Oil-injected screw compressor
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Solution Overview
Problem
Integrated oil-injected screw compressors face challenges in accessing internal parts for maintenance and repair due to complex disassembly requirements, which complicates maintenance and replacement of worn rotating parts.
Innovation Solution
The compression unit is designed to be completely removable from the external casing, allowing the geometry of the tank to be modified independently, with a removable crankcase and flanges for easy assembly and disassembly, and the use of separate materials for different components to manage thermal expansion and mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the compression unit is integrated inside the tank with fixed mounting brackets, then the structural stability and sealing are improved, but the maintenance access and part replacement become difficult
Solution Approach 1:
The compression unit is segmented from the tank structure, mounted on a removable flange assembly rather than fixed brackets. This allows the compression unit to be separated into distinct modules (compression unit, flange, sealing elements) that can be independently removed for maintenance while maintaining structural integrity during operation.
Solution Approach 2:
The mounting system transitions from a static fixed bracket configuration to a dynamic removable flange assembly. The flange with multiple bolt holes and sealing surfaces provides a stable connection during operation but can be easily disconnected when maintenance is required, adapting the structural rigidity based on operational needs.
2Adaptability or versatility
If the tank geometry is modified to accommodate different applications, then the adaptability and versatility are improved, but the complexity of integrating the compression unit increases
Solution Approach 1:
The compression unit extraction mechanism is separated from the tank geometry design. The standardized flange assembly with mounting holes and sealing surfaces is extracted as a universal interface, allowing different tank geometries to be designed independently while maintaining consistent integration methods through the removable flange system.
Solution Approach 2:
The flange assembly serves multiple functions: it provides structural support for the compression unit, creates a seal between the compression unit and tank, and enables easy removal for maintenance. This universal interface can be applied to various tank geometries without increasing integration complexity, as the same flange design works across different tank configurations.
3Ease of repair
If the compression unit is made completely removable with flanges, then the ease of maintenance and material selection are improved, but the sealing complexity and assembly requirements increase
Solution Approach 1:
The sealing elements are pre-installed on the flange assembly during manufacturing, creating a pre-assembled unit with integrated sealing. This preliminary action ensures proper sealing configuration before the compression unit is installed in the tank, reducing the complexity of field assembly and maintenance while maintaining easy removability.
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 facilitates easy maintenance and repair of internal components, allows for customization of the compressor's geometry and materials, and ensures reliable sealing and mechanical resistance, optimizing performance and reducing complexity and weight.
Implementation Method 1
volumetric type machines, which obtain gas compression through the simultaneous rotation and translation of the volume created by the relative meshing of the two coupled rotors
Implementation Method 2
injection of lubrication oil, for the surfaces of the contact rotor profiles, of refrigeration one, to guarantee temperatures at the exit from the machine within limits that are acceptable
Data Source
AI summary
A screw compressor includes a hollow casing inside which a reservoir for air and oil is realized and on which, in an upper position, a suction group for air from outside the reservoir having at least an air intake valve and at least an air filter; on one lateral end a flow block provided with an oil/air separation device and an oil filter and at least a valve for extracting compressed air are disposed. The casing is provided with an opening on the opposite side with respect to that on which the flow block is provided.The compressor includes a casing closure flange to which a screw compression unit is fixed that when the flange is placed to close the opening causes the insertion into the reservoir of the unit.