Integrated Screw Compressor Motor Design
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Solution Overview
Problem
Existing screw compressor devices suffer from energy losses due to stored compressed air, high start-up torque requirements, friction losses in seals, and separate lubrication and cooling systems that are complex and costly.
Innovation Solution
A vertical screw compressor design where the compression and motor chambers are integrated, eliminating the need for seals between them, using a self-regulating inlet valve and shared lubricants and coolants to minimize energy losses and simplify the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the screw compressor is driven at constant speed with a separate drive motor, then the motor structure is simple and reliable, but the start-up torque requirement is very high when the compression chamber is under pressure
Solution Approach 1:
The patent merges the drive motor and compression chamber into a single integrated unit, eliminating the need for a separate drive motor. This integration allows the motor to be positioned such that it does not need to overcome full compression pressure during start-up, as the compression chamber is filled with air at the same pressure as the discharge line, significantly reducing the start-up torque requirement while maintaining structural reliability
Solution Approach 2:
The patent changes the pressure parameter within the compression chamber during operation. By allowing the compression chamber to be filled with air at discharge line pressure rather than maintaining a pressure differential, the mechanical load on the motor during start-up is reduced, enabling the integrated motor-compressor design to operate reliably with lower torque requirements
2Reliability
If seals are used between the motor and compression chamber, then the system can operate under pressure differential, but friction losses in seals increase energy consumption and cause wear
Solution Approach 1:
The patent merges the motor chamber and compression chamber into a single pressure environment, eliminating the need for seals between these components. By integrating the motor within the compression chamber or positioning it such that both chambers operate at the same pressure, the design removes the source of friction losses and wear associated with seals while maintaining the ability to contain pressure through the overall system design
Solution Approach 2:
The patent extracts the seal component from the system by eliminating the interface between motor and compression chambers that would require sealing. This removal of the seal eliminates the associated friction losses and wear problems while the pressure containment function is maintained through the integrated design
3Force
If compressed air is released from the pressure vessel after the screw compressor stops, then the start-up torque is limited, but energy is lost through the stored compressed air
Solution Approach 1:
The patent merges the pressure vessels into a single integrated system where both chambers operate at the same pressure. This allows the compressed air to be retained in the system without creating excessive pressure differentials that would require high start-up torque, as the integrated design naturally balances the pressure distribution across all chambers
Solution Approach 2:
The patent implements a control system that monitors the pressure in the compression chamber and discharge line, and adjusts the inlet valve and outlet valve accordingly. This feedback control allows the system to maintain optimal pressure levels, retaining compressed air energy while preventing excessive pressure build-up that would increase start-up torque requirements
4Ease of manufacture
If separate lubrication and cooling systems are used for the motor and screw compressor, then each component can be optimized independently, but the device complexity increases and costs rise
Solution Approach 1:
The patent merges the lubrication and cooling systems into a single shared system that serves both the motor and compression chamber. By utilizing the same lubricant and coolant circuits for both components, the design reduces the number of separate systems required, simplifying the overall device structure and reducing costs while still allowing each component to receive appropriate lubrication and cooling
Solution Approach 2:
The patent makes the lubrication and cooling systems universal, with a single system performing multiple functions for both the motor and compression chamber. The same lubricant serves to lubricate motor bearings and compression chamber components, while the same coolant circulates through both the motor and compression chamber, eliminating the need for separate dedicated systems
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 reduces energy losses, minimizes wear and leaks, allows for efficient heat recovery, and enables quicker restarts with reduced energy consumption by maintaining pressure within the system.
Implementation Method 1
a screw compressor (2) with a compression chamber (3) formed by a compression housing (4), in which a pair of meshed compressor rotors are rotatably mounted
Implementation Method 2
a drive motor (10) that is provided with a motor chamber (12) formed by a motor housing (11), in which a motor shaft (13) is rotatably mounted that drives at least one of the aforementioned two compressor rotors
Implementation Method 3
an inlet valve (29) at the inlet (24) of the screw compressor (2)... a passage and a hollow space in which a piston can be moved
Implementation Method 4
an outlet (26) for the discharge of compressed air, which outlet (26) is connected to a pressure vessel (32) via an outlet pipe (31)
Data Source
Figure 1
Figure 2
AI summary
Compressor device that is at least provided with a screw compressor (2) with a compression chamber (3) that is formed by a compression housing (4), with a drive motor (10) that is provided with a motor chamber (12) formed by a motor housing (11) and with an outlet (26) for the discharge of compressed air that is connected to a pressure vessel (32) via an outlet pipe (31), whereby the compression housing (4) and the motor housing (11) are connected directly to one another to form a compressor housing (48), whereby the motor chamber (12) and the compression chamber (3) are not sealed off from one another and whereby the outlet pipe (31) between the pressure vessel (32) and the screw compressor (2) is free of closing means.