Piston Compressor Idle Function Relief Valves
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Solution Overview
Problem
Existing piston compressor idle systems rely on a common relief mechanism that connects working spaces to another space via a relief channel, resulting in reduced or no compression during idle operation, which is inefficient and lacks a robust alternative for managing pressure conditions.
Innovation Solution
A two-stage piston compressor with self-closing relief valves integrated into the cylinder head, specifically a first relief valve for the first compressor stage and a second for the second stage, which can be switched to an idle position using control air, electromagnetics, or hydraulics, to manage pressure and prevent compression during idle operation by closing connecting channels and utilizing an intermediate chamber for pressure relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a common relief mechanism is used to connect working spaces to another space via a relief channel, then idle operation is achieved, but compression efficiency is reduced and energy consumption increases
Solution Approach 1:
The patent divides the relief function into separate relief valves for each compressor stage instead of using a common relief mechanism. Each relief valve independently manages pressure relief for its specific stage, allowing precise control over when and where relief occurs, thereby maintaining compression efficiency during idle operation while minimizing energy loss.
Solution Approach 2:
The patent employs dynamically controllable relief valves that can switch between closed and open states based on operational requirements. During idle operation, the relief valves open to allow pressure equalization without full compression, while during compression operation, they close to maintain full compression efficiency. This dynamic control optimizes the balance between productivity and energy consumption.
2Loss of energy
If relief valves are used to prevent compression during idle operation, then energy consumption is reduced, but pressure control precision is compromised
Solution Approach 1:
The patent incorporates pressure sensors that continuously monitor the pressure in each compressor stage and provide feedback to the control system. This feedback enables the relief valves to open or close based on actual pressure conditions, ensuring precise pressure control during both idle and compression operations while minimizing energy consumption.
Solution Approach 2:
The patent replaces purely mechanical relief mechanisms with a control system that uses sensors, actuators, and electronic control logic. This substitution enables more precise pressure control and faster response times compared to traditional mechanical systems, while maintaining energy efficiency during idle operation.
3Device complexity
If a single relief channel is used for both compressor stages, then device complexity is reduced, but operational flexibility is limited
Solution Approach 1:
The patent separates the relief system into independent relief valves for each compressor stage, allowing each stage to be controlled independently. This segmentation provides operational flexibility to manage pressure conditions in each stage separately, optimizing performance for different operating scenarios while keeping the overall structure relatively simple.
Solution Approach 2:
The patent designs the relief valves to serve multiple functions: pressure relief during compression operation, pressure equalization during idle operation, and protection against pressure anomalies. This multi-functionality provides operational flexibility without requiring separate dedicated components for each function, thereby limiting the increase in device 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 allows for efficient switching between delivery and idle modes, maintaining high efficiency and reducing energy consumption by ensuring no pressure drop during idle operation, enabling quicker transitions between modes and improved cooling of compressed air.
Implementation Method 1
the relief valves each comprising a spring that moves the relief valves into the compressor operating position
Implementation Method 2
the first relief valve closes a first connecting channel between a first piston chamber and an inlet channel of the compressor stage and the second relief valve closes a second connecting channel between a piston chamber of the second compressor stage and an intermediate chamber
Data Source
Figure 1~2
AI summary
A reciprocating compressor (1) for a compressed air supply system in a motor vehicle, comprising a cylinder head (21) in which a relief system is integrated, comprising a first relief valve (9) associated with a first compressor stage (2) and a second relief valve (10) associated with a second compressor stage (10), wherein the relief valves (9, 10) are switchable from a compressor operating position to an idle position. In the compressor's operating position, the first relief valve (9) closes a first connecting channel (16) between a first piston chamber (18) and an inlet channel (5) of the first compressor stage (2), and the second relief valve (10) closes a second connecting channel (17) between a second piston chamber (19) of the second compressor stage (3) and an intermediate chamber (13a).