Split Piston High-Pressure Diaphragm Compressor Sealing
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Solution Overview
Problem
High-pressure diaphragm compressors face challenges in piston sealing, oil leakage, and oil supplementation, leading to reduced service life and contamination of the oil-side diaphragm cavity with air, especially at pressures above 200 MPa.
Innovation Solution
A high-pressure diaphragm compressor design featuring a split piston and piston rod structure, a low-pressure oil pump with adjustable oil supplementation, and an energy accumulator to stabilize oil pressure, along with a one-way valve and an overflow valve to manage oil flow and prevent air mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high-pressure combined piston ring or plunger is used for sealing, then sealing performance is improved, but the requirements for centering performance of the piston and oil-side diaphragm head increase, making actual processing and assembly difficult to realize
Solution Approach 1:
The piston is divided into a piston body and a piston rod that are separable. The piston body is retained in the oil-side diaphragm head by a retention groove and retention block structure, allowing the piston rod to be detached for maintenance while keeping the piston body in place. This segmentation simplifies assembly and maintenance while maintaining sealing performance.
Solution Approach 2:
The piston rod is extracted as a separate removable component from the piston body. The retention groove on the piston body and retention block in the oil-side diaphragm head create a retention structure that holds the piston body but allows the piston rod to be removed independently for maintenance or replacement.
2Device complexity
If the oil supplementing amount is determined by the structural parameter of the plunger pump, then the oil supplementing system is simple, but when the leakage amount is larger than the oil supplementing amount, the oil amount in the oil-side diaphragm cavity is reduced, causing the diaphragm to flap and form negative pressure that allows gas to enter
Solution Approach 1:
The oil supplementing system uses a variable displacement plunger pump where the displacement can be adjusted dynamically. The plunger pump's displacement is controlled by a adjusting mechanism that allows the oil supplementing amount to be varied based on actual leakage conditions, ensuring the oil cavity maintains proper oil level and pressure.
Solution Approach 2:
The system changes the operational parameters of the plunger pump by adjusting its displacement. The adjusting mechanism modifies the pump's delivery quantity parameter to match the leakage rate, ensuring adequate oil supplementation without requiring complex additional components.
3Reliability
If a secondary oil supplementing plunger pump is added to increase oil supplementation capability, then oil supply reliability is improved, but the device complexity and difficulty of achieving excessively high oil supplementing pressure increase
Solution Approach 1:
The single plunger pump is designed to perform multiple functions: it can operate in a fixed displacement mode for normal oil supplementation and in a variable displacement mode when higher supplementation is needed. The adjusting mechanism enables the same pump to adapt to different oil supply requirements, eliminating the need for a separate secondary pump.
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
Enhances piston centering and sealing reliability, automatically adjusts oil supplementation based on leakage, and maintains stable oil pressure, preventing air contamination and extending diaphragm life.
Implementation Method 1
an energy accumulator to stabilize oil pressure
Implementation Method 2
A piston pushes the hydraulic oil in the oil-side diaphragm cavity to drive the diaphragm to deform and compress the gas-side diaphragm cavity
Data Source
AI summary
The present application discloses a high-pressure diaphragm compressor. The high-pressure diaphragm compressor includes a gas-side diaphragm head and an oil-side diaphragm head; a diaphragm and an oil distribution disc are disposed between the gas-side diaphragm head and the oil-side diaphragm head, the diaphragm and the oil distribution disc are clamped between the gas-side diaphragm head and the oil-side diaphragm head, and a gas-side diaphragm cavity and an oil-side diaphragm cavity are respectively formed between the diaphragm and the gas-side diaphragm head as well as between the diaphragm and the oil distribution disc; an oil cylinder hole is provided in the oil-side diaphragm head, a piston is arranged in the oil cylinder hole, and a piston rod is disposed below the piston; and the upper end of the piston rod abuts onto the lower end of the piston, the piston may be separated from the piston rod.