Screw Compressor Clutch Control for Power Loss Reduction
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Solution Overview
Problem
Screw compressors experience significant power losses during unload operations due to incomplete closure of the suction channel, leading to increased gas temperature and potential damage, with existing solutions only partially addressing the issue of power loss reduction.
Innovation Solution
A screw compressor with a clutch mechanism controlled by a pressure sensor that disconnects the driving machine from the compressor main body when discharge pressure exceeds a set value, allowing for complete disconnection and reduced power consumption, and includes features to prevent frequent switching and wear on the clutch mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the suction adjustment valve is closed during unload operation, then the discharge capacity is reduced, but the suction channel cannot be completely closed causing infinite compression ratio and excessive temperature increase
Solution Approach 1:
The invention extracts the driving machine from the compressor main body during unload operation by using a clutch mechanism. When unload operation is detected, the clutch mechanism disconnects the driving machine, allowing the compressor to stop or run without load, thereby avoiding the temperature increase problem that occurs when the suction channel is closed.
2Duration of action of stationary object
If the suction adjustment valve is kept open during unload operation, then the compressor can operate continuously, but 20 to 30% of power is wasted due to incomplete closure of the suction channel
Solution Approach 1:
The invention makes the connection between the driving machine and compressor main body dynamic through the clutch mechanism. During unload operation, the clutch mechanism disconnects the driving machine, allowing the compressor to operate with minimal or no load, thereby reducing power loss from 20-30% to nearly zero while maintaining continuous operation capability.
3Loss of energy
If the clutch mechanism is frequently switched between on-state and off-state, then the power loss is reduced, but the clutch mechanism wears out quickly
Solution Approach 1:
The invention implements preliminary action by maintaining the clutch mechanism in the off-state during unload operation and only switching to the on-state when actually needed. This prevents frequent switching and extends clutch mechanism life while still achieving power loss reduction.
Solution Approach 2:
The invention uses feedback from the discharge pressure sensor to control the clutch mechanism. The controller continuously monitors discharge pressure and only switches the clutch mechanism when necessary, based on actual operating conditions, thereby reducing unnecessary switching and extending clutch life.
4Loss of energy
If the driving machine is completely disconnected during unload operation, then power loss is minimized, but the compressor cannot supply compressed gas when needed
Solution Approach 1:
The invention makes the driving machine connection dynamic through the clutch mechanism. During unload operation, the clutch mechanism disconnects the driving machine to minimize power loss. When compressed gas supply is needed, the clutch mechanism can be switched back to the on-state to restore full functionality, thus adapting to changing operational requirements.
Data Source
AI summary
A screw compressor including a driving machine having an output shaft coupled to an input shaft of a compressor main body; a clutch mechanism between the output shaft of the driving machine and the input shaft of the compressor main body; a pressure sensor installed in a discharge channel; and a controller that controls the switching of the clutch mechanism between an engaged state and a disengaged state based on a discharge pressure value detected by the pressure sensor is disclosed. When the discharge pressure value becomes higher than an unload set value that is predetermined, the controller controls the clutch mechanism to be switched to the disengaged state. According to the above screw compressor, power losses are reduced even when the supply of compressed gas is hardly required.