Fluid Coupling Drive for Drill Rig Air Compressor
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Solution Overview
Problem
Oil flooded rotary screw air compressors in blasthole drill rigs are inefficient, consuming excessive energy and fuel during standby operations and requiring additional components that wear out quickly, such as the wet clutch system and air control systems.
Innovation Solution
A fluid coupling is used between the prime mover and the air compressor, allowing for variable speed control by adjusting the amount of oil within the coupling, which generates slippage between the input pump and output turbine, enabling energy and fuel savings by reducing the compressor's speed during standby and quickly restarting it when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a wet clutch system is used to disconnect the air compressor from the diesel engine during standby operations, then fuel consumption is reduced, but the friction clutch wears significantly over time and causes total stoppage requiring air storage tank refilling
Solution Approach 1:
The patent replaces the mechanical wet clutch system with a fluid coupling device that uses hydraulic fluid to transmit power. This substitution eliminates the friction clutch and its associated wear problems while maintaining the ability to disconnect the air compressor from the engine during standby operations. The fluid coupling allows for smooth engagement and disengagement without mechanical contact, thereby improving reliability.
Solution Approach 2:
The patent employs a fluid coupling device that utilizes hydraulic principles to transmit power between the engine and air compressor. By using hydraulic fluid instead of mechanical friction, the system achieves both energy savings during standby and improved reliability through wear-free operation. The hydraulic coupling enables progressive engagement and disengagement, avoiding the total stoppage issues of mechanical clutches.
2Loss of energy
If air is vacuumed from the discharge port and restricted at the inlet to reduce compression ratio while operating at full speed, then energy consumption is reduced, but additional valves and vacuum pump are required and rotational wear increases
Solution Approach 1:
The patent replaces the complex air control system with a fluid coupling device that controls compressor speed hydraulically. Instead of using vacuum pumps, additional valves, and sensors to reduce compression ratio at full speed, the system uses hydraulic fluid pressure to directly control the rotational speed of the compressor. This substitution simplifies the device by eliminating unnecessary components while achieving the same energy-saving goal through speed control rather than compression ratio control.
3Productivity
If the air compressor size is increased to meet demands for increased rates of penetration, then drilling speed is improved, but fuel cost and energy consumption increase
Solution Approach 1:
The patent applies dynamic control to the air compressor system by using a fluid coupling device that allows the compressor speed to vary based on operational needs. During drilling operations, the compressor can operate at full speed to meet high air demand and support increased rates of penetration. During standby operations, the fluid coupling automatically reduces compressor speed, significantly reducing fuel consumption. This dynamic speed control enables the system to maintain large compressor capacity when needed while minimizing energy waste during idle periods.
Solution Approach 2:
The patent changes the operating parameters of the air compressor by controlling its rotational speed through the fluid coupling device. Instead of operating the compressor at constant full speed or using a larger fixed-capacity compressor, the system dynamically adjusts the speed parameter to match actual air demand. This parameter change allows the compressor to deliver high capacity during drilling (supporting increased rates of penetration) while consuming minimal fuel during standby operations.
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 reduces fuel and energy consumption by up to 50%, extends the life of the air compressor and fluid coupling by avoiding additional wear parts, and simplifies control systems, resulting in significant cost savings over time.
Implementation Method 1
generating slippage between an input pump in the fluid coupling and an output turbine in the fluid coupling
Data Source
AI summary
A drill rig includes a base, a drill tower coupled to and extending from the base, a drill pipe coupled to and supported by the drill tower, an air compressor coupled to the base, a prime mover coupled to the air compressor, and a fluid coupling disposed between and coupled to both the prime mover and the air compressor.