Oil-Injected Compressor Cooling Control to Prevent Condensate
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Solution Overview
Problem
Existing compressor devices with oil-injected compressor elements face issues with condensate formation downstream of the oil separator, leading to inefficiencies and shorter oil lifetime due to high temperature settings required to prevent condensate, which are not effectively controlled by traditional methods.
Innovation Solution
A compressor device with controllable cooling means and a control unit that measures and adjusts the temperature of the compressed gas downstream of the oil separator to maintain a temperature above the dew point, using a feed-forward or master-slave control system to stabilize and optimize the cooling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature of compressed gas downstream of the oil separator is controlled to be sufficiently high above the dew point (typically 20°C), then condensate formation is prevented, but oil lifetime decreases and compressor efficiency reduces
Solution Approach 1:
The control unit continuously monitors the actual temperature downstream of the oil separator and adjusts the cooling means accordingly to maintain the temperature within the optimized range, preventing condensate formation while minimizing oil temperature degradation
Solution Approach 2:
The system changes the temperature parameter from a fixed high margin (20°C above dew point) to a dynamically optimized margin (minimum necessary above dew point), thereby reducing oil temperature and extending oil lifetime while still preventing condensate
2Device complexity
If the temperature control is based on the outlet temperature of the compressor element, then the control system is simpler, but the temperature downstream of the oil separator drops below the dew point causing condensate formation
Solution Approach 1:
The control system takes preliminary action by measuring and controlling the temperature downstream of the oil separator (where condensate would form) rather than waiting to measure at the outlet, preventing the harmful effect before it occurs
Solution Approach 2:
The patent introduces an intermediary temperature measurement and control point downstream of the oil separator, which acts as a mediator between the compressor outlet and the final outlet, ensuring temperature is maintained at the critical location where condensate formation occurs
3Measurement precision
If the temperature control responds only when condensate conditions occur downstream of the oil separator, then the control is more targeted, but the response is too late and leads to temperature instabilities
Solution Approach 1:
The control unit uses feedback from the downstream temperature sensor to continuously adjust the cooling means, maintaining stable temperature control downstream of the oil separator and preventing the instabilities that would occur with delayed response
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
This approach effectively prevents condensate formation while keeping the oil temperature low, enhancing the compressor's efficiency and extending its lifespan by allowing for more precise control of the temperature downstream of the oil separator.
Implementation Method 1
a cooler (16) which can be bypassed by means of a bypass line (17)
Implementation Method 2
a controlled mixing valve (18) with an inlet (19) and two outlets (20a, 20b), the mixing valve (18) having its inlet (19) and one of the outlets (20a) connected to the injection line (10) and the other outlet (20b) connected to the bypass line (17)
Implementation Method 3
an oil-injected compressor element (2) with an inlet (3) for gas to be compressed and an outlet (4) for compressed gas
Implementation Method 4
an outlet (4) for compressed gas, wherein the outlet (4) connects to an oil separator (9)
Data Source
Figure 1~2
Figure 3
AI summary
Compressor device comprising an oil-injected compressor element (2) with an outlet (4) connected via an outlet line (8) to an oil separator (9) which is connected via an injection pipe (10) to the compressor element (2), wherein controllable cooling means (15) for the oil are provided, the compressor device (1) being provided with a control unit (21) and thereto connected measuring means (22a, 22b) for controlling the cooling means (15) to control a temperature (T_uit_afsch) downstream of the oil separator (9), the measuring means (22a, 22b) including means (22a) for determining a temperature (T_uit) at the outlet (4) and a temperature sensor (22b) for determining the temperature (T_uit_afsch) downstream of the oil separator (9), the control unit (21) including a controller (25) for controlling the cooling means (15) on the basis of signals from said measuring means (22a, 22b) and on the basis of a dew point.