Blasthole Drill Compressor Drive With Pre-Synchronized Clutch
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Solution Overview
Problem
Blasthole drill rigs consume excessive fuel and energy due to the air compressor remaining powered during standby operations, and existing clutch systems suffer from wear and maintenance issues due to speed discrepancies between the engine and compressor.
Innovation Solution
A connection assembly with a dry clutch and RPM/rev matcher, utilizing a hydraulic or electric starter to synchronize the compressor's speed with the engine before engagement, reducing wear and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a clutch is used to disconnect the air compressor from the engine during standby, then fuel consumption is reduced, but clutch wear increases due to speed discrepancies during engagement
Solution Approach 1:
The patent applies preliminary action by using a starter motor to pre-rotate the compressor to a predetermined speed before the clutch is engaged. This ensures that when the clutch connects the engine to the compressor, both are already at matching speeds, eliminating speed discrepancies and preventing clutch plate wear during engagement.
Solution Approach 2:
The patent introduces an intermediary device (starter motor) between the engine and compressor systems. The starter acts as a mediator that independently brings the compressor to the correct rotational speed before the clutch engagement occurs, preventing direct speed mismatch between engine and compressor during connection.
2Ease of operation
If the engine continuously powers the air compressor during standby operations, then the compressor is ready for immediate operation, but excessive fuel and energy are consumed
Solution Approach 1:
The system performs preliminary action by pre-rotating the compressor to the required speed using the starter motor before clutch engagement. This ensures the compressor is ready for immediate operation once engaged, while avoiding continuous powering during standby, thus reducing fuel consumption significantly.
Solution Approach 2:
The system transitions from continuous operation to periodic action by only activating the compressor when needed. The clutch allows the compressor to be disengaged during standby and selectively engaged when required, eliminating continuous fuel consumption while maintaining operational readiness through on-demand activation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system minimizes fuel waste and extends clutch life by ensuring synchronized speed engagement, reducing wear and maintenance costs.
Implementation Method 1
The hydraulic pumps used on the drill are always connected to the engine and will provide hydraulic power to the compressor starting system
Data Source
AI summary
A compressor drive system is arranged to selectively operate a compressor and engine of a drill rig. The compressor drive system includes a connection assembly coupled between the engine and the compressor. The connection assembly includes a ring gear arranged to be coupled to the compressor and a clutch arranged to be connected to the engine, wherein a starter is connected to the ring gear and arranged to engage the ring gear to rotate the compressor to a predetermined rotation speed before the clutch is engaged.