Capacity control for diaphragm compressor
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2026-02-05
- Publication Date
- 2026-08-13
Smart Images
Figure IB2026051097_13082026_PF_FP_ABST
Abstract
Description
Attorney Docket No. 1490.0184i CAPACITY CONTROL FOR DIAPHRAGM COMPRESSOR CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of U.S. Patent Application No.19 / 048,050, entitled “CAPACITY CONTROL FOR DIAPHRAGM COMPRESSOR,” filed February 7, 2025, the entire disclosure of which is hereby incorporated by reference in its entirety for all purposes.FIELD OF INVENTION
[0002] The present invention relates to the field of diaphragm compressors and, in particular, to techniques for controlling the capacity of a diaphragm compressor by adjusting a hydraulic flow or volume.BACKGROUND
[0003] Diaphragm compressors include a diaphragm and are capable of generating pressure differentials, e.g., by flexing and / or oscillating the diaphragm. The pressure differentials are sufficient to create an intake stroke and an output stroke to act on a working fluid. The diaphragm in a diaphragm compressor also separates a hydraulic fluid side, e.g., an oil side, from a gas or working fluid side, e.g., a gas side. Pressure changes in the oil and / or the working fluid may move the diaphragm through an intake and / or an output stroke. For example, a piston may oscillate on the oil side to change the pressure of the oil and cause the diaphragm to compress and exhaust working fluid.
[0004] Changing the capacity of a diaphragm compressor may be necessary due to process flow requirements, suction or discharge requirements, pressure management, and / or load management. Existing methods used to alter the effective capacity of a positive displacement diaphragm compressor generally involve actuating the flow of working fluid and / or altering the volume of compressed working fluid.Attorney Docket No. 1490.0184i
[0005] Controlling the capacity of a diaphragm compressor by actuating the flow of working fluid and / or altering the volume of compressed working fluid may have an adverse effect on the operation of the compressor. For example, reverse flow may occur, and may cause relatively high frequency pressure pulsations. In addition, the power consumed by a diaphragm compressor in order to control capacity by actuating working fluid and / or altering working fluid volume may be relatively high and, therefore, inefficient.SUMMARY
[0006] Techniques for controlling the capacity of a diaphragm compressor are disclosed. These techniques may be embodied as one or more methods, one or more apparatuses, e.g., capacity control assemblies, and / or one or more systems, e.g., diaphragm compressors.
[0007] In accordance with at least one embodiment, the disclosure is directed to a diaphragm compressor system that comprises a diaphragm compressor, the diaphragm compressor having a cavity defined therein and including a diaphragm, a piston, and a hydraulic fluid flow loop containing a hydraulic fluid. The diaphragm is positioned within the cavity to separate a working fluid side of the cavity from a hydraulic fluid side of the cavity, and the piston and the hydraulic fluid cause the diaphragm to displace within the cavity as the piston travels. The diaphragm compressor system also includes an actuator coupled to the hydraulic fluid flow loop and a drain module, e.g., an atmospheric sump. The actuator is further coupled to the drain module and configured to cause a first amount of the hydraulic fluid to be released from the hydraulic fluid flow loop into the drain module. The amount of the hydraulic fluid is released from the hydraulic fluid flow loop to control a capacity of the working fluid side of the cavity.
[0008] According to another embodiment, a system includes a diaphragm compressor, an actuator, and a drain arrangement. The diaphragm compressor has a cavity defined therein that includes a working fluid side and a hydraulic fluid side, and includes a diaphragm and aAttorney Docket No. 1490.0184i hydraulic fluid flow loop. The diaphragm is positioned to separate the working fluid side and the hydraulic fluid side, wherein the hydraulic fluid loop contains a hydraulic fluid that causes the diaphragm to displace. The actuator is coupled to the hydraulic fluid flow loop and to the drain arrangement, and is configured to be activated to cause a first amount of the hydraulic fluid to be released from the hydraulic fluid flow loop into the atmospheric sump to control a capacity of the working fluid side.
[0009] In accordance with still another aspect, a method for controlling a capacity of a diaphragm compressor that has a cavity defined therein having a working fluid side and a hydraulic fluid side, and includes a diaphragm arranged to separate the working fluid side and the hydraulic fluid side, includes determining when a condition in the cavity is met. When it is determined that the condition in the cavity is met, the method includes activating an actuator to cause a first amount of a hydraulic fluid to be released from a hydraulic fluid flow loop of the diaphragm compressor into a drain module. Causing the first amount of the hydraulic fluid to be released from the hydraulic fluid flow loop enables the capacity to be controlled.
[0010] These and other advantages and features will become evident in view of the drawings and detailed description.BRIEF DESCRIPTION OF THE DRAWINGS
[0011] To complete the description and in order to provide for a better understanding of the present disclosure, a set of drawings is provided. The drawings form an integral part of the description and illustrate an embodiment of the present disclosure, which should not be interpreted as restricting the scope of the disclosure, but just as an example of how the disclosure may be carried out. The drawings comprise the following figures:
[0012] FIG. 1 is a block diagram representation of a diaphragm compressor.
[0013] FIG. 2A is a diagrammatic representation of a diaphragm compressor at the beginning of an operating cycle with a piston at a bottom of a stroke.Attorney Docket No. 1490.0184i
[0014] FIG. 2B is a diagrammatic representation of a diaphragm compressor, e.g., diaphragm compressor 200 of FIG. 2A, with apiston, e.g., piston 210 of FIG. 2A, at the top of a stroke.
[0015] FIG. 3 is a diagrammatic representation of a diaphragm compressor system or assembly which includes drain module or arrangement, e.g., an atmospheric sump, and a hydraulic fluid source, e.g., oil source, that are directly coupled in accordance with an embodiment.
[0016] FIG. 4 is a diagrammatic representation of a diaphragm compressor system which includes an atmospheric sump and a hydraulic fluid source, e.g., an oil source, that are not directly coupled in accordance with an embodiment.
[0017] FIG. 5 is a diagrammatic representation of a diaphragm compressor system which includes an atmospheric sump in accordance with an embodiment.
[0018] FIG. 6 is a diagrammatic representation of a hydraulic fluid flow loop of a diaphragm compressor that is configured to release hydraulic fluid to an atmospheric sump in accordance with an embodiment.
[0019] FIGs. 7A, 7B, and 7C are a process flow diagram which illustrates a method of operating a diaphragm compressor that is configured to release hydraulic fluid to an atmospheric sump in accordance with an embodiment.
[0020] FIG. 8 is a diagrammatic representation of a hydraulic fluid flow loop of a diaphragm compressor that is configured to release hydraulic fluid to a pressurized sump in accordance with an embodiment.
[0021] FIG. 9 is a block diagram representation of a diaphragm compressor system that includes a motor configured to drive a piston in accordance with an embodiment.
[0022] FIG. 10A is a block diagram representation of a diaphragm compressor system that includes an extra piston driven by a system configured to facilitate the release andAttorney Docket No. 1490.0184i replenishment of a hydraulic fluid within the diaphragm compressor in accordance with an embodiment.
[0023] FIG. 10B is a block diagram representation of a diaphragm compressor system that includes an extra piston driven by a crankshaft of the diaphragm compressor configured to facilitate the release and replenishment of a hydraulic fluid within the diaphragm compressor in accordance with an embodiment.
[0024] Like reference numerals have generally been used to identify like elements throughout this disclosure.DETAILED DESCRIPTION
[0025] The following description is not to be taken in a limiting sense but is given solely for the purpose of describing the broad principles of the disclosure. Embodiments of the disclosure will be described by way of example, with reference to the above-mentioned drawings showing elements and results according to the present disclosure.
[0026] Generally, the present disclosure describes techniques for controlling the capacity of a diaphragm compressor by releasing a hydraulic fluid to maintain a desired capacity. Releasing hydraulic fluid, e.g. , oil, from a hydraulic fluid flow loop of a diaphragm compressor when a piston of the diaphragm compressor travels from a bottom dead center position, or towards a top dead center position, controls a capacity of the compressor without causing a diaphragm to move and / or without compressing working fluid, e.g., gas. The released hydraulic fluid may be routed to an atmospheric pressure sump. In some instances, the hydraulic fluid may be replenished when the piston travels towards the bottom dead center position. For example, a hydraulic fluid source may effectively inject hydraulic fluid into the hydraulic fluid flow loop.
[0027] Referring initially to FIG. 1, a diaphragm compressor will be described. A diaphragm compressor 100 is a reciprocating compressor that includes a mechanical frame 102,Attorney Docket No. 1490.0184i a diaphragm head 106, a piston arrangement 110, and an oil flow through limiter 116. Mechanical frame 102 supports a lubrication oil pump 102a, a compensating pump 102b, a crankshaft 102c, a connecting rod 102d, a crosshead 102e, and a sump 102f. Diaphragm head 106, or a cylinder, includes an oil pressure limiter 106a, an inlet check valve 106b, an outlet check valve 106c, and a diaphragm 106d. Diaphragm 106d, or a flexible membrane, generally includes a gas side diaphragm 112a, an intermediate diaphragm 112b, and an oil side diaphragm 112c (e.g., different diaphragm layers) or may include a single diaphragm body with a working fluid side and a hydraulic fluid, e.g, an oil side. Piston arrangement 110 includes piston rings 110a, e.g., seals, and a piston 110b.
[0028] Diaphragm 106d is arranged inside diaphragm head 106 such that a gas side and an oil side are effectively created within diaphragm head 106. Diaphragm 106d generally separates the gas side from the oil side, or a hydraulic fluid side. The gas side is arranged to contain compressed gas, and the oil side is arranged to contain oil. The volume of the gas side may vary based on the position of diaphragm 106d and the maximum volume of the gas side may be a factor that determines the capacity of the compressor, e.g., when considered with working fluid properties (e.g., inlet flow rate and / or inlet pressure). The pressure of the oil contained on the oil side may be manipulated by piston 110b and a displacement volume, e.g., a surface area of piston 110b multiplied by a stroke length travelled by piston 110b. Piston 110b is coupled to connecting rod 102d and crankshaft 102c such that as crankshaft 102c rotates, connecting rod 102d causes piston 110b to travel. As piston 110b travels away from a bottom dead center position, piston 110b pushes oil into oil side diaphragm 112c and causes diaphragm 106d to displace. As will be discussed in more detail below, the capacity of the gas side may be controlled by substantially controlling the amount of oil provided to diaphragm head 106.Attorney Docket No. 1490.0184i
[0029] During an operating cycle of a diaphragm compressor, a piston may oscillate, effectively moving up and down or side to side. A complete operating cycle of a diaphragm compressor typically begins with a piston at a bottom dead center of a stroke. FIG. 2A is a diagrammatic representation of a diaphragm compressor at the beginning of an operating cycle with a piston at a bottom of a stroke. A diaphragm compressor 200 includes a piston 210 coupled to a crankshaft 202c via a connecting rod 202d. In general, when crankshaft 202c rotates, piston 210 may move, as for example towards a top dead center.
[0030] As shown, piston 210 is at a bottom dead center of a stroke. When piston 210 is at the bottom dead center of the stroke, a hydraulic fluid flow loop 220, including piston cylinder 222, contains hydraulic fluid, e.g., oil, and a diaphragm 206d is positioned such that there is a first volume of working fluid such as gas 228 within a cavity 232 of diaphragm compressor 200. A flow through limiter 216 may be closed when piston 210 is at a bottom dead center of a stroke. In one embodiment, the first volume of gas 228 may be a substantially maximum volume that may be supported within diaphragm compressor 200, although it should be appreciated that the first volume of gas 228 may be any suitable amount.
[0031] When piston 210 is at the bottom dead center of a stroke, hydraulic fluid flow loop 220 is substantially filled with hydraulic fluid, and the first volume of compressed gas 228 at suction pressure has entered cavity 232. As a result, diaphragm 206d is effectively forced against the hydraulic fluid.
[0032] In general, as piston 210 begins to travel from the bottom dead center, hydraulic fluid may move diaphragm 206d and begin to compress gas 228. The compression of gas 228 continues until the pressure in cavity 232 exceeds the pressure acting on an output check valve 206c. Output check valve 206c may then open and gas 228 may flow from cavity 232.
[0033] During the operating cycle of diaphragm compressor 200, piston 210 may be at a top of a stroke, or at a top dead center, as shown in FIG. 2B. When piston 210 is at or near theAttorney Docket No. 1490.0184i top of a stroke, flow through limiter 216 may open (e.g., if there is excess hydraulic fluid and / or pressure in the fluid flow loop 220, e.g., due to overcompensation for natural leakage or other lifecycle-related diminishment of hydraulic fluid), and hydraulic fluid is returned back to a sump via hydraulic fluid flow loop 220. A compensating pump acts during the period when piston 210 moves from the top to the bottom of a stroke, moving hydraulic fluid from a sump into cavity 232 in direction 224. Diaphragm 206d is generally at a top of cavity 232 such that there is effectively no volume of gas 228 within cavity 232, and diaphragm 206d conforms to a contour of cavity 232. That is, when piston 210 is at the top of a stroke, there may be substantially no space for compressed gas within cavity 232 of diaphragm compressor 200 as diaphragm 206d may cause gas 228 to be pushed out of cavity 232. Diaphragm 206d may be at a substantially maximum displacement within cavity 232.
[0034] To control the capacity of gas and / or a hydraulic fluid that moves through a compressor via a cavity such as cavity 232 of FIGs. 2A and 2B, the volume of hydraulic fluid within a hydraulic fluid flow loop may be controlled by releasing hydraulic fluid from the hydraulic fluid flow loop as a piston travels toward top of a stroke. Controlling the amount of hydraulic fluid that pushes against a diaphragm by releasing a volume of hydraulic fluid from a hydraulic fluid flow loop allows a capacity for gas in a cavity of a diaphragm compressor to be controlled, as the released hydraulic fluid reduces the diaphragm stroke. . That is, the volume of gas in the cavity may be controlled by releasing or purging a volume of hydraulic fluid from a fluid flow loop. In turn, this causes the diaphragm to push less gas through the cavity, e.g., so that less working fluid exits cavity 232 via output check valve 206c during a diaphragm stroke or flexure. However, to be clear, this release of hydraulic fluid is not a release of excess hydraulic fluid, e.g., as is achieved via flow through limiter 216. Instead, hydraulic fluid that would otherwise be utilized to cause a full or maximum flexure / stroke of theAttorney Docket No. 1490.0184i diaphragm is released to cause the diaphragm to flex or stroke less than its maximum, thereby adjusting (e.g., reducing) the capacity of the compressor.
[0035] In many instances, a volume of hydraulic fluid may be added into the hydraulic fluid flow loop as the piston travels toward a bottom of a stroke to essentially compensate for hydraulic fluid that was released from the hydraulic fluid flow loop. It should be appreciated that although the volume of fluid released from the hydraulic flow loop may be approximately the same as the volume of fluid added into the hydraulic flow loop, the volumes released and added may also differ if desired. Alternatively, the amount of fluid added may be slightly higher than the amount of fluid released from the hydraulic flow loop, or limiter. For example, to substantially ensure that a diaphragm or membrane is effectively pushed against a gas plate when a piston is at a top of a stroke, the amount of fluid added may be more than the amount of fluid released from the hydraulic flow loop. It should be appreciated that when a position of a membrane during a stroke is known and / or when an amount of fluid in a cavity is known, the amount of fluid added into the hydraulic flow loop may effectively be tuned to be appropriate for conditions within a diaphragm compressor.
[0036] In one embodiment, an overall diaphragm compressor system that includes a diaphragm compressor with a hydraulic fluid flow loop that is arranged to release hydraulic fluid to control a capacity of a cavity of the diaphragm compressor may include an actuator, a drain module such as an atmospheric sump, and a hydraulic fluid source. The actuator is configured to enable a volume of hydraulic fluid to be released from a hydraulic fluid flow loop and flow into an atmospheric sump. A hydraulic fluid source, which may be in direct communication the atmospheric sump, is configured to provide a volume of hydraulic fluid to the hydraulic fluid flow loop to essentially replenish the hydraulic fluid that was released into the drain module in order to control the capacity of the cavity of the diaphragm compressor.Attorney Docket No. 1490.0184i
[0037] FIG. 3 is a diagrammatic representation of a diaphragm compressor system or assembly which includes an atmospheric sump and a hydraulic fluid source, e.g., oil source, which are directly coupled in accordance with an embodiment. A diaphragm compressor system 330 includes a diaphragm compressor 300, an atmospheric sump 334, an actuator 338, and an oil source 342. Diaphragm compressor 300 includes a piston 310 coupled to a crank shaft 302c via a connecting rod 302b.
[0038] An oil flow loop 320 is effectively filled with oil, and a diaphragm 306d is positioned such that there is a volume of working fluid 328 within a cavity 332 of diaphragm compressor 300. In the described embodiment, the volume of working fluid 328 within cavity 332 may be a desired volume that achieves desired capacity within cavity 332 for working fluid 328. That is, oil may be released from oil flow loop 320 to control the capacity within cavity for working fluid 328. A flow through limiter 316 may also be arranged to be opened and closed to control the oil flow within oil flow loop 320 when needed.
[0039] Actuator 338 is positioned to facilitate the flow of oil between oil flow loop 320 and atmospheric sump 334. In one embodiment, actuator 338 is positioned in oil flow loop 320 such that when actuator 338 is on or activated, an amount of oil from oil flow loop 320 may flow into atmospheric sump 334. Oil source 342 is arranged to provide an amount of oil to oil flow loop 320, as for example by providing oil to a sump 302f that is part of diaphragm compressor 300. That is, a first amount of oil that is released from oil flow loop 320 and a second amount of oil may be provided to oil flow loop 320. The first amount of oil may be approximately the same as, or may differ from, the second amount of oil. In the described embodiment, oil source 342 is arranged to obtain oil substantially directly from atmospheric sump 334. In other words, oil may flow substantially directly from atmospheric sump 334 to oil source 342. It should be appreciated that in some situations, when oil is released from oil flow loop 320 and replenished by oil added into oil flow loop 320, a controllable compensatingAttorney Docket No. 1490.0184i pump with a larger capacity and / or an actuator may be provided to facilitate the release and replenishment of oil.
[0040] While atmospheric sump 334 and oil source 342 may be substantially coupled such that oil source 342 may obtain an amount or portion of oil from atmospheric sump 334, it should be appreciated that oil source 342 may instead be arranged to obtain oil from other sources and to add that oil to oil flow loop 320. FIG. 4 is a diagrammatic representation of diaphragm compressor system 330’ which includes atmospheric sump 334 and oil source 342 that are not directly coupled in accordance with an embodiment. Diaphragm compressor system 330’ includes diaphragm compressor 300, atmospheric sump 334, actuator 338, and oil source 342. Oil source 342 is coupled to oil flow loop 320 and arranged to provide oil to oil flow loop 320, for example directly to sump 302f, but is not arranged to obtain oil from atmospheric sump 334. That is, oil source 342 may add to the oil in oil flow loop 320 using oil that is not obtained from atmospheric sump 334.
[0041] In one embodiment, a diaphragm compressor system may include an atmospheric sump, but may not include an oil source. In such an embodiment, the atmospheric sump may be substantially directly connected to an oil flow loop, as for example to a sump of a diaphragm compressor that is part of an oil flow loop. That is, an atmospheric sump may be directly connected to an oil flow loop such that the atmospheric sump may provide oil to the oil flow loop.
[0042] FIG. 5 is a diagrammatic representation of a diaphragm compressor system which includes an atmospheric sump in accordance with an embodiment. A diaphragm compressor system 530 includes a diaphragm compressor 500, an atmospheric sump 534, and an actuator 538. Diaphragm compressor 500 includes a piston 510 coupled to a crank shaft 502c via a connecting rod 502d.Attorney Docket No. 1490.0184i
[0043] An oil flow loop 520 is effectively filled with oil, and a diaphragm 506d is positioned such that there is a volume of working fluid such as gas 528 within a cavity 532 of diaphragm compressor 500. A flow through limiter 516 is arranged to be opened and closed to control the oil flow within oil flow loop 520, e.g., as needed.
[0044] Actuator 538 is positioned to facilitate the flow of oil between oil flow loop 520 and atmospheric sump 534. When actuator 538 is on or activated, as for example when conditions indicate that oil is to be released from oil flow loop 520 in order to control a capacity associated with cavity 532, oil from oil flow loop 520 may be released into atmospheric sump 534. When conditions indicate that oil is to cease being released from oil flow loop 520 into atmospheric sump 534, atmospheric sump 534 may provide oil to oil flow loop 520, for example by providing oil to a sump 502f that is part of oil flow loop 520.
[0045] FIG. 6 is a diagrammatic representation of a hydraulic fluid flow loop, as for example an oil flow loop, of a diaphragm compressor that is configured to release hydraulic fluid to an atmospheric sump in accordance with an embodiment. A hydraulic fluid flow loop such as an oil flow loop 620 that is present within a diaphragm compressor system such as diaphragm compressor system 330 of FIG. 3, diaphragm compressor system 330’ of FIG. 4, and / or diaphragm compressor system 530 of FIG. 5, , and oil flow loop 620 includes an actuator 638 that is located in oil flow loop 620. Actuator 638 is arranged to cause oil contained in oil flow loop 620 to be released to an atmospheric sump 634, or a sump or other oil receiving arrangement that is not under pressure. Atmospheric sump 634 may optionally be in substantially direct fluid communication with a hydraulic fluid source such as an oil source 642 to enable oil released to atmospheric sump 634 to be provided to oil source 642. As previously mentioned, when atmospheric sump 634 provides oil to oil source 642, oil source 642 effectively obtains oil that may be reintroduced to or otherwise provided to oil flow loop 620.Attorney Docket No. 1490.0184i In one embodiment, oil may be provided to a sump or other arrangement that is part of oil flow loop 620.
[0046] Actuator 638 may be controlled to or otherwise arranged to be activated or actuated when conditions are met. That is, actuator 638 may cause oil to be released from oil flow loop 620 when conditions indicating that a desired capacity of compressed gas in a diaphragm head have effectively been reached. For example, actuator 638 may enable oil to be provided to atmospheric sump 634 while a piston is moving toward or at a top dead center. Actuator 638 may also be substantially deactivated when a piston begins to move toward a bottom dead center. As shown, a controller or control arrangement 650 that includes a processor 650a and a memory 650b may control actuator 638 to activate and to deactivate actuator 638. It should be appreciated that memory 650b may store logic and / or code devices configured to be executed by processor 650a to control actuator 638.
[0047] With reference to FIGs. 7A, 7B, and 7C, a method of operating a diaphragm compressor that is part of a diaphragm compressor system and is configured to release a hydraulic fluid such as oil to an atmospheric sump in accordance with an embodiment. A method 705 of operating a diaphragm compressor begins at a step 709 in which a piston of the diaphragm compressor travels from a bottom dead center toward a top dead center as part of a stroke, and pushes oil or, more generally, a hydraulic fluid. Pushing the oil enables a diaphragm of the diaphragm compressor to compress gas within a diaphragm head or cylinder.
[0048] In a step 713, a determination is made as to whether one or more oil release conditions are met. For example, it may be determined whether a desired capacity for compressed working fluid in a diaphragm head has been achieved, whether the compressor is operating at a desired capacity, or other similar determinations. The specific capacity to be targeted may be based on a specific use case of the compressor and / or the characteristics of the working fluid flowing through the compressor, and a determination as to whether this capacityAttorney Docket No. 1490.0184i is being achieved may, for example, be rendered based on data representative of the working fluid output from the compressor, e.g., obtained from downstream sensors determining a pressure, volume, and / or flow rate of working fluid exiting the compressor. For example, a flow rate based on a flow over time basis may be measured in a suction and / or discharge process gas lines using a flow meter. It should be appreciated, however, that a suction pressure and / or a discharge pressure is typically a controlled valuable and, as such, an oil release and replenishment process may require limit values in an overall control system to prevent undesirable working conditions and to mitigate potential compressor damage. In any case, controlling the volume of oil within an oil flow loop may control the volume of working fluid compressed by the diaphragm and, thus, may control the capacity of the compressor. At step 713, this capacity may be analyzed to determine if oil release conditions are met (e.g., to determine if capacity should be decreased by releasing more hydraulic fluid from the hydraulic fluid loop).
[0049] If it is determined in step 713 that oil release conditions have not been met, then process flow returns to step 709 in which the piston of the diaphragm compressor continues to travel toward a top dead center. After reaching top dead center, the piston may move towards bottom dead center to continue oscillating or stroking back towards another movement away from bottom dead center, per step 709. Alternatively, if it is determined that oil release conditions are met, the indication is that oil, or at least some portion of oil contained in the oil flow loop, may be released from an oil flow loop of the diaphragm compressor to enable a desired capacity of compressed working fluid to be maintained in the diaphragm head. As such, in a step 717, an actuator installed or otherwise present in the oil flow loop is actuated or opened to release oil from the oil flow loop.Attorney Docket No. 1490.0184i
[0050] The piston continues to travel in a step 721 and causes oil, or at least some portion or volume of the oil contained in the oil flow loop, to be released from the oil flow loop, as the actuator is actuated to release oil from the oil flow loop. This adjusts a stroke or flexure of the diaphragm and controls a capacity of the compressor. Thus, the diaphragm does not compress a maximum amount of working fluid as the piston moves or otherwise travels towards a top dead center. The oil that is released from the oil flow loop is routed to an atmospheric sump in a step 725.
[0051] It is determined in a step 729 whether the oil release conditions continue to be met. In one embodiment, such a determination may include determining whether the piston has begun to travel toward a bottom dead center. If the determination is that the oil release conditions are still met, then process flow returns to step 721 in which the piston continues to travel and cause oil to be released.
[0052] Alternatively, if the determination in step 729 is that the oil release conditions are no longer met, the implication is that the release of oil may be stopped. As such, the actuator closes or otherwise deactivates itself to stop releasing oil in a step 733. That is, the actuator is effectively deactivated in response to the oil release conditions no longer being met. Then, in a step 737, the piston travels from the top dead center toward the bottom dead center.
[0053] In a step 741, oil may be refdled into the oil flow loop as the piston travels toward the bottom dead center. That is, oil may be refilled during a suction or intake phase of the compressor. The oil may be refilled from an oil source, or a reservoir of oil. The amount or volume of oil that is provided into the oil flow loop may vary. For example, the amount or volume of oil provided into the oil flow loop may be approximately the same as the amount or volume of oil that was previously released from the oil flow loop. The oil source may be, but is not limited to being, a relatively high pressure source such as a rail-type storage, or a relatively low pressure source that utilizes a compensating pump. As previously mentioned,Attorney Docket No. 1490.0184i oil released to an atmospheric sump may be provided to the oil source to effectively replenish the oil source. In one embodiment, the pressure of the oil provided by the atmospheric sump to the oil source may be increased prior to the oil being provided back to the oil flow loop. It should be appreciated, however, that the oil provided to refdl the oil flow loop is not limited to being provided to the oil source by the atmospheric sump.
[0054] From step 741, process flow proceeds to a step 745 in which it is determined whether the refdl of oil into the oil flow loop is complete. In other words, it is determined whether oil from the oil source to continue to be provided to refdl the oil flow loop. Such a determination may involve determining whether a pressure differential across the diaphragm is at a desired level. If it is determined that the refdl is not complete, process flow returns to step 741 in which oil continues to be provided into the oil flow loop.
[0055] Alternatively, if it is determined in step 745 that the refdl is complete, then a determination is made in a step 749 as to whether the piston has reached the bottom dead center. If the determination is that the piston has not reached the bottom dead center, the indication is that the piston is continuing to travel. As such, the piston continues to travel in a step 753 from the top dead center toward the bottom dead center. Process flow then returns to step 749 in which it is determined whether the piston has reached the bottom dead center.
[0056] On the other hand, if it is determined in step 749 that the piston has reached the bottom dead center, a determination is made in a step 757 regarding whether the piston is to perform another stroke. If the determination is that the piston is to perform another stroke, process flow moves from step 757 back to step 709 in which the piston travels from the bottom dead center toward the top dead center. Alternatively, if the determination is that the piston is not to perform another stroke, the method of operating a diaphragm compressor is completed.Attorney Docket No. 1490.0184i
[0057] While the use of an atmospheric sump as a drain module to substantially receive hydraulic fluid released from a hydraulic fluid flow loop of a diaphragm compressor has been described, hydraulic fluid is not limited to being received by an atmospheric sump. By way of example, hydraulic fluid drained from a hydraulic flow loop may be released to or otherwise provided to a pressurized sump. Such a pressurized sump may be arranged to provide hydraulic fluid to replenish the hydraulic flow loop.
[0058] With reference to FIG. 8, a hydraulic fluid flow loop of a diaphragm compressor that is configured to release hydraulic fluid such as oil to a pressurized sump will be described in accordance with an embodiment. An oil flow loop 820 includes an actuator 838 that is arranged to cause oil contained in oil flow loop 820 to be released to a pressurized sump 880 or pressurized vessel. In one embodiment, pressurized sump 880 may provide oil to replenish oil flow loop 820. That is, pressurized sump 880 may substantially directly provide oil to oil flow loop 820. In another embodiment, pressurized sump 880 may instead be in fluid communication with a pressurized oil source 882 to enable oil released to pressurized sump 880 to be provided to pressurized oil source 882 such that pressurized oil source 882 may provide oil to oil flow loop 820. It should be appreciated that the pressure within pressurized sump 880 and pressurized oil source 882 may be approximately the same, e.g., the pressure may be maintained at a level that is approximately the same as the pressure within oil flow loop 820.
[0059] Actuator 838 may cause oil to be released from oil flow loop 820 when conditions indicating that a desired capacity of compressed gas in a diaphragm head have effectively been reached., e.g., actuator 838 may enable oil to be provided to pressurized sump 880 while a piston is moving toward or at a top dead center. A control arrangement 850 that includes a processor 850a and a memory 850b may activate and deactivate actuator 838.Attorney Docket No. 1490.0184i
[0060] A diaphragm compressor such as diaphragm compressor 300 of FIG. 3 includes a crankshaft that is coupled to a piston via a connecting rod such that when the crankshaft rotates the piston may move between a top dead center and a bottom dead center. In lieu of utilizing a crankshaft to cause a piston to move, a hydraulic cylinder or a linear motor may instead be used. When a hydraulic cylinder or a linear motor are used to drive a piston in a diaphragm compressor, it should be appreciated that by controlling the hydraulic cylinder or the linear motor, the piston stroke may be varied and, as a result, the volume of hydraulic fluid in the diaphragm compressor may be controlled.
[0061] FIG. 9 is a block diagram representation of a diaphragm compressor system that includes a motor configured to drive a piston in accordance with an embodiment. A diaphragm compressor system 930 includes a piston 910 which is driven by a piston-driving actuator 986 which may be, but is not limited to being, a hydraulic cylinder or a linear motor. When pistondriving actuator 986 drives piston 910, piston 910 may move between a top dead center and a bottom dead center, and cause hydraulic fluid contained in a hydraulic fluid flow loop 920 to cause a diaphragm 906 to compress gas within a cavity (not shown).
[0062] In one embodiment, an actuator 938 may be used to release hydraulic fluid from hydraulic fluid flow loop 920 as necessary to maintain a desired volume of gas within a cavity (not shown). Hydraulic fluid released from hydraulic fluid flow loop 920 may be provided to a drain module 990 which may be a sump, e.g., an atmospheric sump or a pressurized sump. Drain module 990 may directly provide hydraulic fluid to replenish hydraulic fluid flow loop 920. Alternatively, hydraulic fluid from an optional hydraulic fluid source 992 may provide hydraulic fluid to replenish hydraulic flow loop 920. It should be appreciated that drain module 990 may provide hydraulic fluid released from hydraulic fluid flow loop 920 to optional hydraulic fluid source 992.Attorney Docket No. 1490.0184i
[0063] The release of a hydraulic fluid and the replenishment of the hydraulic fluid within a hydraulic fluid flow loop generally enables the capacity within a diaphragm compressor to be controlled such that a desired capacity may be maintained. While the use of an actuator, a sump, and an optional hydraulic fluid source as discussed above enables the capacity within a diaphragm compressor to be controlled, other method may enable the capacity within a diaphragm compressor to be controlled.
[0064] In one embodiment, an actuator may be provided in the form of an auxiliary or secondary piston may be interfaced with a hydraulic fluid flow loop of a diaphragm compressor such that the auxiliary piston may effectively move away from the hydraulic fluid flow loop when a piston, z.e., a main or primary piston, within the diaphragm compressor, is moving towards a top dead center, to increase an amount of hydraulic fluid in the hydraulic fluid flow loop. In such an embodiment, when the main piston moves towards a bottom dead center, the auxiliary piston may move towards the hydraulic fluid flow loop to decrease the amount of hydraulic fluid in the hydraulic fluid flow loop.
[0065] Referring to FIG. 10A, a diaphragm compressor system that includes an auxiliary piston (which, at least for the purposes of this application, may be considered an actuator) driven by a system to facilitate the release and replenishment of a hydraulic fluid within the diaphragm compressor will be described in accordance with an embodiment. A diaphragm compressor system 1030 includes a diaphragm compressor 1000, an auxiliary piston 1094, and a system 1096. Diaphragm compressor 1000 includes a main piston 1010 coupled to a crank shaft and connecting rod assembly 1002 which is arranged to drive main piston 1010.
[0066] A hydraulic fluid flow loop 1020 is effectively filled with a hydraulic fluid, and the hydraulic fluid may be released from hydraulic fluid flow loop 1020 to control the capacity within a cavity by essentially adjusting a position of a diaphragm 1006.Attorney Docket No. 1490.0184i
[0067] Auxiliary piston 1094 is in fluid communication with hydraulic fluid flow loop 1020. and may be arranged to move in coordination with main piston 1010 to vary the amount of hydraulic fluid within hydraulic fluid flow loop 1020. As main piston 1010 moves up towards a top dead center, auxiliary piston 1094 may move away from hydraulic fluid flow loop 1020 to effectively increase a volume of hydraulic fluid within hydraulic fluid flow loop 1020. As main piston 1010 moves down towards a bottom dead center, auxiliary piston 1094 may move toward hydraulic fluid flow loop 1020 to effectively decrease a volume of hydraulic fluid within hydraulic fluid flow loop 1020. As shown, system 1096 may be arranged to control the movement of auxiliary piston 1094 and, hence, the stroke of diaphragm 1006 and the capacity of a cavity (not shown). System 1096 may be any suitable system which may control the movement of auxiliary piston 1094 including, but not limited to including, a cam, a hydraulic cylinder, and / or an electronic actuator such as a linear motor.
[0068] In one embodiment, auxiliary piston 1094 may be controlled using crankshaft and connecting rod assembly 1002. FIG. 10B illustrates a diaphragm compressor 1030’ in which auxiliary piston 1094 is driven by crankshaft and connecting rod assembly 1002 in accordance with an embodiment. When crankshaft and connecting rod assembly 1002 drives main piston 1010, crankshaft and connecting rod assembly 1002 may also drive auxiliary piston 1094 through the use of a gear or cam arrangement 1098. Although only a few embodiments have been described in this disclosure, it should be understood that the disclosure may be embodied in many other specific forms without departing from the spirit or the scope of the present disclosure. By way of example, while an atmospheric sump or a pressurized sump have been described as obtaining or otherwise receiving released oil, a low pressure storage arrangement may be utilized in some embodiments in lieu of an atmospheric sump or a pressurized sump. For example, a drain module, drain arrangement, or reservoir may be used instead of, or in addition to, an atmospheric sump or a pressurized sump.Attorney Docket No. 1490.0184i
[0069] While oil has been described as one example of a hydraulic fluid, and gas has been described as one example of a working fluid, a hydraulic fluid is not limited to being oil and a working fluid is not limited to being gas. In general, any suitable hydraulic fluid may be used instead or, in addition to, oil. Additionally, any suitable working fluid may be used instead of, or in addition to, gas.
[0070] While the disclosure has described the techniques presented herein in detail and with reference to specific embodiments thereof, it is nevertheless not intended to be limited to the details shown, since it will be apparent that various modifications and structural changes may be made therein without departing from the scope of the inventions and within the scope and range of equivalents of the claims. In addition, various features from one of the embodiments may be incorporated into another of the embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure as set forth in the following claims.
[0071] Finally, it is intended that the present disclosure cover the modifications and variations of this invention that come within the scope of the appended claims and their equivalents. For example, it is to be understood that terms such as “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “inner,” “outer” and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration. Further, the term “exemplary” is used herein to describe an example or illustration. Any embodiment described herein as exemplary is not to be construed as a preferred or advantageous embodiment, but rather as one example or illustration of a possible embodiment of the disclosure.Attorney Docket No. 1490.0184i
[0072] Similarly, when used herein, the term “comprises” and its derivations (such as “comprising,” etc.) should not be understood in a limiting or excluding sense, that is, these terms should not be interpreted as excluding the possibility that what is described and defined may include further elements, steps, etc. Meanwhile, when used herein, the term “approximately” and terms of its family (such as “approximate,” etc.) should be understood as indicating values very near to those which accompany the aforementioned term. That is to say, a deviation within reasonable limits from an exact value should be accepted, because a skilled person in the art will understand that such a deviation from the values indicated is inevitable due to measurement inaccuracies, etc. The same applies to the terms “about” and “around” and “substantially.” Finally, for the purposes of the present disclosure, the phrase “A and / or B” means (A), (B), or (A and B). For the purposes of the present disclosure, the phrase “A, B, and / or C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).
Claims
Attorney Docket No. 1490.0184i CLAIMS1. A diaphragm compressor system comprising:a diaphragm compressor, the diaphragm compressor having a cavity defined therein, the diaphragm compressor including:a diaphragm,a piston, anda hydraulic fluid flow loop containing a hydraulic fluid, wherein the diaphragm is positioned within the cavity to separate a working fluid side of the cavity from a hydraulic fluid side of the cavity and wherein the piston and the hydraulic fluid cause the diaphragm to displace within the cavity as the piston travels;an actuator, the actuator being coupled to the hydraulic fluid flow loop; and a drain module, wherein the actuator is further coupled to the drain module and configured to cause a first amount of the hydraulic fluid to be released from the hydraulic fluid flow loop into the drain module to control a capacity of the working fluid side of the cavity.
2. The diaphragm compressor system of claim 1 further including a hydraulic fluid source arranged to add a second amount of fluid to the hydraulic fluid in the hydraulic fluid flow loop, wherein the hydraulic fluid source is not coupled to the drain module.
3. The diaphragm compressor system of claim 1 wherein the drain module is an atmospheric sump, the diaphragm compressor system further including a hydraulic fluid source, the hydraulic fluid source being directly coupled to the atmospheric sump and arranged to provide the first amount of the hydraulic fluid to the hydraulic fluid flow loop.Attorney Docket No. 1490.0184i 4. The diaphragm compressor system of claim 1 wherein when the piston travels from a bottom dead center position, the piston pushes the hydraulic fluid and displaces the first amount of the hydraulic fluid to the drain module.
5. The diaphragm compressor system of claim 4 wherein when the piston travels toward the bottom dead center position, a hydraulic fluid source provides the first amount of the hydraulic fluid to the hydraulic fluid flow loop.
6. A system comprising:a diaphragm compressor, the diaphragm compressor having a cavity defined therein, the cavity including a working fluid side and a hydraulic fluid side, wherein the diaphragm compressor includes a diaphragm and a hydraulic fluid flow loop, the diaphragm being positioned to separate the working fluid side and the hydraulic fluid side, wherein the hydraulic fluid flow loop contains a hydraulic fluid that causes the diaphragm to displace;an actuator coupled to the hydraulic fluid flow loop; anda drain module, wherein the actuator is further coupled to the drain module and configured to be activated to cause a first amount of the hydraulic fluid to be released from the hydraulic fluid flow loop into the drain module to control a capacity of the working fluid side.
7. The system of claim 6 further comprising:a hydraulic fluid source, wherein the hydraulic fluid source is arranged to add a second amount of the hydraulic fluid to the hydraulic fluid flow loop to control the capacity of the working fluid side.Attorney Docket No. 1490.0184i 8. The system of claim 7 wherein the diaphragm compressor further includes a piston, the piston and the hydraulic fluid being arranged to cause the diaphragm to displace.
9. The system of claim 8 wherein the piston is configured to move from a bottom dead center toward a top dead center, and wherein the actuator is activated to cause the first amount of the hydraulic fluid to be released from the hydraulic fluid flow loop into the drain module when the piston moves from the bottom dead center towards the top dead center.
10. The system of claim 8 wherein the piston is configured to move from a top dead center toward bottom dead center, and wherein the hydraulic fluid source is arranged to add the second amount of the hydraulic fluid to the hydraulic fluid flow loop when the piston moves from the top dead center toward the bottom dead center.
11. The system of claim 7 wherein the drain module is an atmospheric sump, and wherein the hydraulic fluid source is coupled to the atmospheric sump and the second amount of the hydraulic fluid is obtained by the hydraulic fluid source from the atmospheric sump.
12. The system of claim 6 wherein the drain module is configured to add the first amount of fluid to the hydraulic fluid flow loop after the first amount of hydraulic fluid flows into the drain module.
13. The system of claim 12 wherein the diaphragm compressor further includes a piston, the piston and the hydraulic fluid being arranged to cause the diaphragm to displace, wherein when the piston travels from a bottom dead center toward a top dead center, the actuator isAttorney Docket No. 1490.0184i activated to cause the first amount of the hydraulic fluid to be released from the hydraulic fluid flow loop into the drain module.
14. The system of claim 13 wherein when the piston travels from the top dead center toward the bottom dead center, the drain module adds the first amount of hydraulic fluid to the hydraulic fluid flow loop.
15. A method for controlling a capacity of a diaphragm compressor, the diaphragm compressor having a cavity defined therein having a working fluid side and a hydraulic fluid side, the capacity being associated with the cavity, the diaphragm compressor including a diaphragm arranged to separate the working fluid side and the hydraulic fluid side, the diaphragm compressor further including a hydraulic fluid flow loop that contains a hydraulic fluid, the method comprising:determining when a condition in the cavity is met; andwhen it is determined that the condition in the cavity is met, activating an actuator to cause a first amount of the hydraulic fluid to be released from the hydraulic fluid flow loop into a drain module to control the capacity.
16. The method of claim 15 wherein after causing the first amount of the hydraulic fluid to be released, determining whether the condition in the cavity is still met, the method further includes:causing the first amount of the hydraulic fluid to be added to the hydraulic fluid flow loop when it is determined that the condition in the cavity is no longer met.Attorney Docket No. 1490.0184i 17. The method of claim 16 wherein the first amount of the hydraulic fluid is added to the hydraulic fluid flow loop by a hydraulic fluid source.
18. The method of claim 16 wherein the drain module is an atmospheric sump and wherein the first amount of the hydraulic fluid is added to the hydraulic fluid flow loop by the atmospheric sump.
19. The method of claim 15 wherein after causing the first amount of the hydraulic fluid to be released, determining whether the condition in the cavity is still met, the method further includes:deactivating the actuator in response to the condition no longer being met.
20. The method of claim 15 wherein the diaphragm compressor includes a piston, wherein the piston travels from a bottom dead center towards a top dead center when the condition is met and the piston travels from the top dead center towards the bottom dead center when the condition is not met.