Balanced cyclone high pressure air compressor

Abstract

The present invention discloses a balanced liner high-pressure air compressor, including a crankcase, a crankshaft, and a connecting rod. The crankcase is composed of a front box body, a rear box body, and a cover body. The crankcase is movably connected to the crankshaft through a sealed bearing. A cylinder assembly is fixedly arranged on the crankcase. An intake assembly and an exhaust assembly are arranged on the cylinder assembly. A balanced transmission liner group and a cyclone structure are arranged inside the high-pressure air compressor, and a heat dissipation and noise reduction mechanism is arranged outside the high-pressure air compressor body. The structural design of the present invention is reasonable. Through the balanced transmission liner group, the eccentric inertia force is balanced and offset without changing the original structural size of the air compressor, the vibration friction and mutual vibration are reduced, and the balance performance of the whole machine is improved; the cyclone structure is arranged to prevent the wear of the eccentric movement of the piston from a microscopic point of view, and to prevent the "waist drum wear" phenomenon caused by the instantaneous high air pressure around the piston; the heat dissipation and noise reduction mechanism is arranged to reduce vibration and noise without affecting the original heat dissipation effect.

Description

Technical Field

[0001] The invention relates to the technical field of air compressors, and in particular to a balanced cyclone high-pressure air compressor. Background Art

[0002] Compared with ordinary air compressors, high-pressure air compressors have very high requirements for balanced transmission under high-pressure and high-temperature conditions. The transmission part is the key to the performance of high-pressure air compressors. Due to the limitations of the cavity space and structure, the general balance block of a reciprocating micro high-pressure air compressor only balances 1 / 2-2 / 3 of the eccentric inertia force and cannot achieve further balance. The trajectory of its reciprocating inertia force is an ellipse, so it vibrates greatly.

[0003] Insufficient balance and high vibration are technical problems of air compressors, which specifically include the consumption of ineffective friction. The power consumed by friction in existing micro air compressors accounts for 45-50% of the total power. Among them, the friction work between the piston and the cylinder is the largest. When the piston exhausts upward, the gas is squeezed and first sprayed downward to the micro-gap around the piston and the piston ring. The piston is prone to shaking and vibrating, and oil is prone to blowby. For a long time, the piston has only relied on the piston ring to balance the movement. The piston ring plays a dual role of sealing movement and piston balance, but the piston ring is elastic and cannot achieve complete balance; the second is the crankshaft and connecting rod. The rotational inertia force and reciprocating inertia force of the piston, crankshaft, and connecting rod often generate alternating branch reaction force at the bearing or transmission node, causing severe vibration or even damage to the machine.

[0004] The most common heat dissipation method for existing high-pressure air compressors is to use cooling fins. The cooling fins installed on high-pressure air compressors are usually longer, wider and denser. There are usually 12-15 fins on a single cylinder block, and the whole machine is generally equipped with 30-40 fins. Metal cooling fins are good audio sounding bodies and vibration conductors. Under the conditions of high voltage and high speed operation, the cooling fins not only dissipate heat, but also transmit the audio of vibration waves and noise without compromise, thereby increasing vibration and noise, and also producing mutual resonance effects on external vibration waves and audio. Summary of the invention

[0005] In view of the problems existing in the prior art, the purpose of the present invention is to design and provide a balanced cyclone high-pressure air compressor.

[0006] The balanced cyclone high-pressure air compressor comprises a crankcase, a crankshaft and a connecting rod. The crankcase consists of a front box body, a rear box body and a cover body. The crankcase is movably connected to the crankshaft through a sealed bearing. A cylinder assembly is fixedly arranged on the crankcase. An intake assembly and an exhaust assembly are arranged on the cylinder assembly. The characteristic is that a balanced transmission lining group and a cyclone structure are arranged inside the high-pressure air compressor, and a heat dissipation and noise reduction mechanism is arranged outside the high-pressure air compressor body. The balanced transmission lining group comprises a cylinder group, a connecting rod piston pin group, a connecting rod crankshaft group and a piston pin group.

[0007] The balanced cyclone high-pressure air compressor is characterized in that the cylinder group includes a cylinder body, a cylinder liner, a piston ring and a piston arranged in the cylinder body, the cylinder body is made of ZL108 material, the cylinder liner is made of 40Cr material, the piston ring is made of NHC-5 material, and the piston is made of 7075 aluminum alloy material; the connecting rod piston pin group includes a connecting rod, a small connecting rod liner, and a piston pin, and the connecting rod crankshaft group includes a connecting rod, a large connecting rod liner, and a crankshaft. The connecting rod and the crankshaft are both made of 40CrM0 material, the small connecting rod liner is made of OQI10-4-4 material, the piston pin is made of 20Cr material, and the large connecting rod liner is made of Qsn7-0.2 material; the piston pin group includes a piston, a liner, and a piston pin. The piston is made of 7075 aluminum alloy material, the liner is made of OQI10-4-4 material, and the piston pin is made of 20Cr material.

[0008] The balanced cyclone high-pressure air compressor is characterized in that the cyclone structure is a balanced cyclone surface, which is an inclined conical surface structure with a taper of 160-175 degrees, preferably 170 degrees, and the vertical distance from the lowest point of the cone to the highest point of the cone is less than 1.5 mm, preferably 1 mm.

[0009] The balanced cyclone high-pressure air compressor is characterized in that the cyclone structure includes a piston cyclone and a valve cyclone. The piston cyclone is arranged on the end face of each piston or on the inner end face of the cylinder head, and the valve cyclone is arranged on the gas-bearing end face of the valve.

[0010] The balanced cyclone high-pressure air compressor is characterized in that the heat dissipation and noise reduction mechanism includes a plurality of noise reduction heat sink fins arranged in parallel, each of the noise reduction heat sink fins is provided with upper and lower corresponding noise reduction heat sink holes, the noise reduction heat sink holes at the same longitudinal position form a noise reduction heat sink hole group, the noise reduction heat sink fins between adjacent noise reduction heat sink hole groups are provided with upper and lower corresponding heat sink linings, the heat sink linings at the same longitudinal position form a heat sink lining group.

[0011] The balanced cyclone high-pressure air compressor is characterized in that the noise reduction heat dissipation hole group and the heat dissipation lining group are each provided with four groups, and are evenly distributed.

[0012] The balanced cyclone high-pressure air compressor is characterized in that the aperture of the noise reduction and heat dissipation holes is less than 0.8 cm, preferably 0.6 cm, 0.7 cm, 0.5 cm, 0.4 cm, and the size of the aperture depends on the size of the noise reduction and heat dissipation fins.

[0013] The balanced cyclone high-pressure air compressor is characterized in that the heat dissipation and noise reduction mechanism is arranged on the outer wall of the cylinder body of the cylinder assembly and on the outer wall of the exhaust pipe of the intake assembly and the exhaust assembly.

[0014] The balanced cyclone high-pressure air compressor is characterized in that the cylinder assembly is assembled using the following steps:

[0015] 1) Pre-treatment: Drill a small process hole at the exhaust hole of the cylinder body. The small process hole is located at the position of the product gas valve in the subsequent processing, and deburring is performed to facilitate exhaust during lining assembly;

[0016] 2) Cylinder preheating: The cylinder is heated to 200-220 degrees in a constant temperature box and maintained for 60 minutes;

[0017] 3) Bushing cooling: Immerse the cylinder bushing in liquid nitrogen for 8-10 minutes;

[0018] 4) Lining agent coating: When the cylinder body temperature is at 200-210℃, evenly coat the lining agent on its inner wall, then fit the cylinder liner into the cylinder body, and apply a certain pressure for 1 minute with a motorized or manual press;

[0019] 5) Cooling: Allow the assembled cylinder to cool naturally to complete the assembly.

[0020] The balanced cyclone high-pressure air compressor is characterized in that the fit between the cylinder body and the cylinder body bushing is an interference fit with an interference amount of 0.1 mm, and the lining agent is Ergo4460.

[0021] The present invention has a reasonable structural design. By setting a balanced transmission lining group, the eccentric inertial force is balanced and offset without changing the original structural size of the air compressor, thereby reducing vibration friction and mutual vibration and improving the balance performance of the whole machine. The setting of the cyclone structure prevents the wear of the piston eccentric movement from a microscopic point of view, and prevents the "waist drum wear" phenomenon caused by the instantaneous high air pressure around the piston, so that the air path is ideal, the charging efficiency is improved, and the wear is reduced. The setting of the heat dissipation and noise reduction mechanism reduces the vibration and noise by reducing the audio frequency without affecting the original heat dissipation effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the overall structure of the invention;

[0023] Figure 2 An exploded view of the present invention;

[0024] Figure 3 It is a structural schematic diagram of a cyclone structure arranged on the upper end surface of a piston;

[0025] Figure 4 It is a schematic diagram of the heat dissipation structure arranged on the cylinder;

[0026] In the figure, 1-crankshaft, 2-connecting rod, 3-front housing, 4-rear housing, 5-cover, 6-cylinder body, 7-piston, 8-small connecting rod liner, 9-large connecting rod liner, 10-noise reduction heat dissipation fins, 11-noise reduction heat dissipation holes, 12-heat dissipation liner, 13-balanced cyclone surface. DETAILED DESCRIPTION

[0027] The present invention is further described in detail below with reference to the accompanying drawings, and specific implementation methods are given.

[0028] like Figure 1-4 As shown, the balanced cyclone high-pressure air compressor of the present invention includes a crankcase, a crankshaft, and a connecting rod. The crankcase consists of a front box body, a rear box body and a cover body. The crankshaft is movably connected to the crankcase through a sealed bearing. A cylinder assembly is fixedly arranged on the crankcase. An intake assembly and an exhaust assembly are arranged on the cylinder assembly. A balanced transmission lining group and a cyclone structure are arranged inside the high-pressure air compressor. A heat dissipation and noise reduction mechanism is arranged outside the high-pressure air compressor body. The balanced transmission lining group includes a cylinder group, a connecting rod piston pin group, a connecting rod crankshaft group, and a piston pin group.

[0029] The cylinder block group includes a cylinder block, a cylinder block liner, a piston ring and a piston arranged in the cylinder block. The cylinder block is made of ZL108 material, the cylinder block liner is made of 40Cr material, the piston ring is made of NHC-5 material, and the piston is made of 7075 aluminum alloy material; the connecting rod and piston pin group includes a connecting rod, a small connecting rod liner and a piston pin; the connecting rod and crankshaft group includes a connecting rod, a large connecting rod liner and a crankshaft. The connecting rod and the crankshaft are both made of 40CrM0 material, the small connecting rod liner is made of OQI10-4-4 material, the piston pin is made of 20Cr material, and the large connecting rod liner is made of Qsn7-0.2 material; the piston pin group includes a piston, a liner and a piston pin. The piston is made of 7075 aluminum alloy, the liner is made of OQI10-4-4 material, and the piston pin is made of 20Cr material.

[0030] Among them, the cylinder group is assembled using the following steps: 1) Pretreatment: drill a small process hole at the exhaust hole of the cylinder body. The small process hole is located at the position of the product gas valve in the subsequent processing, and is deburred to facilitate exhaust during lining assembly; 2) Cylinder preheating: The cylinder body is heated to 200-220 degrees in a constant temperature box and maintained for 60 minutes; 3) Bushing cooling: The cylinder bushing is immersed in liquid nitrogen for 8-10 minutes; 4) Lining agent coating: When the cylinder temperature is at 200-210℃, the lining agent is evenly coated on its inner wall, and then the cylinder bushing is assembled into the cylinder body, and a certain pressure is applied for 1 minute with a motorized or manual press; Among them, the fit between the cylinder body and the cylinder bushing is an interference fit, the interference is 0.1mm, and the lining agent is Ergo4460; 5) Cooling: The assembled cylinder body is cooled naturally to complete the assembly. Among them, the lining agent is applied to the heated inner wall of the cylinder body and allowed to enter the cylinder liner. It is thick but not flowing, and there is no solidification. There is a slight white smoke phenomenon during the instantaneous reaction. The balanced transmission lining group of the cylinder group is matched with materials to form a lining chain. The materials are 40Cr + NHC-5; ZL108 +40Cr. It is the best compliance relationship of this lining group, and Ergo4460 retaining agent is added to assist the lining. The catalytic principle and interaction formula of the lining are as follows:

[0031]

[0032] Under the condition of 200 degrees Celsius, the high temperature interaction between the lining and the heat exchanger makes the whole machine connected to the valve structure leak-proof.

[0033] The design of the balanced transmission lining group balances and offsets the eccentric inertia force, limits the alternating branch reaction force to the minimum range, increases balance, reduces friction vibration, reduces the variable branch reaction force, and reduces mutual vibration, thereby improving the balance performance of the whole machine; the balanced lining group structure is highly targeted, does not need to change the original structure size, has significant vibration reduction, has the advantages of energy saving and noise reduction, stable operation, reduced operating costs, safety and reliability, and promotes product performance improvement. Continuous, balanced and stable high-pressure filling and exhaust work has significantly increased the filling speed and continuous air pressure indicators, and the filling efficiency has been improved by 20%. The main performance indicators exceed the Russian AK150M high-pressure air compressor standard. The balanced lining group technology not only combines the mechanical compliance balance of lining materials, lining parts and supporting parts, lined parts, and lining pressure process, but also includes the changes in the material element combination of connected or combined parts and the balance requirements of node modeling. That is, the balance of component structural mechanics and material mechanics.

[0034] The cyclone structure is a balanced cyclone surface, which is an inclined conical surface structure, the taper of which is 160-175 degrees, preferably 170 degrees, and the vertical distance from the lowest point of the cone to the highest point of the cone is less than 1.5 mm, preferably 1 mm. The cyclone structure includes a piston cyclone and a valve cyclone. The piston cyclone is arranged on the end surface of each piston or on the inner end surface of the cylinder head, and the valve cyclone is arranged on the gas force end surface of the valve.

[0035] Piston cyclone: ​​a balancing cyclone is made on the upper part of the cylinder piston, and the cyclone is balanced in the center through steam flow guidance. It can prevent the wear of the piston due to eccentric movement from a microscopic point of view, and can also prevent the "waist drum wear" phenomenon caused by excessive air pressure around the piston. The returned airflow is concentrated along the center line of the piston and guided into the air valve through the cylinder head. The air path is ideal, the charging efficiency is improved, and the wear of the piston ring is reduced. The cylinder head structure of some products allows that the position of the exhaust valve can be redesigned to be centered, while the traditional intake and exhaust ports are all eccentric designs; or a small cyclone concentric with the exhaust valve can be designed to produce inertial guidance.

[0036] Air valve cyclone: ​​It can concentrate the air pressure along the center line of the valve plug, reduce the air flow to the micro gap around the valve, thereby improving the air flow efficiency and reducing the clearance wear of the valve needle. The check balance cyclone can help adjust the valve plug posture to the center through the check air pressure.

[0037] Heat dissipation and noise reduction mechanism The heat dissipation and noise reduction mechanism is arranged on the outer wall of the cylinder body of the cylinder assembly and on the outer wall of the exhaust pipe of the intake assembly and the exhaust assembly, and includes a plurality of noise reduction heat dissipation fins arranged in parallel. The noise reduction heat dissipation fins are provided with corresponding noise reduction heat dissipation holes with an aperture of less than 0.8 cm. The noise reduction heat dissipation holes at the same longitudinal position form a noise reduction heat dissipation hole group. The noise reduction heat dissipation fins between adjacent noise reduction heat dissipation hole groups are provided with heat dissipation linings that are opposite to each other from top to bottom. The heat dissipation linings at the same longitudinal position form a heat dissipation lining group. There are four groups of noise reduction heat dissipation hole groups and four groups of heat dissipation lining groups, and they are evenly distributed. Drilling holes in the noise-reducing heat sink fins can speed up heat dissipation and reduce vibration frequency; adding heat sink linings between holes and connecting the noise-reducing heat sink fins can further speed up heat dissipation, reduce vibration frequency, and support and enhance the fin function. The noise-reducing heat sink holes with an aperture of 0.5 cm can speed up heat dissipation and prevent audio transmission. The heat sink lining can directly prevent the vibration frequency of the wing end and increase the strength of the wing end, and can also reduce audio. When designing, low-frequency wing materials and shapes are used to offset vibration and noise through low-frequency balance. Damping, balancing and offsetting the vibration and noise transmission of the air compressor from the heat sink fins.

[0038] A comparison table of performance test data of the high-pressure air compressor obtained by adopting the technical solution and assembly method of the present invention is shown in Table 1.

[0039] Table 1: Comparison of high pressure air compressor performance test data

[0040]

[0041] It can be seen from Table 1 that the high-pressure air compressor produced by Taizhou Zhongji Company equipped with the balanced cyclone of the present invention has a fast air supply speed, and the time taken to reach the pressure of 50kg, 100kg, and 150kg is significantly lower than that of other models of high-pressure air compressors in the same industry, which greatly improves the working efficiency of the high-pressure air compressor. Among them, the efficiency in the table refers to the volumetric efficiency

[0042] η v , which has been converted, refers to the ratio of the actual volumetric flow rate of the compressor to the ideal volumetric flow rate. It is a main indicator of the referenced standards "GB / T3853-1998 Acceptance test of positive displacement air compressors", "GB-T 12929-2008 Marine high-pressure piston air compressors", and "QC / T 29078-2016 Performance requirements and bench test methods for automotive air compressors".

Claims

1. A balanced liner high-pressure air compressor, comprising a crankcase, a crankshaft (1), and a connecting rod (2), wherein the crankcase is composed of a front case (3), a rear case (4), and a cover (5), the crankcase being movably connected to the crankshaft (1) via a sealed bearing, a cylinder assembly being fixedly arranged on the crankcase, and an intake assembly and an exhaust assembly being arranged on the cylinder assembly, wherein: The high-pressure air compressor is provided with a balanced transmission liner group and a cyclone structure inside. The cyclone structure is a balanced cyclone surface (13). The balanced cyclone surface (13) is an inclined conical surface structure. The conicity of the conical surface is 160-175 degrees, and the vertical distance from the lowest point of the conical surface to the highest point of the conical surface is not more than 1.5 mm. The cyclone structure includes a piston cyclone and a valve cyclone. The piston cyclone is arranged on the end surface of each piston or on the inner end surface of the cylinder head. The valve cyclone is arranged on the gas stress end surface of the valve. A heat dissipation and noise reduction mechanism is arranged outside the high-pressure air compressor body. The balanced transmission liner group includes a cylinder group, a connecting rod piston pin group, a connecting rod crankshaft group, and a piston pin group. The cylinder group includes a cylinder (6), a cylinder liner arranged in the cylinder (6), a piston ring and a piston ( 7), the cylinder body (6) is made of ZL108 material, the cylinder body liner is made of 40Cr material, the piston ring is made of NHC-5 material, and the piston (7) is made of 7075 aluminum alloy material; the connecting rod piston pin assembly includes a connecting rod (2), a small connecting rod liner (8), and a piston pin; the connecting rod crankshaft assembly includes a connecting rod (2), a large connecting rod liner (9), and a crankshaft (1); the connecting rod (2) and the crankshaft (1) are both made of 40CrM0 material, the small connecting rod liner (8) is made of QAl10-4-4 material, the piston pin is made of 20Cr material, and the large connecting rod liner (9) is made of Qsn7-0.2 material; the piston pin assembly includes a piston (7), a liner, and a piston pin; the piston is made of 7075 aluminum alloy material, the liner is made of QAl10-4-4 material, and the piston pin is made of 20Cr material.

2. The balanced liner high pressure air compressor according to claim 1, characterized in that: The heat dissipation and noise reduction mechanism comprises a plurality of noise reduction heat dissipation fins (10) arranged in parallel, each of the noise reduction heat dissipation fins (10) being provided with upper and lower corresponding noise reduction heat dissipation holes (11), the noise reduction heat dissipation holes (11) at the same longitudinal position forming a noise reduction heat dissipation hole group, the noise reduction heat dissipation fins (10) between adjacent noise reduction heat dissipation hole groups being provided with upper and lower corresponding heat dissipation liners (12), the heat dissipation liners (12) at the same longitudinal position forming a heat dissipation liner group.

3. The balanced liner high pressure air compressor according to claim 2, characterized in that: The noise reduction heat dissipation hole group and the heat dissipation lining group are each provided with four groups, and are evenly distributed.

4. The balanced liner high pressure air compressor according to claim 2, characterized in that: The diameter of the noise reduction and heat dissipation hole (11) is less than 0.8 cm.

5. The balanced liner high pressure air compressor according to claim 1 or 2, characterized in that: The heat dissipation and noise reduction mechanism is arranged on the outer wall of the cylinder body assembly and on the outer wall of the exhaust pipe of the intake assembly and the exhaust assembly.

6. The balanced liner high pressure air compressor according to claim 1, characterized in that: The cylinder block is assembled by the following steps: 1) Pre-treatment: Drill a small process hole at the exhaust hole of the cylinder body (6). The small process hole is located at the position of the product gas valve in the subsequent processing, and deburring is performed to facilitate exhaust during lining assembly; 2) Cylinder preheating: The cylinder (6) is heated to 200-220 degrees in a constant temperature box and maintained for 60 minutes; 3) Bushing cooling: Immerse the cylinder bushing in liquid nitrogen for 8-10 minutes; 4) Lining agent coating: When the temperature of the cylinder (6) is at 200-210°C, the lining agent is evenly coated on the inner wall thereof, and then the cylinder liner is assembled into the cylinder, and a certain pressure is applied for 1 minute using a motorized or manual press; 5) Cooling: Allow the assembled cylinder to cool naturally to complete the assembly.

7. The balanced liner high pressure air compressor according to claim 6, characterized in that: The fit between the cylinder body (6) and the cylinder body bushing is an interference fit, the interference amount is 0.1 mm, and the lining aid is Ergo4460.

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