Compressor Inlet Valve Discrete Step Control for Vibration Reduction
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Solution Overview
Problem
Conventional compressors experience high vibration levels and potential damage during the transition from a loaded to an unloaded state due to sudden changes in pressure ratios, which can lead to undesirable temperature peaks and mechanical stress, especially when there is no elastic coupling between the drive and compressor elements.
Innovation Solution
A method for controlling the compressor that involves partially closing the inlet valve in successive discrete steps during the transition from the loaded to the unloaded state, allowing a greater suction flow to maintain a higher equilibrium pressure, thereby reducing the pressure ratio peak and minimizing vibrations. This is achieved by determining the operating pressure in the consumer network and initiating the transition when it reaches a set maximum, and then gradually reducing the flow to the residual flow required for the unloaded state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the inlet valve is immediately closed and blow-off valve is opened during transition from loaded to unloaded state, then the transition to unloaded state is achieved quickly, but high pressure ratio peaks occur causing dangerous vibration levels and potential compressor failure
Solution Approach 1:
The transition process is segmented into multiple discrete steps rather than a single sudden change. The inlet valve is closed in successive discrete transitional steps, allowing the pressure ratio to decrease gradually through intermediate states rather than jumping directly to the final unloaded state, thereby avoiding dangerous vibration peaks
Solution Approach 2:
The inlet valve is partially closed in preliminary steps before complete closure is achieved. This preliminary action reduces the pressure ratio incrementally in advance of the final transition completion, preventing the sudden pressure ratio peak that would occur with immediate full closure
2Use of energy by moving object
If the inlet valve is closed completely in the unloaded state, then no gas is suctioned and energy consumption is minimized, but the calibrated passages cannot maintain sufficient pressure for fluid injection cooling and lubrication
Solution Approach 1:
The inlet valve closure is not absolute but localized with calibrated passages remaining open. This creates different flow conditions in different parts of the inlet system - the main inlet is closed to minimize energy consumption while specific calibrated passages remain open to maintain minimum pressure for fluid injection, achieving both energy efficiency and component protection
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 method effectively reduces the peak pressure ratio between the outlet and inlet, preventing hazardous vibration levels and allowing for safe operation without an elastic coupling, while also optimizing energy use by maintaining a higher equilibrium pressure in the pressure tank.
Implementation Method 1
a compressor element (2) with an inlet (5) and an outlet (10)
Implementation Method 2
a controllable inlet valve (6) with a valve inlet (7), in which the inlet valve (6) can at least partially close the inlet (5) of the compressor element (2)
Implementation Method 3
a controllable blow-off valve (19) which is connected to the pressure line (11)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method for controlling a compressor towards an unloaded state, in which the compressor comprises a compressor element 2) with an inlet (5), in which in the unloaded state, a residual flow (QD) is suctioned via the inlet (5) towards and into the compressor element (2), and in which for a transition from a loaded state of the compressor to the unloaded state, the inlet (5) of the compressor element (2) is partially closed in successive discrete transitional steps,