Reciprocating Compressor Valve Speed Control
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Solution Overview
Problem
Existing methods for controlling the flow rate of reciprocating compressors, such as stepless reverse flow control and intermittent control, lead to high wear on compressor valves and increased maintenance due to high impact stress and uneven gas delivery, with reverse flow control causing gas heating and reduced delivery reliability at lower flow rates.
Innovation Solution
A method combining stepless reverse flow control and intermittent control, using an unloader driven by a control device to influence the closing element of the suction valve, allowing for precise speed control of the closing element to reduce impact stress and maintain valve operation at lower speeds, thereby reducing wear and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stepless reverse flow control is used to control delivery quantity, then flow rate can be continuously adjusted, but valve wear increases due to high impact stress
Solution Approach 1:
The unloader is activated before the suction valve closing element makes contact with the seat, pre-opening the valve at a controlled rate. This preliminary action prevents the closing element from accelerating to high speeds and impacting the seat with high stress, thereby reducing wear while maintaining delivery quantity control capability
Solution Approach 2:
The system dynamically switches between different control modes (stepless reverse flow control for high delivery quantities, intermittent control for low delivery quantities) based on the required flow rate. This dynamic adaptation optimizes valve operation conditions across different operating ranges, reducing wear while maintaining versatility
2Reliability
If intermittent control is used to regulate flow rate, then valve wear is reduced, but delivery quantity can only be adjusted in stages
Solution Approach 1:
The invention merges intermittent control and stepless reverse flow control into a unified system that combines the advantages of both methods. Intermittent control keeps the valve open during entire work cycles to reduce wear, while stepless reverse flow control provides continuous flow rate adjustment within each cycle, achieving both reduced wear and precise delivery quantity regulation
3Productivity
If unloader prevents closing element closure during entire cycle, then delivery quantity is reduced, but gas heating occurs in compression chamber
Solution Approach 1:
Instead of preventing closure during the entire cycle, the unloader applies partial action by pre-opening the valve only during a specific portion of the compression stroke. This allows the valve to close normally during other portions, maintaining adequate gas heating and delivery quantity while still achieving flow rate control through the controlled pre-opening phase
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for delivery quantity control of a reciprocating compressor, wherein the motion of a closing organ (5b) of an automatic suction valve (5) is influenced during at least one part of a cycle of the crankshaft by means of a retraction gripper (6), wherein the method comprises a continuously variable return flow control, wherein the retraction gripper (6) contacts the closing organ (5b) and prevents the same from closing during a first partial segment (K1) of the cycle of the crankshaft, and wherein the retraction gripper (6) is retracted during a second partial segment (K2) of the cycle of the crankshaft and the closing organ (5b) is closed, wherein the retraction gripper (6) is retracted such that the speed of the moving closing organ (5b) is reduced prior to contacting the suction valve (5).