System for compressing a working fluid with a piston mechanism

Abstract

A mechanical system with a piston mechanism is designed for compressing working fluid in either a gaseous or liquid state. The system includes a cylinder-piston group, a piston rod, a roller or sliding element, and a rotor with a shaft. The rotor features at least two circular profiles along its circumference, inclined at specific angles. The roller or sliding element, connected to the piston rod, interacts with these profiles. As the rotor rotates, the inclined profiles move the roller or sliding element, which then converts the rotor's circular motion into linear piston movement within the cylinder. The rotor is connected to a drive motor via its shaft. The length of the piston stroke depends on the angle of inclination and the length of the circular arc of the profile intended for compressing the fluid.A special calculation of regressions determines the design of the circular profiles on the rotor, their inclinations and the length of the corresponding circular arcs, as well as the mechanical advantages (M.A.) applied in this mechanical system.

Description

SYSTEM FOR COMPRESSING A WORKING FLUID WITH A PISTON MECHANISMFIELD OF THE INVENTION

[0001] The present disclosure relates to an improved mechanical system for transforming circular motion into rectilinear motion, and more particularly, a mechanical system featuring a specially designed rotor in the form of a right cylinder or disc, with circular inclined profiles. By rotating the rotor of this new mechanism, which is connected via a rotor shaft to the driving machine, a linear movement of the piston in the cylinder is achieved, increasing the pressure of the working fluid of a certain mass and volume. When used to compress gaseous fluids, embodiments of the present disclosure are compressors, while for liquid fluids, embodiments of the present disclosure are hydraulic pumps. Embodiment in accordance with the present disclosure may be applied to all piston devices and machines that use a piston as the basic element for increasing the pressure of working fluids.BACKGROUND OF THE INVENTION

[0002] As technology has advanced, so has the development of devices for compressing working fluids. Over time, these devices were designed to meet greater and more demanding conditions, leading to the development of different types. Today, various types of these devices exist, such as reciprocating, rotary screw, and rotary centrifugal compressors and pumps. These types can be further specified depending on the number of stages of fluid compression, the cooling method (air, water, or oil), the drive method (internal combustion engine, electric motor, etc.), and the lubrication method (oil or oil-free).

[0003] Standard devices for compressing fluids and increasing pressure, which are based on the circular movement of the crankshaft and its transmission to the linear movement of the piston, use classical configurations. These configurations represent standard solutions and serve as the basis for various designs of piston devices that use external drive machines for propulsion. The construction of these versions of compressors and hydraulic pumps is well-known and thoroughly developed in practice. Standard piston systems use an external drive mechanism to rotate thecrankshaft, where half a revolution of the crankshaft moves the piston through its entire stroke. This results in low utilization and efficiency of the device, limiting further development possibilities.

[0004] In recent years, several attempts have been made to address these shortcomings, particularly by manufacturers aiming to develop devices with better characteristics and greater efficiency. This mainly involves improving the cylinderpiston group with better thermodynamic solutions and improved valve constructions. However, there have been few attempts to develop compressors and hydraulic pumps with better technical solutions in the transmission system required to compress the working fluid from the shaft to the piston. The piston is a key element for fluid intake, pressure increase, and discharge of compressed fluid from the cylinder.

[0005] The main characteristics of these systems derive from the current state of the art, where:• Forces in the fluid compression phase act on the piston, resisting its movement, which is connected to the crankshaft via the connecting rod. At the same time, one full stroke of the piston corresponds to half a turn of the crankshaft.• These characteristics highlight significant shortcomings of this technical solution, preventing current piston devices from providing better operational efficiency.• Additionally, there are significant thermodynamic losses during operation that adversely affect the overall efficiency and effectiveness of the device.

[0006] Accordingly, there is a desire to provide a system for transforming the circular motion of the shaft into the rectilinear motion of the piston without the shortcomings of the prior art.SUMMARY OF THE INVENTION

[0007] Embodiments in accordance with the present disclsoure represent a significant improvement and utilization of reciprocating compressors and hydraulic piston pumps for the production of gases under pressure and the achievement ofworking pressures of liquid fluids, achieving significant energy savings. The disclosed embodiments enable the creation of a new piston mechanism that can use different standard drive machines and systems, including all known drive systems that can develop the required force on the shaft of the piston device. The application of this innovation results in significantly better utilization of the drive motor, substantial fuel savings in the operation of the drive motor when it is an internal combustion engine, and significantly lower electricity consumption when the drive machine is an electric motor. This innovation enables operation at a lower speed regime compared to standard versions, achieving greater force for compressing the fluid with significantly lower energy consumption and thermodynamic losses.

[0008] Embodiments in accordance with the present disclsoure introduce a new solution that transfers the rotational movement of the rotor in a unique manner to the linear movement of the piston in the cylinder, replacing the classic connecting rod with a fixed piston bar and the standard crankshaft with a shaft carrying the rotor. The rotor can be in the form of a right circular cylinder, disc, or other circular shapes. Embodiments in accordance with the present disclsoure include at least one group of cylinders / pistons, a piston rod connected to the piston at one end and a rolling or sliding element at the other end, and a specially constructed rotor connected to the external drive machine by its shaft. The rotor features at least two different circular profiles made around its circumference at different angles of inclination. The rolling or sliding element is always in contact with the working surfaces of these rotor profiles, rolling or sliding on them.

[0009] One of these profiles on the rotor is determined by calculating the linear regression for the angle of inclination and the length of the circular arc. This profile, realized by the obtained circular arc, represents the part of the rotor through which the fluid is compressed. Furthermore, the calculation of the mechanical advantage (MA) is crucial in constructing this profile. The MA ratio is important for the construction of this innovative device as it determines the relationship between the forces resisting the piston's movement during fluid compression and the power from an external source on the rotor shaft necessary to overcome all resistances during operation. The piston's stroke length is independent of the rotor's radius.

[0010] In practice, this means that with the application of mechanical advantage (MA), the force required for the piston to operate during the compression phase is significantly lower than in classical piston compressor designs of the same characteristics. This can be achieved by applying the results of a regression calculation for the angle of the inclined circular profile on the rotor intended for fluid compression in the cylinder. At the same time, the mechanical advantage (calculated by the expression 1 / sin(0°)) gives the relationship between the resistance forces and the force provided by the driving machine to overcome all operational resistances. The desired optimal mechanical advantage will determine the angle of inclination of this compression profile, its length around the rotor's circumference, and the rotor's diameter.

[0011] The second inclined circular profile on the rotor is intended for the suction phase of the fluid into the cylinder. This profile is made along a circular arc connecting the ends of the compression profile. An important characteristic of the rotor design is the possibility to connect the ends of these profiles with additional profiles that do not cause piston displacement while the roller / slid ing element is on them. This is significant because it allows the piston to stop moving when it is at Top Dead Center (T.D.C.) and Bottom Dead Center (B.D.C.). In these positions, the piston is not affected by the rotor's rotation along these profiles.

[0012] When the piston is at T.D.C. , the compressed fluid is completely expelled from the cylinder. The piston stop period is determined by the length of the circular arc of the profile, based on the discharge valve's reaction speed, i.e. , the time required for the valve to close completely. The piston remains at rest, preventing the return of some displaced fluid into the cylinder, which cannot be avoided in current classical devices and represents a volumetric loss in operation. The profile that keeps the piston at B.D.C. works on the same principle, with its length determined by the optimal cylinder filling time and the intake valve's reaction time.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present disclosure is better understood reading the written desription with refernce to accompanying drawings figures in which the reference numerals denote the similar structures and refer to the elements throughout in which:

[0014] Fig.1 is an schematic view of the first embodiments of a system in accordance with the invention;

[0015] Fig. 2 shows an example of the execution of inclined circular profiles around the circumference of the rotor (5) with the application of angle regression calculations;

[0016] Fig. 3 is an schematic example of a system configuration with several cylinders symmetrically arranged around the rotor (5);

[0017] Fig. 4 is an schematic example of the configuration of a multi-stage fluid compression system;

[0018] Fig. 5 is a cross-section view of the system with a disk-shaped rotor (5). On the circumference of the disk, there are inclined profiles along which the roller (4) rolls and which is always in contact with the surface of the profile;

[0019] Fig. 6 shows a schematic cross-section of the system where two parallel rotor-discs (5) are placed on the same shaft (8), each with a corresponding group of cylinders;

[0020] Fig. 7A shows a schematic cross-section of the system with a cylinder (3) placed vertically on the inclined profiles of the rotor (5) and Fig. 7B shows a schematic view of the rotor(5) with inclined circular profiles.

[0021] Fig. 8 shows a schematic example of the performance of the rotor profiles 9 and 10 by which the piston (1 ) rests in T.D.C. and in B.D.C. during the rotation of the rotor (5);

[0022] Fig. 9 shows a schematic view of the rotor in the form of a right circular cylinder with grooved profiles around the circumference;

[0023] Fig. 10 is an schematic section view of the system with the application of another possible design of the rotor (15), which is in the form of a cylinder, as shown in Fig. 9;

[0024] Fig. 11 shows the schematic design of the system as shown in Fig. 10, where on the rotor (15) the joining of two inclined profiles (16 and 17) is performed with an additional profile (19) which is completely horizontal for a certain length; and

[0025] Fig. 12 is an schematic construction of the system with a rotor (15) in the form of a longer right cylinder, which has grooved profiles along its circumference for compressing and suctioning fluid.DETAILED DESCRIPTION

[0026] Embodiments in accordance with the present disclosure present a new system that use a particular way for transferring the rotational movement of the rotor to the linear movement of the piston in the cylinder. This solution is intended for application to piston compressors and hydraulic piston devices in order to obtain a more efficient and economical use of external energy for work. At the same time, all standard characteristics of the device, such as capacity and pressure, reliability, as well as other necessary characteristics, should be maintained. The system uses a especially constructed rotor whit at least two different circular and inclined profiles which were derived from the calculation of linear regression of angles and circular arcs. These profiles are always in contact with the rolling or sliding element, which is connected via a rod with a piston. The rotor is connected to the drive machine via its shaft. During rotation, the rotor acts on the roller by its inclined profiles and thereby moves the piston in the cylinder.

[0027] Reference is first made to Fig.1, which shows a schematic basic example of a system configuration where the cylinder (3) and the piston (1 ) are components of a standard reciprocating compressor, while the piston rod is here replaced by a fixed rod (2) and the crankshaft is replaced by a rotor (5). The transmission of force from the shaft (8) of the rotor (5) to the piston (1 ) in the phase of fluid compression takes place via the inclined circular profile (6) around the circumference of the rotor (5). Thesecond inclined circular profile (7) serves for the suction phase and connects the ends of the compression profile (6). The roller (4) is connected to the rod (2). The roller (4) is always in contact with the rotor profiles. In the phase of fluid compression, which takes place on profile 6, piston(1 ) moves linearly in cylinder (3) towards top dead center (T.D.C.) due to the inclination of profile 6, which pushes the piston (1 ) and thus compresses the fluid, by means of rollers (4).

[0028] Reference is now made to Fig.2, which shows an example of the execution of inclined circular profiles around the circumference of the rotor (5) with the application of angle regression calculations. In the example shown, the profile intended for the compression phase (6) extends around the circumference of the rotor (5) for a 270°. The profile intended for the intake phase (7) extends around the circumference of the rotor (5) for a 90°. The extension of the profiles depends on the design requirements and the necessary characteristics of the device. Both profiles are developed along the corresponding circular arcs "L1" and "L2", along with the slopes of the angles "a" and "I3>". "R2" represents the given radius of the rotor (5) from which the compression profile (6) is derived from the point "A", with an angular slope "a" and for the length of the arc "L1". "R1" represents the radius described by point "B" and which marks the end of the profile for the compression phase (6). The difference between the radii of R1 and R2 represents the stroke length of the piston "h". By connecting points "A" and "B" with a circular arc "L2", a inclined profile (7) for the intake phase is obtained.

[0029] Fig. 3 shows an example of a system configuration with several cylinders symmetrically arranged around the rotor (5). Depending on the need, a system with several cylindrical groups symmetrically distributed around the rotor (5) can be implemented. All cylinders operate on the same rotor profiles.

[0030] As seen in Fig. 4, a system in accordance with the present disclosure may include a configuration of a multi-stage fluid compression system, which includes one cylinder with a larger volume (3a) and one cylinder with a smaller volume (3b). The pistons in the cylinders have the same stroke length. The larger volume cylinder (3a) serves to raise the pressure of the fluid in the first stage of compression and empties into the low-pressure intermediate tank (9). The smaller volume cylinder (3b) is filled in the suction phase from the low-pressure intermediate tank (9) and during thecompression phase delivers fluid under high pressure to the main tank (10) from which the fluid is distributed to the work processes.

[0031] Fig. 6 shows a schematic cross-section of the system where two parallel rotor-discs (5) are placed on the same shaft (8), each with a corresponding group of cylinders. If necessary, it is possible to place several disks with the corresponding groups of cylinders on the same shaft.

[0032] Fig. 7A shows a schematic cross-section of the system with a rotor that has raised profiles around its circumference. Cylinder (3) is placed radially on the inclined surface of one of the rotor profiles (5). Fig. 7B shows a schematic view of the rotor(5) with raised circular profiles.

[0033] An additional feature of embodiments in accordance with the present disclosure is the ability to stop the piston at T.D.C. and B.D.C. This is an advantageous feature because stopping the piston at T.D.C. ensures complete emptying of the cylinder and prevent the fluid that is under pressure to return to the cylinder. In order to achieve this, two additional profiles were made on the rotor. Fig. 8 shows a schematic example of the design of the rotor profile 9 and 10 by which the piston (1 ) rests in T.D.C. and B.D.C. during the rotation of the rotor (5). Profile 10 come's from the circular arc derived from the radius "R2". The length of that profile depends on the angle " I3> ". The stop period of the piston in T.D.C. is determined by the length of the profile 10 which is in relation to the reaction speed of the discharge valve, i.e. , the time required for the valve to close completely. At the same time, the piston is at rest and prevents the return of a certain amount of displaced fluid into the cylinder.

[0034] The profile 9 of the rotor (5) keeps the piston (1 ) at rest in the B.D.C. The length of this circular profile is achieved by the circular arc derived from the radius "R1". The length of that profile depends on the angle “ a ” which is in relation to the time required for optimal filling of the cylinder with fluid and the reaction time of the intake valve.

[0035] An additional version of this system is presented in Fig. 10, where the system is shown schematically with the application of another possible design of the rotor (15), which is in the form of a cylinder, as shown in Fig. 9. The rotor (15) has a groove (14) around its circumference, which is made with parallel inclined profiles (16, 17). The groove (14) ensures that the roller (4) is in constant contact with the working surfaces of the inclined profiles. In the phase of fluid compression, due to the rotation of the rotor (15), the working surface of the profile (16), by means of the roller (4) and the rod (2), moves the piston (1 ) in the cylinder (3) towards the T.D.C. During the suction phase the working surface of the profile (17) acts on the roller (4). The roller (4) pulls the rod (2) and the piston (1 ) towards the B.D.C., during which the suction of fluid into the cylinder (3) takes place.

[0036] Fig. 11 shows the schematic design of the system as shown in Fig. 10, where on the rotor (15) the joining of two inclined profiles (16 and 17) is performed with an additional profile (19) which is completely horizontal for a certain length. This allows the piston (1 ) to stop in the T.D.C. during the passage of this profile along the roller (4). The same is done at the other end of the inclined profiles, where the additional profile (20) allows the piston (1 ) to stop in the B.D.C. The need for this solution arises from what has already been described in relation to Fig. 8.

[0037] The additionally developed system represents a design where the rotor is in the form of a longer right cylinder around the circumference of which a spiral groove is made. As can be seen from the Fig. 12, rotor (15) is in the form of a right cylinder, which has grooved profiles along its circumference for compressing and suction of the fluid (as can be seen from the Figure 10). The compression profile (16) extends spirally, like a thread, around the circumference of the rotor, while the fluid suction profile (17) extends along a circular arc that connects the ends of the compression profile (16). Depending on the height of the rotor, the compression profile can be stretched spirally in several threads around the circumference of the rotor. The suction profile (17) intersects the compression profile (16). This construction of the rotor enables the compression profile to develop maximally around the circumference of the rotor, which leads to a longer stroke of the piston (1 ). This also means that the entire stroke of the piston (h) in the compression phase will be performed in morerevolutions of the rotor(15), while the same stroke (h) of the piston in the suction phase will be performed in less revolutions of the rotor.

[0038] In the described manner, embodiments in accordance with the present disclosure enable the development and construction of reciprocating compressors as well as other reciprocating devices for increasing fluid pressure with greater efficiency and with significantly reduced energy consumption required for operation. At the same time, embodiments in accordance with the present disclosure contribute to lower working temperatures in operation, which contributes to the reduction of thermodynamic losses as well as less impact on the environment.

[0039] While the present disclosure has been particularly described, in conjunction with specific preferred embodiments, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present disclosure.

Claims

PATENT CLAIMS1 . A mechanical system, comprising: a piston mechanism having a piston and a cyclinder configured for compressing a working fluid in a gaseous or liquid state, characterized by a linear displacement of the piston in the cylinder being caused by the rotation of a rotor, wherein: the rotor features at least two fundamental and distinct circular profiles along its perimeter with working surfaces inclined at specific angles, a roller or sliding element, which is connected to the piston through a rod, is always in contact with the working surfaces of the profiles, a rotation of the rotor, through the inclined profiles, imparts motion to the roller or sliding element, which, via the piston rod, converts the rotational motion of the rotor into linear motion of the piston, and the rotor has a shaft connected to a driving machine.

2. The mechanical system of claim 1 , wherein the rotor is in the form of a disk or a cyclinder.

3. The mechanical system of claim 1 , characterized by one of the inclined circular profiles of the rotor being intended for driving the piston during the fluid compression phase, while the other inclined circular profile of the rotor is intended for the intake of fluid into the cylinder.

4. The mechanical system of claim 1 , characterized by use of linear regression calculations to determine an angle of inclination and a length of a circular arc along which the profile for increasing fluid pressure develops around the rotor.

5. The mechanical system of claim 4, wherein, for the fluid intake phase into the cylinder, a different inclined circular profile is used.

6. The mechanical system of claim 5, wherein the different inclined profile is constructed along a circular arc that connects ends of the profile for increasing pressure.

7. The mechanical system of claim 6, characterized by a mechanical advantage (MA) being calculated based on the angle of inclination of the profile for increasing fluid pressure, wherein the MA determines the relationship between a force required to operate the piston during the fluid compression phase and all opposing forces that cause resistance to piston movement in this phase.

8. The mechanical system of claim 6, characterized by a piston stroke length being dependent on a design of the profile intended for increasing pressure, its circular arc length, and the angle of inclination.

9. The mechanical system of claim 1 , characterized by a length of the circular arc along which the circular profile for increasing fluid pressure develops being adjusted along the perimeter of the rotor based on specific requirements for an optimal operation of the mechanical system.

10. The mechanical system of claim 1 , characterized by multiple piston mechanisms configured for a multi-stage fluid compression process.11 . The mechanical system of claim 10, wherein cylinders for lower compression stages are mounted on the same rotor with cylinders for higher compression stages.

12. The mechanical system of claim 11 , wherein cylinders for lower pressure stages have larger volumes and cylinders for higher pressure stages have smaller volumes.

13. The mechanical system of claim 11 , wherein all cylinders are arranged around the rotor, which, through its rotation, drives movement of the pistons within the cylinders.

14. The mechanical system of claim 13, wherein a piston stroke length is the same in all cylinders.

15. The mechanical system of claim 1 , characterized by having multiple discshaped rotors mounted in parallel on a same shaft, each disc-shaped rotor having a diameter and profile characteristics configured to drive a corresponding group of pistons.

16. The mechanical system of claim 1 , characterized by additional profiles selected for maintaining the piston position at top dead center (TDC) and bottom dead center (BDC) in the construction of the inclined circular profiles along the perimeter of the rotor, wherein the additional profiles connect ends of a compression profile and a fluid intake profile in such a way that the circular arc along which they develop does not affect the movement of the piston during the rotor's rotation, but keeps it stationary while these profiles move along the roller or sliding element.

17. The mechanical system of claim 16, wherein a length of the circular arc of the profile for holding the piston at TDC is determined in relation to the reaction speed of the discharge valve to fully close.

18. The mechanical system of claim 1 , characterized by a rotor in the shape of a cylinder constructed such that its circumference has grooved and inclined circular profiles, one of which is intended for compressing the fluid.

19. The mechanical system of claim 18, wherein the one inclined circular profile spirals around the rotor's circumference at a specific angle of inclination and extends along the rotor like a thread.

20. The mechanical system of claim 19, wherein an other inclined circular profile is intended for fluid intake into the cylinder and is constructed along a circular arc connecting ends of the fluid-compressing profile, wherein the other inclined circular profile is not of the same length as the compressing profile but is significantly shorter.

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