Adjustable constant pressure air compressor

Abstract

The utility model relates to an adjustable constant pressure air compressor, including motor, the crankshaft of compressor is directly driven to rotate through the elastic coupling of motor, the crankshaft one end of compressor drives its link and piston reciprocating linear motion in respective cylinder, all cylinder group composed W type five cylinder structure, two parallel one stage cylinder, a two stage cylinder, a three stage cylinder and a four stage cylinder all with an interstage cooler, the interstage cooler is communicated with cooling fan, the crankshaft other end of compressor drives cooling fan sustained rotation through the pulley, the gas outlet of five stage cylinder connects rear cooler, the gas outlet of rear cooler connects gas water separation structure, and the gas water separation structure is equipped with electromagnetic blowdown valve, and the gas outlet of gas water separation structure connects exhaust pipe, and the exhaust pipe is equipped with check valve, the utility model discloses the exhaust pressure is 30.0MPa, and the adjustable pressure is 2.5Mpa to 30Mpa.

Description

Technical Field

[0001] This utility model relates to an adjustable constant pressure air compressor. Background Technology

[0002] Existing air compressor equipment operates at ambient temperature to a minimum of -25°C, with pressures only reaching between 0.7 MPa and 1.2 MPa. This is insufficient for de-icing and use in extremely cold regions, making such equipment unavailable in some working environments in frigid areas. Summary of the Invention

[0003] The purpose of this invention is to overcome the above-mentioned shortcomings and provide an adjustable constant pressure air compressor.

[0004] The purpose of this utility model is achieved through the following technical solution: An adjustable constant pressure air compressor includes an electric motor, which directly drives the crankshaft of the compressor to rotate through a flexible coupling. One end of the crankshaft of the compressor drives the connecting rod and piston on it to perform reciprocating linear motion in their respective cylinders. The cylinders include two parallel primary cylinders, one secondary cylinder, one tertiary cylinder, one quaternary cylinder, and one quinary cylinder, all of which form a W-type five-cylinder structure. The two parallel primary cylinders, one secondary cylinder, one tertiary cylinder, and one quaternary cylinder are all connected to an interstage cooler, which is connected to a cooling fan. The other end of the crankshaft of the compressor drives the cooling fan to rotate continuously through a pulley. The outlet of the quinary cylinder is connected to an aftercooler, and the outlet of the aftercooler is connected to a gas-water separation structure. The gas-water separation structure is equipped with an electromagnetic drain valve, and the outlet of the gas-water separation structure is connected to an exhaust pipe, which is equipped with a check valve.

[0005] A further improvement of this utility model is that an insulation cover is provided on the outside of the air compressor, and the insulation cover moves via a gear track.

[0006] A further improvement of this invention is that air enters two parallel first-stage cylinders through a filter and is compressed to an intermediate pressure by the piston.

[0007] A further improvement of this utility model is that the cylinder diameter of the first-stage cylinder is 140mm, the cylinder diameter of the second-stage cylinder is 100mm, the cylinder diameter of the third-stage cylinder is 60mm, the cylinder diameter of the fourth-stage cylinder is 35mm, and the cylinder diameter of the fifth-stage cylinder is 20mm.

[0008] This utility model has the following advantages compared with the prior art: This invention can meet the requirements of ultra-high pressure applications, with an exhaust pressure as high as 30.0 MPa and an adjustable pressure from 2.5 MPa to 30 MPa. It can be set via PLC and can autonomously adjust the required working pressure according to the set conditions.

[0009] This invention utilizes an electronic pressure sensor and PID control, employs a check valve installed at the air compressor outlet for overpressure protection, and is controlled by a PLC. The pressure can be adjusted within the rated pressure range as needed. This invention features a simple structure, controllable cost, and basic pressure control near the set point. Through multi-stage pressurization, the pressure is increased to 30 MPa and stored in 12 high-pressure cylinders for later use.

[0010] To address the impact of low-temperature operating environments on air compressors, an openable or closable insulation cover is now provided. The temperature inside the insulation cover remains constant between 25℃ and 30℃ throughout the year, ensuring the stable operation of the air compressor. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the structure of this utility model; Figure 3 This is a schematic diagram of the structure of the present invention with a heat insulation cover; The following components are labeled in the diagram: Electric motor-1, Flexible coupling-2, Compressor-3, First-stage cylinder-4, Second-stage cylinder-5, Third-stage cylinder-6, Fourth-stage cylinder-7, Fifth-stage cylinder-8, Interstage cooler-9, Cooling fan-10, Aftercooler-11, Air-water separation structure-12, Electromagnetic drain valve-13, Exhaust pipe-14, Check valve-15, Filter-16, Insulation cover-17, Gear track-18. Detailed Implementation

[0012] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions in the embodiments of this utility model will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Elements and features described in one embodiment of this utility model can be combined with elements and features shown in one or more other embodiments. It should be noted that, for clarity, representations and descriptions of components and processes unrelated to this utility model and known to those skilled in the art are omitted in the description. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model.

[0013] An adjustable constant pressure air compressor includes an electric motor 1, which directly drives the crankshaft of a compressor 3 to rotate via a flexible coupling 2. One end of the crankshaft of the compressor 3 drives a connecting rod and a piston to perform reciprocating linear motion within their respective cylinders. The cylinders include two parallel primary cylinders 4 (each with a diameter of 140mm), a secondary cylinder 5, a tertiary cylinder 6, a quaternary cylinder 7, and a quinary cylinder 8. All cylinders form a W-type five-cylinder structure, wherein the two parallel primary cylinders 4, a secondary cylinder 5, a tertiary cylinder 6, a quaternary cylinder 7, and a quinary cylinder 8... The second-stage cylinder 5, a third-stage cylinder 6, and a fourth-stage cylinder 7 are all connected to an interstage cooler 9. The interstage cooler 9 is connected to a cooling fan 10. The other end of the crankshaft of the compressor 3 drives the cooling fan 10 to rotate continuously via a pulley. The outlet of the fifth-stage cylinder 8 is connected to the aftercooler 11. The outlet of the aftercooler 11 is connected to the gas-water separation structure 12. The gas-water separation structure 12 is equipped with an electromagnetic drain valve 13. The outlet of the gas-water separation structure 12 is connected to the exhaust pipe 14. The exhaust pipe 14 is equipped with a check valve 15.

[0014] An insulation cover 17 is provided on the outside of the air compressor. The insulation cover 17 is moved by the gear track 18 to open or close the insulation cover 17, which solves the problem of the impact of low temperature working environment on the air compressor. The temperature inside the insulation cover is kept constant between 25℃ and 30℃ throughout the year, ensuring the stable operation of the air compressor.

[0015] The power transmission and drive of this utility model are as follows: A 55kW electric motor 1 directly drives the crankshaft of the compressor 3 to rotate via a flexible coupling 2. The crankshaft of the compressor 3 drives the connecting rod and piston on it to perform reciprocating linear motion within the cylinder. At the same time, the other end of the crankshaft of the compressor 3 drives the cooling fan 10 to rotate continuously via a pulley.

[0016] The air compression and cooling cycle of this invention is as follows: First-stage compression: Air enters two parallel first-stage cylinders 4 through filter 16 and is compressed to an intermediate pressure by the piston. The compression process generates heat.

[0017] Cooling and oil separation: The discharged high-temperature compressed air from the first stage enters the interstage cooler 9 and is cooled by the cold air blown in by the cooling fan 10. After cooling, the lubricating oil mist contained in the air will condense and be discharged through the electromagnetic drain valve 13 (automatic or manual). While the splash lubrication system lubricates the moving parts, it cannot avoid allowing some lubricating oil to participate in the compression process.

[0018] The process proceeds in stages: the cooled, low-temperature air then enters the second-stage cylinder 5 (100mm diameter) for recompression, and then is cooled and separated again... This process is repeated through the third-stage cylinder 6 (60mm diameter), the fourth-stage cylinder 7 (35mm diameter), and finally enters the fifth-stage cylinder 8 (20mm diameter).

[0019] Final compression: In the fifth stage, the air is compressed to a final pressure of 30 MPa. Since the pressure has been increased step by step in the first four stages and the exhaust temperature of each stage has been effectively controlled, the fifth stage only needs to complete the final pressure increase under relatively reasonable operating conditions.

[0020] Final processing and output: The ultra-high pressure air discharged from the fifth stage is still at a very high temperature. It enters the aftercooler 11 for final cooling. The small amount of moisture and oil that may be contained in the cooled high pressure air is separated in the gas-water separation structure 12 and discharged through the electromagnetic drain valve 13. Finally, the pure and dry ultra-high pressure air is output through the check valve (to prevent backflow of high pressure gas) and can be filled into 12 gas cylinders or directly supplied to the equipment through a 50-meter pressure-resistant gas pipe.

[0021] The working principle of an air compressor is essentially a progressive energy transfer and gas density increase process of "compression-cooling-recompression". Through a sophisticated W-type five-cylinder structure, integrated air-cooling system and basic automatic control, the core engineering and technical challenges of high temperature, high load and high risk brought about by compressing air to ultra-high pressure of 30MPa have been successfully solved.

[0022] Finally, it should be noted that although the present invention and its advantages have been described in detail above, it should be understood that various changes, substitutions, and modifications can be made without departing from the spirit and scope of the present invention as defined by the appended claims. Furthermore, the scope of the present invention is not limited to the specific embodiments of the processes, apparatus, means, methods, and steps described in the specification. Those skilled in the art will readily understand from the disclosure of the present invention that existing and future processes, apparatus, means, methods, or steps that perform substantially the same functions or obtain substantially the same results as the corresponding embodiments described herein can be used according to the present invention. Therefore, the appended claims are intended to include such processes, apparatus, means, methods, or steps within their scope.

Claims

1. An adjustable constant pressure air compressor, characterized in that: The compressor (3) is powered by an electric motor (1) which directly drives the crankshaft of the compressor (3) to rotate via a flexible coupling (2). One end of the crankshaft of the compressor (3) drives the connecting rod and piston on it to reciprocate linearly within their respective cylinders. The cylinders include two parallel primary cylinders (4), one secondary cylinder (5), one tertiary cylinder (6), one quaternary cylinder (7), and one quinary cylinder (8). All the cylinders form a W-type five-cylinder structure, in which the two parallel primary cylinders (4), one secondary cylinder (5), one tertiary cylinder (6), and one quinary cylinder (8) form a W-type five-cylinder structure. Each of the four-stage cylinders (7) is connected to an interstage cooler (9), which is connected to a cooling fan (10). The other end of the crankshaft of the compressor (3) drives the cooling fan (10) to rotate continuously via a pulley. The outlet of the fifth-stage cylinder (8) is connected to the aftercooler (11), and the outlet of the aftercooler (11) is connected to the gas-water separation structure (12). The gas-water separation structure (12) is equipped with an electromagnetic drain valve (13), and the outlet of the gas-water separation structure (12) is connected to the exhaust pipe (14). The exhaust pipe (14) is equipped with a check valve (15).

2. The adjustable constant pressure air compressor according to claim 1, characterized in that: The air compressor is provided with an insulation cover (17) on the outside, and the insulation cover (17) moves through a gear track (18).

3. An adjustable constant pressure air compressor according to claim 1, characterized in that... Air enters two parallel first-stage cylinders (4) through a filter (16) and is compressed to an intermediate pressure by the piston.

4. An adjustable constant pressure air compressor according to claim 1, characterized in that: The diameter of the first-stage cylinder (4) is 140mm, the diameter of the second-stage cylinder (5) is 100mm, the diameter of the third-stage cylinder (6) is 60mm, the diameter of the fourth-stage cylinder (7) is 35mm, and the diameter of the fifth-stage cylinder (8) is 20mm.

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