Variable Oil Temperature Control in Air Compressors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing oil feed type air compressors have a fixed target discharge temperature set higher than the dew-point temperature, which does not account for pressure fluctuations between load and unload operations, leading to inefficient power consumption during unload operations.
Innovation Solution
A controller is used to variably control the cooling power of the oil cooler, adjusting the oil temperature to a lower target value during unload operations compared to load operations, optimizing the oil temperature for efficient cooling and reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed target discharge temperature higher than the dew-point temperature is used, then the compressed air can be prevented from supercooling and generating condensed water, but the power consumption increases during unload operations due to excessive cooling
Solution Approach 1:
The patent applies dynamics by making the target discharge temperature variable rather than fixed. The controller dynamically adjusts the target discharge temperature based on the operating mode (load or unload) detected by the pressure sensor. During unload operations, the target temperature is lowered to reduce unnecessary cooling and power consumption, while during load operations, the target temperature is maintained higher to prevent condensed water generation. This dynamic adjustment resolves the contradiction between reliability and energy efficiency.
Solution Approach 2:
The patent applies parameter changes by modifying the target discharge temperature parameter according to operating conditions. The controller changes the target temperature parameter from a fixed value to a variable value that adapts to load and unload operations. This parameter change allows the system to optimize power consumption during unload operations while maintaining sufficient cooling to prevent condensed water generation, thereby resolving the technical contradiction.
2Reliability
If the cooling power of the oil cooler is increased to maintain a fixed target discharge temperature, then the oil temperature can be controlled to prevent condensed water, but the power consumption increases unnecessarily during unload operations
Solution Approach 1:
The patent applies dynamics by making the cooling power of the oil cooler variable rather than constant. The controller dynamically adjusts the cooling power based on the detected operating mode. During unload operations, the cooling power is reduced to match the lower cooling demand, preventing excessive energy consumption. During load operations, the cooling power is increased to maintain adequate temperature control and prevent condensed water generation.
Solution Approach 2:
The patent applies parameter changes by modifying the cooling power parameter according to operating conditions. The controller changes the cooling power parameter from a fixed value to a variable value that adapts to load and unload operations. This parameter change allows the system to optimize energy efficiency during unload operations while maintaining sufficient cooling capacity to prevent condensed water generation, thereby resolving the technical contradiction between reliability and energy loss.
3Use of energy by moving object
If the discharge temperature is lowered to reduce power consumption, then the cooling efficiency improves, but the risk of supercooling and condensed water generation increases
Solution Approach 1:
The patent applies dynamics by making the discharge temperature variable rather than fixed. The controller dynamically adjusts the discharge temperature based on the operating mode detected by the pressure sensor. During unload operations, the discharge temperature is lowered to improve cooling efficiency and reduce power consumption. During load operations, the discharge temperature is raised to prevent supercooling and condensed water generation. This dynamic adjustment resolves the contradiction between energy efficiency and harmful effects.
Solution Approach 2:
The patent applies parameter changes by modifying the discharge temperature parameter according to operating conditions. The controller changes the discharge temperature parameter from a fixed value to a variable value that adapts to load and unload operations. This parameter change allows the system to optimize power consumption during unload operations while preventing supercooling and condensed water generation during load operations, thereby resolving the technical contradiction.
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 approach reduces the power consumption of the compressor body during unload operations by efficiently cooling the compressed air, aligning with the decreased dew-point temperature at lower pressures.
Implementation Method 1
The oil-feeding system has an oil cooler for cooling the oil
Implementation Method 2
The separator separates the compressed air discharged from the compressor body and the oil contained in the air
Implementation Method 3
The compressor body compresses air while feeding the oil into the compression chamber
Implementation Method 4
a cooling fan for feeding cooling air to an oil cooler
Data Source
AI summary
The present invention provides an oil feed type air compressor that can reduce a power consumption of a compressor body during an unload operation. The oil feed type air compressor includes: a compressor body (1) compressing air while feeding an oil into a compression chamber; a separator (4) disposed on a discharge side of the compressor body; a compressed air-feeding system (5) feeding the compressed air separated by the separator to a use destination of the compressed air; an oil-feeding system (6) feeding the oil separated by the separator to the compression chamber of the compressor body; an oil cooler (11) and a temperature sensor (12) disposed in the oil-feeding system; and a controller enabling execution of a temperature control. The temperature control by the controller is performed by variably controlling a rotation speed of a cooling fan (13) such that, during the load operation, a temperature detected by the temperature sensor is a target value T1, and during the unload operation, the temperature detected by the temperature sensor is a target value T2 (with the proviso of T1>T2).