Hydraulic Compressor Piston Sealing for Gas Contamination
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Solution Overview
Problem
Hydraulically driven piston compressors face contamination risks due to hydraulic fluid and particle propagation, especially in sensitive gases like hydrogen, and wear-related issues with seals in horizontal arrangements.
Innovation Solution
A compressor device design featuring separate drive cylinders and compression cylinders with non-positive fluidic coupling and pressure compensation, along with a mechanical connection system to synchronize piston movement, and a connection chamber filled with a functional gas for purging and leak detection, minimizes contamination by maintaining spatial separation and using a labyrinth seal for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hydraulic fluid is used to drive the piston compressor, then the compressor can achieve high power and efficient operation, but the hydraulic fluid may leak and contaminate the compressed gas
Solution Approach 1:
The compressor is divided into separate hydraulic drive section and gas compression section with distinct sealing systems. The piston rod passes through a sealed interface that separates the hydraulic fluid environment from the gas environment, preventing contamination while maintaining independent high-power hydraulic drive functionality.
Solution Approach 2:
A sealed interface or seal system acts as an intermediary between the hydraulic drive mechanism and the gas compression chamber. This intermediary component allows mechanical force transmission while blocking the migration of hydraulic fluid into the gas space, thus enabling power transmission without contamination.
2Area of stationary object
If the compressor is arranged horizontally to save space, then the footprint is reduced, but seal wear increases due to gravitational effects on hydraulic fluid
Solution Approach 1:
The seal interface is designed to minimize the influence of gravitational potential differences on hydraulic fluid pressure distribution. By optimizing the seal geometry and positioning, the system achieves more uniform pressure distribution across the seal contact surface, reducing asymmetric wear even in horizontal orientation.
Solution Approach 2:
Flexible seal elements or membrane-like sealing structures are employed that can adapt to pressure variations and maintain effective sealing contact. These flexible seals compensate for minor misalignments and pressure imbalances caused by horizontal positioning, extending seal life and reliability.
3Productivity
If multiple compression stages are used to increase compression ratio, then the compression efficiency is improved, but the complexity of the device increases
Solution Approach 1:
Multiple compression stages are merged into a single integrated compressor unit with shared hydraulic drive mechanisms and common structural support systems. The pistons for different stages are coupled to the same hydraulic piston rod, allowing multi-stage compression to be achieved without proportionally increasing the number of hydraulic cylinders or drive mechanisms.
Solution Approach 2:
The hydraulic drive system is designed with universal components that can drive multiple compression pistons simultaneously. A single hydraulic piston rod can be mechanically coupled to multiple compression pistons through linkage mechanisms, allowing one hydraulic system to perform the function of driving multiple compression stages, thus reducing overall system 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 design effectively reduces the risk of gas contamination by ensuring synchronized piston movement, preventing hydraulic fluid leakage, and maintaining a clean environment for the gas compression process, enhancing the reliability and efficiency of gas compression.
Implementation Method 1
The at least one first or second drive chamber is able to be periodically impinged with a hydraulic fluid pressure in order for the respective drive piston to be moved
Implementation Method 2
a movement of a drive piston which by way of a mechanical connection means such as, for example, a piston rod, is connected to a compression piston by way of which a volumetric variation of a compression chamber
Implementation Method 3
a volumetric variation of a compression chamber, and thus a compression of the gas, is periodically caused
Data Source
AI summary
A compressor device for compressing a gas in at least one compression chamber in at least one compression cylinder is disclosed. In each of at least two drive cylinders, at least one drive piston is disposed, said at least one drive piston dividing each of the at least two drive cylinders into two drive chambers. The at least one first and second drive chamber, by way of a hydraulic fluid, are able to be periodically impinged with a fluid pressure in order for the respective drive piston to be moved. Each of the remaining drive chambers in the at least two drive cylinders, by way of a connection piece, are connected in a non-positive locking manner by a fluid. The movement of the drive pistons by way of at least one mechanical connection means is able to be transmitted to at least one compression piston.