Eccentric Plunger Compressor Wear Reduction
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Solution Overview
Problem
Positive-displacement reciprocating compressors face issues with sealing element wear due to the oscillating piston mechanism, leading to reduced efficiency, incomplete air compression, and the need for storage tanks that increase size and complexity, while also causing energy inefficiencies and safety concerns.
Innovation Solution
A compressor design featuring a motor with a rotation shaft coupled to eccentric means, allowing for axial motion of the plunger within the cylinder, which reduces sealing element wear and eliminates the need for storage tanks by providing a continuous air flow through a collection chamber that refills quickly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an oscillating piston mechanism is used, then the compressor can perform reciprocating motion to compress air, but the sealing elements undergo excessive wear due to continuous irregular oscillation and rubbing against cylinder walls
Solution Approach 1:
Instead of using an oscillating piston mechanism where the piston itself oscillates irregularly, the invention inverts the approach by using a rotating crank mechanism that converts rotational motion into linear reciprocating motion of the piston. This inversion of the motion generation method eliminates the irregular oscillation and excessive rubbing of sealing elements against cylinder walls, thereby improving sealing element durability while maintaining reciprocating compression capability
2Reliability
If the oscillating piston performs an incomplete stroke to limit sealing element wear, then sealing element life is extended, but compressed air production decreases and compressor efficiency is reduced
Solution Approach 1:
The invention inverts the motion generation approach by using a rotating crank mechanism instead of oscillating piston motion. This allows the piston to complete full strokes without the irregular oscillations that cause excessive sealing element wear, thereby simultaneously improving sealing element life and maximizing compressed air production efficiency
3Ease of operation
If a storage tank is added to provide continuous compressed air flow, then air flow continuity is improved, but the overall dimensions and constructional complexity of the compressor increase
Solution Approach 1:
The invention applies the continuity of useful action principle by using multiple pistons arranged in parallel, each driven by the rotating crank mechanism. This multi-piston configuration ensures that while one piston is completing its compression stroke, other pistons are in different phases of their cycle, providing a continuous and steady flow of compressed air without the need for large storage tanks, thereby maintaining flow continuity while reducing overall device complexity
4Ease of operation
If a storage tank is added to store compressed air, then continuous air supply is achieved, but the compressor requires more space and has reduced manoeuvrability
Solution Approach 1:
The invention achieves continuous air supply without large storage tanks by using multiple pistons operating in parallel. The synchronized reciprocating motion of multiple pistons ensures continuous compression and delivery of air, eliminating the need for large-volume storage tanks and maintaining compact overall dimensions for improved manoeuvrability
5Reliability
If the compressor is stopped and then restarted, the storage tank must be refilled with nominal flow rate, causing energy loss and additional operations
Solution Approach 1:
The multi-piston configuration ensures that compressed air flow is continuous and stable even during operational transitions. When the compressor is restarted, the synchronized pistons immediately resume compression without requiring a refill period, eliminating energy waste and operational delays associated with tank refilling
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 design minimizes sealing element wear, enhances efficiency, and provides a continuous air flow without the need for storage tanks, reducing overall dimensions, constructional complexity, and energy consumption, while improving handling and safety.
Implementation Method 1
said driving means comprise a motor having the rotation shaft coupled with eccentric means mechanically connected to said plunger and able to impose longitudinal displacements to said plunger according to an orthogonal direction with respect to the rotation axis of said shaft
Data Source
AI summary
A positive-displacement reciprocating compressor, comprising a plunger slidingly coupled inside a cylinder, in which a compression chamber is located, and operatively connected to a motor which put it in motion inside the cylinder. The motor has a rotation shaft coupled with an eccentric cam mechanically connected to the plunger and able to impose longitudinal displacements to the plunger according to an orthogonal direction with respect to the rotation axis of the shaft.