Rotary Compressor Near-Isothermal Cooling Gate
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Solution Overview
Problem
Current rotary compressor designs face limitations in achieving high pressure ratios and efficiency due to mechanical stress, vibration, noise, and inefficiencies related to liquid handling and heat transfer, particularly in near-isothermal compression applications.
Innovation Solution
A rotary compressor design featuring a non-circular rotor with cycloid and constant radius portions, a gate mechanism that separates compression chambers, and atomized liquid injection for rapid heat transfer, allowing for high-pressure compression with reduced vibration and noise, and the ability to handle liquids effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If traditional rotary compressor designs are used, then the structure is simpler, but the pressure ratio is limited to less than 20:1 and efficiency is reduced
Solution Approach 1:
The compression process is divided into multiple stages through the use of multiple rotors (first rotor and second rotor) with different compression ratios. The first rotor provides initial compression while the second rotor completes the compression to achieve high pressure ratios, allowing each rotor to operate within optimal parameters and reducing overall system complexity compared to a single-stage high-ratio compressor
Solution Approach 2:
The patent employs dynamic adjustment of compression parameters through variable speed operation and adjustable clearance volumes between rotors and housing. This allows the compressor to adapt to different pressure ratio requirements and maintain high efficiency across a range of operating conditions without requiring complex fixed-ratio multi-stage designs
2Productivity
If compression speed is increased to achieve higher flow rates, then productivity improves, but vibration and noise increase
Solution Approach 1:
The harmful vibrations and noise generated during compression are extracted and isolated through dedicated vibration isolation mounts and noise barriers. These components separate the compression process from the external environment, allowing high-speed operation for improved productivity while preventing vibration and noise from propagating to the surrounding structure
Solution Approach 2:
Vibration isolation mounts and damping elements are installed beforehand to cushion and absorb vibrations before they can propagate through the compressor structure. This preventive measure reduces noise and vibration without requiring active control systems, maintaining productivity while mitigating harmful effects
3Temperature
If liquid is injected for cooling, then heat transfer efficiency improves, but liquid handling complexity increases
Solution Approach 1:
The liquid cooling system is designed to be self-regulating, where the liquid level in the cooling chamber automatically adjusts to the required amount based on thermal load. The liquid is introduced through simple injection mechanisms and excess liquid is drained automatically, eliminating the need for complex dosing systems and control mechanisms while maintaining effective heat transfer
4Stress or pressure
If mechanical force is applied to increase compression pressure, then pressure ratio improves, but mechanical stress and component wear increase
Solution Approach 1:
The patent reduces direct mechanical stress by using a liquid-cooled compression system where thermal management plays a critical role in reducing mechanical loads. The liquid cooling system removes heat that would otherwise cause thermal expansion and increased mechanical stress, allowing compression to be achieved with reduced mechanical force and consequently lower component wear
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
The design achieves near-isothermal compression with high efficiency, enabling higher pressure ratios and reduced mechanical stress, while being tolerant of liquids and minimizing inefficiencies from over- and under-compression.
Implementation Method 1
atomized liquid is injected into the compression chamber in such a way that a high and rapid rate of heat transfer is achieved between the gas being compressed and the injected cooling liquid
Implementation Method 2
The liquid is atomized to provide increased surface area for heat absorption
Data Source
AI summary
A positive displacement compressor designed for near isothermal compression. A rotor includes a curved sealing portion that coincides with a in an interior rotor casing wall. Liquid injectors provide cooling liquid. A gate moves within the compression chamber to either make contact with or be proximate to the rotor as it turns. Gate positioning systems position the gate in this manner, taking into account the shape of the rotor. Outlet valves allow for expulsion of liquids and compressed gas. The unique geometry and relationship between the parts provides for efficiencies and higher pressures not previously found in existing compressor designs.