 100 is disposed within housing 202, the noise output level of compressor 100 may be reduced. In one or more embodiments, the compression system 200 may further comprise a noise absorption material 406 disposed inside the housing 202 along the interior of the housing 202. The noise absorption material 406 may be any suitable material configured to reduce the sound or noise output level of compressor 100. The noise absorption material 406 may be disposed along a portion of the housing 202, uniformly along the housing 202, randomly along the housing 202, in an organized pattern along the housing 202, or any combination thereof. Without limitations, the noise absorption material 406 may be a porous material, such as a foam.

Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and any optional element disclosed herein. While compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods can also "consist essentially of or "consist of the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, "from about a to about b," or, equivalently, "from approximately a to b," or, equivalently, "from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Further, the term “about” is construed as allowing a certain amount of tolerance to a value, such as 1% -5% of the value. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the element that it introduces.

Claims

WHAT IS CLAIMED IS:

1. A compression system, comprising: a compressor configured to receive and compress inlet airflow received by the compressor, the compressor comprising a body having a plurality of ribs extending therefrom, wherein the body comprises: an inlet defined in a first side of the body; and an outlet defined in a second side of the body; and a housing configured to contain the compressor, wherein the compressor is disposed within the housing, the housing comprising an inlet port and an outlet port each configured to provide fluid communication between an interior and an exterior of the housing, wherein the housing is configured to reduce a noise level output by the compressor to about 75 decibels.

2. The compression system of claim 1, wherein the first side of the body is disposed perpendicular to the second side of the body.

3. The compression system of claim 1, wherein the plurality of ribs extend from the body and abut against the housing.

4. The compression system of claim 1, further comprising a noise absorption material disposed inside the housing along the interior of the housing.

5. The compression system of claim 1, wherein the inlet port is disposed on a side of the housing.

6. The compression system of claim 1, wherein the outlet port is disposed in proximity to the inlet of the compressor, the outlet port providing fluid communication between the interior of the housing and the inlet of the compressor.

7. The compression system of claim 6, wherein external air is configured to enter into the housing through the inlet port based on a pressure differential between the outlet port and the inlet port created by operation of the compressor, wherein the outlet port is configured to discharge the external air to the inlet of the compressor.

8. The compression system of claim 1, wherein the plurality of ribs define one or more channels disposed around at least a portion of the body of the compressor configured to direct a flow of external air.

9. The compression system of claim 1, further comprising a motor coupled to the compressor and configured to drive the compressor.

10. The compression system of claim 1, further comprising a filter disposed at the outlet port within the housing configured to remove particles from a flow of external air.

11. A method of operating a compression system, comprising: actuating a compressor to increase the pressure of an inlet airflow, wherein the compressor is disposed within a housing having an inlet port and an outlet port each configured to provide fluid communication between an interior and an exterior of the housing; introducing a flow of external air into the housing via the inlet port, wherein the flow of external air is introduced based on a pressure differential between the outlet port and the inlet port; directing the flow of external air around at least a portion of the compressor; and discharging the flow of external air out through the outlet port and to an inlet of the compressor.

12. The method of claim 11, further comprising receiving the inlet airflow through the inlet defined in a first side of a body of the compressor.

13. The method of claim 11, further comprising removing particles from the flow of external air as the flow of external air is discharged from the outlet port.

14. The method of claim 11, wherein the compressor comprises a plurality of ribs extending outward towards the housing that define one or more channels disposed around at least a portion of the compressor that are configured to direct the flow of external air.

15. A compression system, comprising: a compressor configured to receive and compress inlet airflow received by the compressor, the compressor comprising a body having a plurality of ribs extending therefrom, wherein the body comprises: an inlet defined in a first side of the body; and an outlet defined in a second side of the body; a housing configured to contain the compressor, wherein the compressor is disposed within the housing, the housing comprising an inlet port and an outlet port each configured to provide fluid communication between an interior and an exterior of the housing; and a motor coupled to the compressor and configured to drive the compressor.

16. The compression system of claim 15, further comprising a noise absorption material disposed inside the housing along the interior of the housing.

17. The compression system of claim 15, wherein the plurality of ribs extend from the body and abut against the housing.

18. The compression system of claim 15, wherein the plurality of ribs define one or more channels disposed around at least a portion of the body of the compressor configured to direct a flow of external air.

19. The compression system of claim 15, further comprising a filter disposed at the outlet port within the housing configured to remove particles from a flow of external air.

20. The compression system of claim 15, wherein the inlet port is disposed on a side of the housing, wherein the outlet port is disposed in proximity to the inlet of the compressor, the outlet port providing fluid communication between the interior of the housing and the inlet of the compressor.