Compressor Piston Rod Control for Drive Fluid Reduction
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Solution Overview
Problem
Existing compressors consume excessive drive fluid, leading to high operational costs and ecological concerns, despite maintaining power, especially during the last third of the pressure build-up in the compression process.
Innovation Solution
A double-stage piston compressor design with a second control unit that activates the second drive piston only when actual pressure in the target system reaches a specific level, reducing the need for both drive chambers during most of the filling and compression process, utilizing pilot valves and a control slide for efficient fluid distribution and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If both drive chambers are filled with drive fluid throughout the entire compression process, then the maximum transmission ratio is available for pressure build-up, but drive fluid consumption increases excessively
Solution Approach 1:
The patent applies dynamics by making the drive fluid supply to the second drive chamber conditional and variable rather than continuous. The second control unit activates the second drive piston only when the actual pressure in the target system reaches a predetermined level, thereby dynamically adjusting the drive fluid consumption based on the actual compression needs throughout the process.
Solution Approach 2:
The patent changes the operational parameters of the drive system by introducing pressure-dependent control. The second drive chamber remains inactive during the initial filling phase and is activated only when pressure reaches a threshold level, thereby optimizing the balance between transmission ratio availability and drive fluid consumption.
2Stress or pressure
If a second drive piston is added to double the transmission ratio, then the desired target pressure can be achieved, but the device complexity increases
Solution Approach 1:
The patent segments the drive system into two independent drive chambers, each with its own control unit. The first drive chamber handles the initial filling and compression, while the second drive chamber is activated only when needed. This segmentation allows the system to achieve high transmission ratios when necessary while keeping the system simpler during normal operation.
Solution Approach 2:
The second drive piston and its control unit serve multiple functions: they provide additional transmission ratio when high pressure is needed, and can remain inactive during normal operation. This multi-functionality allows the system to handle both routine compression and high-pressure scenarios with a single integrated design.
3Productivity
If the compressor operates with maximum transmission ratio throughout, then the compression speed is maintained, but operational costs increase due to excessive drive fluid consumption
Solution Approach 1:
The patent implements periodic action by activating the second drive piston only during specific phases of the compression process when the actual pressure reaches predetermined levels. This periodic activation maintains compression speed when needed while reducing drive fluid consumption during other phases, thereby lowering operational costs.
Solution Approach 2:
The system uses feedback from the actual pressure in the target system to control the activation of the second drive piston. When pressure reaches a threshold level, the second control unit activates the second drive chamber, ensuring that maximum transmission ratio is applied only when necessary, thus optimizing both productivity and operational costs.
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 reduces drive fluid consumption by up to 40% and shortens filling time by up to 20%, lowering operating costs and providing ecological and economic benefits, while allowing existing compressors to be retrofitted with minimal modifications.
Implementation Method 1
The first drive piston and the second drive piston are each able to be subjected to a drive fluid on alternate sides in a manner controlled via a control unit
Implementation Method 2
Compressors increase the pressure of gaseous fluids in one or more stages and are designed inter alia as piston compressors. A piston compressor increases the pressure by reducing the working space.
Implementation Method 3
Movement of the high-pressure piston out of the pressure cylinder results in the formation of a negative pressure, and the suction valve allows fluid for conveyance to flow in
Data Source
AI summary
A compressor and a method for conveying and compressing a fluid into a target system. The compressor has a first drive part having a first drive piston, a second drive part having a second drive piston and at least a first high-pressure part having a high-pressure piston. The first drive piston and the second drive piston are each able to be subjected to a drive fluid piston on alternate sides controlled via a first control unit. The first drive, the second drive piston and the high-pressure piston are jointly movable axially coupled via a piston rod arrangement. The second drive part is assigned a second control unit, which is arranged after the first control unit and via which the subjecting of the second drive piston to drive fluid is able to be activated.