Compressor Module Integrated Cooling Circuits
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Solution Overview
Problem
Conventional compressor modules face high maintenance costs and inefficiencies due to external pipes and connections for coolant and oil circulation, leading to heat loss and reduced cooling effectiveness, especially with air cooling methods which require large, expensive coolers and are prone to dust accumulation and leaks.
Innovation Solution
A compressor module with integrated cooling circuits where water or oil is used as a coolant, circulating internally through the motor, compressor element, and oil circuit, allowing for efficient heat recovery and reduced external components, minimizing external pipes and enhancing cooling efficiency by shortening the heat transfer distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If external pipes and connections are used to guide coolant and oil around the compressor module, then the system can be assembled with separate components, but the cost price increases and the risk of defects and leaks increases
Solution Approach 1:
The patent integrates the cooling circuits and oil circuit directly into the housing structure, merging previously separate components (coolers, pipes, connections) into a unified integrated assembly. This eliminates external piping while maintaining manufacturing feasibility through modular housing design.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides structural support, contains the compression elements, and acts as the cooling circuit and oil circuit pathways. This multi-functionality eliminates the need for separate external piping systems while simplifying assembly.
2Adaptability or versatility
If external pipes and connections are used for coolant circulation, then flexibility in routing is improved, but the cost price and risk of defects increase
Solution Approach 1:
The routing flexibility previously provided by external pipes is integrated directly into the housing structure through internal channels and passages. This combines the routing function with the housing structure, eliminating separate pipe components while maintaining adaptable coolant flow paths.
3Temperature
If air cooling is used with large radiators, then cooling capacity is sufficient, but the equipment size and cost increase
Solution Approach 1:
The patent transitions from air cooling to liquid cooling (water or oil) as the cooling medium. Liquid cooling provides superior heat transfer efficiency, enabling compact heat exchanger design while maintaining adequate cooling capacity. The liquid coolant circulates through integrated channels in the housing, eliminating large external radiators.
4Use of energy by moving object
If water cooling is used for heat recovery, then heat can be recovered usefully, but the number of external pipes and connections increases
Solution Approach 1:
The housing structure serves dual purposes: it provides mechanical support and containment while simultaneously serving as the water cooling circuit pathways for heat recovery. This integration allows heat recovery functionality without adding external piping complexity.
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 solution reduces assembly costs, minimizes heat loss, and improves compression efficiency by maintaining components at lower temperatures, allowing for compact, low-noise, and efficient heat recovery without the need for extensive external ventilation or cooling systems.
Implementation Method 1
a gas cooler (10) for cooling the compressed gas... the coolant is heated by the heat-exchanging contact with the heat of compression of the compressed gas in the gas cooler
Implementation Method 2
the coolant is heated by the heat-exchanging contact with the compressor element and with the motor
Implementation Method 3
the oil in the oil circuit is in heat-exchanging contact with the first cooling circuit and/or with the second cooling circuit via the aforementioned internal channels and/or the oil sump
Implementation Method 4
a compressor element (2) with an input (3) for gas to be compressed and an output (4) for the compressed gas
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Compressor module for compressing gas composed of a compressor element (2) with a housing with integrated compressor element cooler (22); a motor (5) and a gas cooler (10) for cooling the compressed gas originating from the compressor element (2), characterised in that the gas cooler (10) comprises a primary section (13) through which the gas to be cooled can be guided and a secondary section (16) that is in heat-exchanging contact with the primary section (13); that a first cooling circuit (17) can guide a coolant through the secondary section (16) of the gas cooler (10) or through a section thereof and a second cooling circuit (23) can guide a coolant through the compressor element cooler (22); and whereby the first cooling circuit (17) and the second cooling circuit (23) are joined together in series or in parallel and are guided to a common output (19).