Piston Compressor Hybrid Drive for Lower Mechanical Load
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Solution Overview
Problem
Existing piston compressors face inefficiencies due to power loss in belt drives, mechanical load limitations, and high costs associated with over-dimensioned drive groups, particularly for high power applications, and require complex motion control to prevent piston collisions.
Innovation Solution
A piston compressor design incorporating a complementary electromagnetic linear drive alongside a traditional crank and rod mechanism, allowing for a share of 20-90% of the total power to be supplied electromagnetically, reducing mechanical load and enabling smaller, less expensive drive groups and bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a belt drive is used to transmit power from the motor to the drive shaft, then the drive group can be designed with standardized components, but power loss increases by 3-5% of the delivered motor power
Solution Approach 1:
The patent extracts the belt drive from the power transmission system and replaces it with a direct drive configuration where the motor shaft is directly coupled to the drive shaft, eliminating the intermediate belt transmission and its associated power losses while maintaining standardized component design
2Power
If a high power drive group is selected to meet flow rate and pressure requirements, then the compressor can handle higher loads, but the drive group becomes heavier and more expensive
Solution Approach 1:
The patent applies dynamic load distribution by using multiple drive shafts that can independently adjust their power contribution based on instantaneous load requirements, allowing the system to handle peak loads without requiring all drive shafts to be permanently oversized, thus reducing overall drive group weight
3Stress or pressure
If oil film bearings are used to handle high mechanical forces, then the compressor can operate at high pressures, but power loss increases by 5-10%
Solution Approach 1:
The patent replaces the mechanical oil film bearing system with a magnetic bearing system that uses magnetic fields to support and rotate the drive shafts without physical contact, eliminating the friction and power loss associated with oil film bearings while maintaining the capability to handle high operating pressures
4Strength
If the critical load of the piston rod and articulation is considered, then the mechanical transmission can be properly dimensioned, but the drive group must be over-dimensioned leading to higher costs
Solution Approach 1:
The patent segments the power transmission into multiple independent drive shafts, each driving its own piston compressor element, which distributes the mechanical loads and allows each component to be optimally dimensioned for its specific load rather than requiring all components to be over-dimensioned for peak loads
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 power loss, enables smaller and lighter compressors, and allows for higher operating pressures with improved volumetric efficiency and reduced costs, eliminating the need for complex safety margins.
Implementation Method 1
the piston being provided with a complementary drive in the form of an electromagnetic linear drive
Data Source
AI summary
A piston compressor, including at least one piston compressor element (3) that is provided with a housing (8) with a compression chamber (13) in which a piston (10) is arranged movably back and forth in an axial direction (X-X′) between an upper dead point and a lower dead point by means of a drive shaft (5) driven by a rotary motor (6), and in which between this drive shaft (5) and the piston (10), a kinematic transmission (20) is provided for the primary drive of the piston (10), wherein the piston (10) is provided with a complementary drive (25) in the form of an electromagnetic linear drive.