Blasthole Drill Compressor Clutch Sync to Cut Fuel Waste
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Solution Overview
Problem
Blasthole drill rigs consume excessive fuel and energy due to the air compressor being powered during standby operations, and existing clutch systems suffer from wear and maintenance issues.
Innovation Solution
A connection assembly with a dry clutch and RPM matcher, utilizing a hydraulic or electric starter to synchronize the compressor's speed with the engine before engagement, reducing wear and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a dry clutch is used to disconnect the compressor from the engine during standby, then fuel consumption is reduced, but clutch wear increases due to start/stop cycles and speed mismatch
Solution Approach 1:
The system pre-rotates the compressor to match engine speed before engaging the clutch, eliminating speed mismatch during engagement. This preliminary speed synchronization prevents the friction and wear that would otherwise occur during clutch engagement, allowing frequent start/stop cycles without compromising clutch life.
Solution Approach 2:
A hydraulic motor acts as an intermediary device between the engine and compressor during startup. The hydraulic motor temporarily drives the compressor to match engine speed before the clutch engages, mediating the speed difference and preventing direct frictional contact between mismatched components.
2Reliability
If a wet clutch is used to reduce clutch plate wear through lubrication, then clutch wear is reduced, but system complexity increases due to additional components
Solution Approach 1:
The patent replaces the mechanical lubrication system of a wet clutch with a hydraulic motor-based speed matching system. Instead of using lubricated clutch plates that require hydraulic oil, coolers, and reservoirs, the invention uses a hydraulic motor to pre-rotate the compressor, eliminating the need for complex lubrication infrastructure while achieving the same wear reduction goal.
3Productivity
If the compressor is continuously powered during standby operations, then immediate air supply is available when needed, but fuel and energy are wasted
Solution Approach 1:
The system performs preliminary rotation of the compressor using the hydraulic motor to bring it up to operating speed before clutch engagement. This allows the compressor to be quickly activated when needed without requiring continuous operation during standby, as the pre-rotation capability enables rapid startup without fuel waste.
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 system minimizes fuel waste and extends clutch life by ensuring synchronized startup, eliminating frictional wear and reducing energy consumption during standby.
Implementation Method 1
As the compressor is brought up to the engine rotating speed by a hydraulic or electric system
Data Source
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AI summary
A compressor drive system is arranged to selectively operate a compressor (18) and engine (14) of a drill rig (10). The compressor drive system includes a connection assembly (20) coupled between the engine and the compressor. The connection assembly includes a ring gear (28) arranged to be coupled to the compressor and a clutch (26) arranged to be connected to the engine, wherein a starter (24) is connected to the ring gear and arranged to engage the ring gear to rotate the compressor to a predetermined rotation speed before the clutch is engaged.