Compressor Oil Control Valve with Bypass Pre-Conditioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional control valves for oil-injected screw-type compressors experience oscillation and rapid wear due to sudden temperature changes and high flow resistance, leading to inefficient heating and maintenance challenges, especially during intermittent use.
Innovation Solution
A control valve design featuring a control piston with a bypass opening that cooperates with a heat exchanger opening, allowing pre-conditioning of oil flow through the heat exchanger and minimizing temperature shocks, along with a control element acting as an expanding element and a valve spring for precise control, ensuring stable operation and reduced wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional control valves are used with direct bypass openings, then the structure is simple, but the valve experiences oscillation and rapid wear due to sudden temperature changes and high flow resistance
Solution Approach 1:
The patent introduces a pre-cooler opening that allows oil to be pre-cooled before reaching the main control element. This preliminary action reduces the temperature shock to the control element, preventing oscillation and wear. The pre-cooler opening is positioned to allow gradual temperature adjustment rather than sudden exposure to extreme temperatures.
Solution Approach 2:
The control valve is divided into multiple functional openings: a first bypass opening for direct bypass flow, a heat exchanger opening for cooled oil flow, and a pre-cooler opening for intermediate cooling. This segmentation allows different portions of the oil flow to be treated differently, improving overall valve stability while managing complexity through functional division.
2Productivity
If the control valve directs all oil through the heat exchanger rapidly, then heating is fast, but temperature shocks cause valve oscillation and wear
Solution Approach 1:
The pre-cooler opening provides a gradual cooling path before the oil reaches the main control element. This preliminary cooling action allows the oil temperature to adjust progressively, preventing sudden temperature shocks that would cause valve oscillation. The system achieves both rapid overall heating and stable control by staging the cooling process.
Solution Approach 2:
The patent changes the temperature parameter gradually through the pre-cooler opening rather than abruptly. By introducing an intermediate cooling stage, the oil temperature transitions smoothly from hot to cold states, preventing the thermal shocks that cause valve oscillation while maintaining efficient heat exchange.
3Ease of operation
If the control element is exposed directly to cold oil from the bypass, then the bypass function is effective, but the control element suffers thermal shock and wears rapidly
Solution Approach 1:
The pre-cooler opening acts as an intermediary between the bypass opening and the control element. Instead of cold bypass oil directly contacting the control element, the pre-cooler provides an intermediate zone that gradually cools the oil. This mediator protects the control element from thermal shock while preserving the bypass functionality.
Solution Approach 2:
The pre-cooler opening performs preliminary cooling of the bypass oil before it reaches the control element. This preliminary action prepares the oil by reducing its temperature shock potential, allowing the bypass to function effectively without damaging the control element through direct exposure to extreme cold.
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 control valve achieves rapid heating of the compressor oil with stable control behavior, reducing the minimum connection period required to prevent condensation and extending the valve's lifespan by minimizing oscillation and wear.
Implementation Method 1
a control element (3) which co-operates respectively with a heat exchanger opening (13) disposed in a valve housing (1) and a bypass opening (11), and that the control piston (2) controls at least one further bypass opening (12) co-operating with the heat exchanger opening (13)
Implementation Method 2
wherein oil present in a screw-type compressor housing can be supplied in a controlled manner via the control valve to a heat exchanger and/or to a bypass
Data Source
AI summary
A control valve for an oil-injected screw-type compressor, in particular for installation in a vehicle, wherein oil located in a screw-type compressor housing can be supplied in a controlled manner via the control valve to a heat exchanger and/or to a bypass in such a way that cold oil is conducted through a bypass around the heat exchanger and warm oil is conducted through the heat exchanger. A control valve is provided for an oil-injected screw-type compressor and ensures rapid heating of the oil in the screw-type compressor even with a short activation time. The control valve has a control piston that is actuated by a control element and cooperates respectively with a heat exchanger opening disposed in a control valve housing and a bypass opening, and that the control piston controls at least one bypass opening which cooperates with the heat exchanger opening.