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EP3601797B1 - Reciprocating compressor with an extended control range - Google Patents

Reciprocating compressor with an extended control range Download PDF

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Publication number
EP3601797B1
EP3601797B1 EP17712994.7A EP17712994A EP3601797B1 EP 3601797 B1 EP3601797 B1 EP 3601797B1 EP 17712994 A EP17712994 A EP 17712994A EP 3601797 B1 EP3601797 B1 EP 3601797B1
Authority
EP
European Patent Office
Prior art keywords
air
piston compressor
piston
compression
compressor
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP17712994.7A
Other languages
German (de)
French (fr)
Other versions
EP3601797A1 (en
Inventor
Thomas Kipp
Fedor Assonov
Michael Winkler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Knorr Bremse Systeme fuer Schienenfahrzeuge GmbH
Original Assignee
Knorr Bremse Systeme fuer Schienenfahrzeuge GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Knorr Bremse Systeme fuer Schienenfahrzeuge GmbH filed Critical Knorr Bremse Systeme fuer Schienenfahrzeuge GmbH
Publication of EP3601797A1 publication Critical patent/EP3601797A1/en
Application granted granted Critical
Publication of EP3601797B1 publication Critical patent/EP3601797B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B41/00Pumping installations or systems specially adapted for elastic fluids
    • F04B41/02Pumping installations or systems specially adapted for elastic fluids having reservoirs
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B23/00Pumping installations or systems
    • F04B23/04Combinations of two or more pumps
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B23/00Pumping installations or systems
    • F04B23/04Combinations of two or more pumps
    • F04B23/08Combinations of two or more pumps the pumps being of different types
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B35/00Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for
    • F04B35/01Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for the means being mechanical
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/06Cooling; Heating; Prevention of freezing
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/06Cooling; Heating; Prevention of freezing
    • F04B39/064Cooling by a cooling jacket in the pump casing
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B41/00Pumping installations or systems specially adapted for elastic fluids
    • F04B41/06Combinations of two or more pumps
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/08Regulating by delivery pressure
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/20Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00 by changing the driving speed
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B53/00Component parts, details or accessories not provided for in, or of interest apart from, groups F04B1/00 - F04B23/00 or F04B39/00 - F04B47/00
    • F04B53/08Cooling; Heating; Preventing freezing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B61RAILWAYS
    • B61CLOCOMOTIVES; MOTOR RAILCARS
    • B61C17/00Arrangement or disposition of parts; Details or accessories not otherwise provided for; Use of control gear and control systems

Definitions

  • the invention relates to a piston compressor with at least one cylinder for compressing air with a piston arranged movably therein in a compression chamber arranged above the piston in the cylinder, which is connected to an inlet arrangement for air to be compressed and to an outlet arrangement for compressed air.
  • Piston compressors such as, in particular, oil-free piston compressors for rail vehicles, are used to fill compressed air tanks from which compressed air is withdrawn, in particular, at irregular intervals.
  • the piston compressors are usually dimensioned for the filling operation, in which a pressure vessel is to be filled up quickly, which is why a maximum volume flow is made available.
  • operation with maximum volume flow means a rather unfavorable operating state that could be avoided if the delivery capacity of such piston compressors was regulated according to requirements.
  • the interruption control of the compressed air delivery is implemented in that the compressor is switched to standstill as soon as the System pressure has reached the cut-out pressure. If the system pressure then falls to the switch-on pressure, in particular due to the withdrawal of compressed air, the piston compressor is switched to load operation, in which it delivers a maximum volume flow at the nominal speed. Unless larger amounts of compressed air are taken from the compressed air tank or the compressed air system at the same time, the compressed air tank fills up relatively quickly, so that the piston compressor is switched off again for a long time after a short switch-on time.
  • the control spectrum of this known solution is therefore limited to standstill and running under load and is unfavorable and even unsuitable for certain operating conditions due to the associated cold start as well as the higher wear and the longer downtimes of the piston compressor.
  • intermittent operation is implemented at various predefined speeds, for example by switching the motor between four and six poles or by an inverter that can be switched between 50 Hz and 60 Hz.
  • intermittent operation is implemented at various predefined speeds, for example by switching the motor between four and six poles or by an inverter that can be switched between 50 Hz and 60 Hz.
  • only a relatively limited control range can be implemented with the respective compressor due to the motor speeds specified in this process.
  • high engine speeds cause a high thermal load, particularly on oil-free sliding pairs, which significantly reduces the service life of a piston compressor.
  • the solution is a simple approach to regulating the volume flow, the control spectrum is limited by the fixed motor speeds and, under certain operating conditions, the changeover cannot generate a sufficient volume flow.
  • AT 135585 discloses a method for cooling gaseous media, according to which the gas is compressed in two stages, optionally with the interposition of a cooling device, whereupon the compressed gas flows to an expansion machine via a cooling device.
  • the US 2005/0220628 A1 relates to a method for checking a compressor system for malfunctions.
  • the compressor system cited for this purpose comprises two parallel low-pressure cylinders which are connected upstream of a high-pressure cylinder.
  • the invention is therefore based on the object of providing an improved reciprocating compressor with a larger control range of the delivery rate while improving the energy efficiency and power density.
  • a piston compressor with at least one cylinder for compressing air with a piston arranged movably therein in a compression space arranged above the piston in the cylinder is proposed.
  • the compression space has an air inlet and an air outlet and is connected at the air inlet to an inlet arrangement for air to be compressed and is connected to an outlet arrangement for compressed air at the air outlet.
  • the piston compressor can be driven by a first drive device.
  • the inlet arrangement has a pre-compression device, which can be driven by a second drive device with variable power, for increasing the intake pressure and a cooling device for cooling the air to be compressed.
  • the proposed solution makes it possible to increase the volume flow of a reciprocating compressor through the increased intake pressure and the reduced intake temperature of the intake air, whereby its delivery capacity increases.
  • the piston compressor is a known type of piston compressor with a cylinder in which a piston arranged therein is axially movable and in a reciprocating motion sucks in air to be compressed, in particular via an inlet valve arranged at the air inlet, compresses it from an inlet arrangement and in particular via an air outlet discharges arranged outlet valve against a pressure in an outlet arrangement.
  • the piston compressor is one of the first Drive device drivable.
  • the first drive device is an internal combustion engine, an electric drive device or another suitable drive device.
  • a piston compressor according to the invention can be both a dry-running, that is to say oil-free, piston compressor and a piston compressor that is not designed to be oil-free.
  • the inlet arrangement has a pre-compression device that can be driven by a second drive device with variable power.
  • the intake pressure in particular at the air inlet, can be increased variably from an output pressure p 0 up to a maximum pressure p max due to the variable power.
  • the higher suction pressure of the first cylinder in multi-stage piston compressors or the single cylinder in single-stage piston compressors increases the volume flow by ⁇ V, since the compression chamber of the cylinder is filled with air that is to be compressed under higher pressure.
  • the second drive device which is used to drive the pre-compression device, can also be an electric drive device or another suitable drive device, depending on the application.
  • the drive power of the second drive device can also be transferred to the first drive device or another available drive device, for example by means of a gear with a variable ratio.
  • the power transmitted by the second drive device can be variably adjusted.
  • the inlet arrangement has a cooling device through which the air to be compressed, which flows through the inlet arrangement suitable measures cool.
  • the cooling device is arranged in particular in the flow direction of the intake air after the pre-compression device, since the air is heated by the pre-compression.
  • the piston compressor it can also be provided that the intake air is cooled before and after the pre-compression.
  • the inlet arrangement in particular also has at least one conduit device which directs the intake air to the at least one cooling device and to the at least one compression device and connects them to one another and / or to the air inlet of the compression chamber.
  • a cooling device can also be arranged on the outside of a line device.
  • Suitable cooling devices of the inlet arrangement can be, for example, coolant heat exchangers or devices for enlarging the outer surface of the inlet arrangement or a line device such as line loops or cooling fins, which are used, for example, in connection with fans, or any other suitable type of device by means of which the flowing in the inlet arrangement Intake air heat energy can be withdrawn.
  • the proposed solution makes it possible to increase the volume flow of a reciprocating compressor by the factor p Max p 0 to increase the pre-compression device.
  • the delivery capacity of the piston compressor increases due to the increased intake pressure and the reduced intake temperature of the intake air.
  • the variable output of the pre-compression device in conjunction with the increase in output of the piston compressor, enables the piston compressor to have a broader control range towards the top. This also makes it possible to use piston compressors with a smaller overall size, since higher volume flows are achieved due to the increased suction pressure.
  • the proposed solution enables regulated compressor operation with briefly very high performance in the filling operation (large volume flow of the piston compressor) and constant operation with low power (lower volume flow of the piston compressor) in normal operation. This means that there is no risk of vibrations due to free inertia forces at low speeds and the maximum relative speeds of, in particular, oil-free sliding pairs can be maintained.
  • the proposed solution can lower the overall temperature level of a reciprocating compressor.
  • the proposed solution thus increases the control range of the volume flow and thus the delivery capacity of a compressor, leads to a reduction in relevant temperature levels and at the same time increases the energy efficiency and power density of the piston compressor.
  • the piston compressor is driven by a crankshaft which is rotatably mounted in a crankcase.
  • One or more connecting rods, each connected to a piston, are rotatably mounted at an eccentric position of the crankshaft in such a way that their rotational movement is transmitted as a stroke movement to the piston moving axially in a cylinder.
  • the piston compressor has at least one cylinder for compressing air, but can also have two or more cylinders arranged one after the other or in parallel, which are provided for compressing air by means of a piston movably arranged therein, so that the piston compressor can be designed in one or more stages can.
  • the piston compressor also has a crankcase in which a crankshaft is arranged, on which at least one connecting rod connected to a piston is rotatably mounted, the intake air of the at least one cylinder being guided through the crankcase.
  • the intake air of the at least one cylinder is guided through the crankcase, flowing over the elements of the crank drive, essentially the crankshaft, the connecting rods, the underside of the piston or pistons and the bearing elements arranged in between, and cooling them in the process.
  • the intake air is essentially the air that is later sucked into the at least one cylinder of the piston compressor and compressed there.
  • the inlet arrangement has an air discharge device.
  • This embodiment makes it possible to guide a larger volume flow through the crankcase than is later received as intake air in the at least one cylinder of the piston compressor and is compressed there. In this way, the volume flow of cooling air in the crankcase can be increased and, at the same time, the heating of the intake air as it flows through the crankcase can be reduced.
  • the air diverting device can be designed, for example, in the form of a check valve or pressure relief valve, which opens from a predetermined pressure of the intake air.
  • the air discharge device can, however, also be designed in such a way that it can be opened and closed depending on predetermined parameter values, in particular by a control device.
  • excess intake air is discharged from the inlet arrangement into the environment; in another embodiment of an air discharge device, for example, a predetermined proportion of the cooled volume flow of the intake air can be returned to the crankcase.
  • an after-cooling device is arranged for cooling the compressed air after it has passed through the at least one cylinder of the piston compressor.
  • the outlet arrangement has an after-cooling device for cooling the compressed air.
  • the air in the cylinder is heated, so that the compressed air expelled from the compression chamber through the air outlet has an increased temperature. Cooling the compressed air after it has passed through the at least one cylinder by means of at least one after-cooling device of the outlet arrangement simplifies, for example, a subsequent storage of the air or further processing such as e.g. B. dehumidifying the air.
  • the after-cooling device of the outlet arrangement is formed by a partition of the cooling device for cooling the intake air of the inlet arrangement.
  • the piston compressor has a regulating device with which the output of the pre-compression device and thus the suction pressure at the air inlet can be regulated, in particular continuously.
  • the control device is operatively connected to the second drive device, which drives the pre-compression device with variable power.
  • the control device receives signals and / or measured values which are in particular related to the required delivery capacity of the piston compressor and by means of which the control device adjusts the output of the second drive device and thus the pre-compression device. In this way, the degree of pre-compression of the air flowing through the inlet arrangement into the cylinder is regulated by means of the pre-compression device.
  • a method for controlling a reciprocating compressor of the type described above wherein the regulating device adjusts the performance of the pre-compression device between a maximum value that corresponds to a maximum suction pressure (p max ) at the air inlet and a minimum value that corresponds to that caused by the Piston stroke movement in the cylinder corresponds to suction pressure (p 0 ) at the air inlet, regulates.
  • the delivery performance of the piston compressor can thus be adjusted, in particular steplessly, by the method according to the invention in an extended control range between a maximum intake pressure and a minimum intake pressure at the air inlet. In this way, the control range of the volume flow of the compressor is expanded, whereby the energy efficiency and the power density are increased.
  • the regulating device is signal-connected to at least one signal transmitter and / or at least one sensor, the regulating device measuring the performance of the pre-compression device as a function of at least one value and / or signal from this at least one signal transmitter and / or sensor regulates.
  • the control device receives relevant values or signals for the currently required delivery capacity of the piston compressor from at least one sensor and / or at least one signal transmitter, from which the control device determines the currently required volume flow and the output of the Pre-compression device regulates according to this need. In this way, the control device can be used to adapt the volume flow of the piston compressor, for example, depending on a current requirement, the operating state or the current situation of the system having the compressor, such as a rail vehicle.
  • the control device receives values from at least one sensor.
  • the at least one sensor is selected from a group which in particular has pressure sensors, temperature sensors, volume flow sensors, speed sensors or other suitable sensors. These sensors record relevant parameter values in particular for the regulation of the pre-compression device.
  • a suitable pressure sensor detects, for example, the pressure in the pressure system supplied by the piston compressor. This can be positioned, for example, on the outlet arrangement before or after an after-cooling device, which may be arranged there, or in the compressed air tank. Depending on the pressure value recorded in the compressed air system, it may be necessary to fill up quickly, with a high delivery rate of the reciprocating compressor being required, or to refill smaller amounts of extracted compressed air, which can be done more economically with a lower delivery rate.
  • the volume flow taken from the compressed air system can be recorded directly by means of a volume flow sensor. This value also influences, for example, the amount of compressed air required when the piston compressor is being refilled.
  • a speed sensor which transmits the speed of the crankshaft to the regulating device
  • a value for the volume flow which flows through the intake arrangement can be derived in the method for controlling the piston compressor.
  • a temperature sensor for example, the air temperature in the crankcase, in the inlet arrangement, in the outlet arrangement or in the compressed air system can be detected, from which different requirements for the delivery capacity of the piston compressor can also be derived, which can be adjusted with the help of the control device.
  • the regulating device is signal-connected to at least one signal transmitter, which is selected from a group which has operating management systems, control devices such as a control device of the first drive device or other suitable devices that process information that are relevant for controlling the delivery capacity of the reciprocating compressor.
  • control devices such as a control device of the first drive device or other suitable devices that process information that are relevant for controlling the delivery capacity of the reciprocating compressor.
  • a control device for a reciprocating compressor receives, for example, values relating to the current operating state of a vehicle, such as the driving speed, braking operation or route operation and the like, from which the current compressed air consumption and the currently required level of the compressed air system can be derived.
  • the control device Based on signals from the control device of the first drive device, the control device can derive information regarding the current operating situation and the operating state of the system in which the piston compressor is currently being used and can determine and apply control values for the required volume flow of the piston compressor from this.
  • the regulating device regulates the output of the cooling device independently of the output of the pre-compression device.
  • the setpoint values for the output of the cooling device can be transmitted directly to the control device.
  • the control device can also determine the setpoint to be adjusted, in particular as a function of sensor or signal transmitter values, which contain, for example, the temperature of the environment, in the crankcase or in the compressed air tank.
  • a greater or lesser cooling capacity of the cooling device may be required, regardless of the capacity of the pre-compression device, for example to bring about greater or lesser compression of the air in the reciprocating compressor, or to indirectly increase the temperature level of the pressure system through a lower or higher temperature of the intake air of the reciprocating compressor influence.
  • Fig. 1 3 shows a schematic representation of a first embodiment of an exemplary piston compressor 10 according to the invention.
  • the piston compressor 10 shown in one stage in the exemplary embodiment has a cylinder 11 with a compression chamber 14 for compressing air by means of a piston 12 arranged in the cylinder 11, which is driven via a connecting rod 13 rotatably mounted eccentrically on the crankshaft 21.
  • the cylinder 11 has an air inlet 30, which is connected to an inlet arrangement 31, which guides air to be compressed to the air inlet 30 of the compression chamber 14. Furthermore, the cylinder 11 has an air outlet 33 which is connected to an outlet arrangement 34 which takes up compressed air from the compression chamber 14.
  • the crankcase 20 of the exemplary embodiment is connected via an air supply line 25 to an air filter 26, via which ambient air is sucked in and is fed into the crankcase 20 via the air supply line 25.
  • the inlet arrangement 31 is arranged at a region of the crankcase 20 remote from the connection of the air supply line 25, so that the Air guided by the air supply line 25 into the crankcase 20 can leave the crankcase 20 again through the inlet arrangement 31 after flowing through the crankcase 20.
  • the air flow formed in this way flows over in particular the elements of the crank drive 15 and absorbs thermal energy while cooling the crank drive 15 at the same time.
  • the inlet arrangement 31 has a pre-compression device 28 in the form of an external high-performance fan which is driven by a pre-compressor drive (second drive device) 29.
  • a pre-compressor drive second drive device 29.
  • ambient air is sucked through the air filter 26 into the crankcase 20, where it flows over the elements of the crank drive 15 and thereby extracts thermal energy from them.
  • the pre-compression device 28 sucks the heated air into the inlet arrangement 31 after it has flowed through the crankcase 20, compresses it and, depending on the current output of the pre-compressor drive 29, builds up a pressure that is higher than the ambient pressure at the air inlet 30 in front of the cylinder 11.
  • this increased pressure at the air inlet 30 more air can flow into the compression chamber 14 during an intake stroke of the piston 12, as a result of which the delivery performance and the efficiency of the piston compressor 10 are increased.
  • the inlet arrangement 31 has a cooling device 32 between the pre-compression device 28 and the cylinder 11, which cools the air flowing through the inlet arrangement 31.
  • the intake air heats up, which leads to an increase in volume which causes a reduction in the amount of air that can be absorbed into the compression chamber 14 during an intake stroke.
  • the inlet arrangement 31 has, in the flow direction of the intake air, after the pre-compression device 28, a cooling device 32 which cools the pre-compressed intake air. As a result, a larger amount of air can be taken up in the compression chamber 14. This measure further increases the delivery performance and efficiency of the reciprocating compressor 10.
  • the pre-compressor drive 29 is connected to a control device 40 which regulates the output of the pre-compression device 28 and thus the suction pressure at the air inlet 31.
  • a control device 40 which regulates the output of the pre-compression device 28 and thus the suction pressure at the air inlet 31.
  • Several pressure sensors 41a, 41b, 41c and several temperature sensors 42a, 42b, 42c are arranged at suitable points on the inlet arrangement 31 and on the outlet arrangement 34 of the reciprocating compressor 10, each of which is signal-connected to the control device 40 (not shown).
  • the pressure sensors 41a, 41b, 41c and the temperature sensors 42a, 42b, 42c transmit the respective prevailing air temperature or the pressure at their respective position on the inlet arrangement 31 or on the outlet arrangement 34 to the control device 40.
  • control device 40 is signal-connected to a device management system 45, which transmits further data relevant to the compressed air supply to the reciprocating compressor 10 to the control device 40. From the data that the control device 40 receives, in particular from the pressure sensors 41a, 41b, 41c, the temperature sensors 42a, 42b, 42c and from the device management system 45, the control device 40 determines the current requirement of the compressed air supply system and thus the required delivery capacity of the piston compressor 10 The control device 40 adapts the degree of pre-compression of the intake air at the air inlet 31 by means of the pre-compression device 28 to the demand requirement resulting therefrom by suitable regulation of the pre-compressor drive 29.
  • a power control of the cooling device 32 and of the post-cooling device 35 is also connected to the regulating device 40.
  • the cooling output of the two cooling devices 32, 35 can then also be regulated by means of the regulating device 40 to a required cooling output, in particular determined in each case.
  • Fig. 2 shows a schematic representation of a second embodiment of an exemplary piston compressor 10 according to the invention.
  • the piston compressor 10 the end Fig. 2 largely corresponds to that in Fig. 1 piston compressor 10 illustrated and described for this purpose, so that the same elements of the piston compressors 10 are denoted by the same reference numerals. In the following, only the differences between the two piston compressors 10 shown schematically are explained.
  • the piston compressor 10 shown has opposite the piston compressor 10 Fig. 1 an air discharge device 36 arranged on the inlet arrangement 31 in the form of a pressure relief valve.
  • the pressure relief valve of the air discharge device 36 opens as soon as the pressure in the inlet arrangement 31 in the flow direction of the intake air after the cooling device 32 exceeds a predetermined value and discharges the excess intake air in the inlet arrangement 31 to the surroundings of the reciprocating compressor 10. In this way, the volume flow of air for cooling the crankcase 20 can be greater than the delivery rate of the reciprocating compressor 10, since the excess air can be discharged from the inlet arrangement 31 after flowing through the crankcase 20 and after the pre-compression.
  • a largely arbitrarily large air volume flow through the crankcase 20 can be achieved, the cooling device 32 possibly being off opposite the reciprocating compressor 10 Fig. 1 is to be designed larger for the increased volume flow.
  • the amount of air drawn in through the air filter 26 also increases.
  • FIG. 8 shows a diagram which illustrates the change in the volume flow delivered by the reciprocating compressor 10 due to a precompression and cooling of the intake air as it flows through the inlet arrangement 31.
  • the diagram shows the pressure of the intake air at the air inlet 30 over the volume flow conveyed by the piston compressor 10.
  • the volume flow 51 conveyed by a piston compressor 10 according to the prior art is shown by a curve shown in dashed lines.
  • the volume flow 52 conveyed by the piston compressor 10 according to the invention is illustrated by a curve shown continuously.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Compressor (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
  • Compressors, Vaccum Pumps And Other Relevant Systems (AREA)

Description

Die Erfindung betrifft einen Kolbenkompressor mit wenigstens einem Zylinder zum Verdichten von Luft mit einem darin bewegbar angeordneten Kolben in einem oberhalb des Kolbens im Zylinder angeordneten Verdichtungsraum, der mit einer Einlassanordnung für zu verdichtende Luft und mit einer Auslassanordnung für verdichtete Luft verbunden ist.The invention relates to a piston compressor with at least one cylinder for compressing air with a piston arranged movably therein in a compression chamber arranged above the piston in the cylinder, which is connected to an inlet arrangement for air to be compressed and to an outlet arrangement for compressed air.

Kolbenkompressoren wie insbesondere ölfreie Kolbenkompressoren für Schienenfahrzeuge dienen zum Befüllen von Druckluftbehältern, welchen insbesondere in unregelmäßigen Intervallen Druckluft entnommen wird. Die Kolbenkompressoren werden üblicherweise für den Auffüllbetrieb dimensioniert, in welchem ein Druckbehälter schnell aufgefüllt werden soll, weshalb ein maximaler Volumenstrom zur Verfügung gestellt wird. Für den Regelbetrieb, in welchem unter Umständen nach längeren Aussetzzeiten und nur zum Nachfüllen von entnommener Druckluft der Kompressor eher kurzzeitig betrieben wird, bedeutet ein Betrieb mit maximalem Volumenstrom einen eher ungünstigen Betriebszustand, der bei einer bedarfsgerechten Regelung der Lieferleistung solcher Kolbenkompressoren vermieden werden könnte.Piston compressors, such as, in particular, oil-free piston compressors for rail vehicles, are used to fill compressed air tanks from which compressed air is withdrawn, in particular, at irregular intervals. The piston compressors are usually dimensioned for the filling operation, in which a pressure vessel is to be filled up quickly, which is why a maximum volume flow is made available. For normal operation, in which the compressor may be operated for a short period of time after long intermittent periods and only to refill the compressed air that has been withdrawn, operation with maximum volume flow means a rather unfavorable operating state that could be avoided if the delivery capacity of such piston compressors was regulated according to requirements.

Die Regelbarkeit bekannter Kolbenkompressoren wird durch bauartbedingte maximale und minimale Drehzahlen begrenzt. So ist die obere Drehzahlgrenze von insbesondere ölfreien, trockenlaufendenden Kolbenkompressoren durch die maximale Relativgeschwindigkeit trockenlaufender Gleitpaarungen begrenzt. Bei niedrigen Drehzahlen entstehen dagegen Vibrationen durch freie Massenkräfte im Kolbenkompressor, wodurch auch die untere Drehzahl beim Betrieb eines Kolbenkompressors begrenzt ist. Hieraus ergibt sich eine nur geringe Drehzahlvariabilität von Kolbenkompressoren, die bei den meisten Anwendungsfällen eine Druckluftförderung im Aussetzbetrieb erfordert.The controllability of known piston compressors is limited by the design-related maximum and minimum speeds. The upper speed limit of, in particular, oil-free, dry-running piston compressors is limited by the maximum relative speed of dry-running sliding pairs. At low speeds, on the other hand, vibrations occur due to free inertia forces in the piston compressor, which also limits the lower speed when operating a piston compressor. This results in only a slight variability in the speed of reciprocating compressors, which in most applications requires the delivery of compressed air in intermittent operation.

Bei bekannten Kolbenkompressoren ist die Aussetzregelung der Druckluftförderung dadurch realisiert, dass der Kompressor in den Stillstand geschaltet wird, sobald der Systemdruck den Ausschaltdruck erreicht. Fällt der Systemdruck dann insbesondere durch eine Entnahme von Druckluft auf den Einschaltdruck, wird der Kolbenkompressor in den Lastlauf geschaltet, in welchem dieser bei Nenndrehzahl einen maximalen Volumenstrom liefert. Sofern dem Druckluftbehälter bzw. dem Druckluftsystem nicht gleichzeitig größere Mengen von Druckluft entnommen werden, füllt sich der Druckluftbehälter relativ schnell, so dass der Kolbenkompressor nach einer kurzen Einschaltzeit wieder für längere Zeit ausgeschaltet wird. Das Regelspektrum dieser bekannten Lösung ist damit auf Stillstand und Lastlauf limitiert und aufgrund des damit verbundenen jeweiligen Kaltstarts sowie des höheren Verschleißes und der längeren Standzeiten des Kolbenkompressors ungünstig und für bestimmte Einsatzbedingungen sogar ungeeignet.In known reciprocating compressors, the interruption control of the compressed air delivery is implemented in that the compressor is switched to standstill as soon as the System pressure has reached the cut-out pressure. If the system pressure then falls to the switch-on pressure, in particular due to the withdrawal of compressed air, the piston compressor is switched to load operation, in which it delivers a maximum volume flow at the nominal speed. Unless larger amounts of compressed air are taken from the compressed air tank or the compressed air system at the same time, the compressed air tank fills up relatively quickly, so that the piston compressor is switched off again for a long time after a short switch-on time. The control spectrum of this known solution is therefore limited to standstill and running under load and is unfavorable and even unsuitable for certain operating conditions due to the associated cold start as well as the higher wear and the longer downtimes of the piston compressor.

Bei einer alternativen Ausführung eines Kolbenkompressors wird der Aussetzbetrieb mit verschiedenen vordefinierten Drehzahlen realisiert, beispielsweise über eine Umschaltung des Motors zwischen vier und sechs Pole oder über einen Inverter, der zwischen 50 Hz und 60 Hz schaltbar ist. Allerdings kann durch die dabei festgelegten Motordrehzahlen beim jeweiligen Kompressor auch nur ein relativ eingeschränkter Regelungsbereich realisiert werden. Hohe Motordrehzahlen bewirken auch hier eine starke thermische Belastung insbesondere von ölfreien Gleitpaarungen, wodurch die Lebensdauer eines Kolbenkompressors signifikant sinkt. Die Lösung ist zwar ein einfacher Ansatz, den Volumenstrom zu regeln, jedoch ist das Regelspektrum durch die festen Motordrehzahlen limitiert und bei bestimmten Einsatzbedingungen kann durch die Umschaltung kein ausreichender Volumenstrom erzeugt werden.In an alternative embodiment of a reciprocating compressor, intermittent operation is implemented at various predefined speeds, for example by switching the motor between four and six poles or by an inverter that can be switched between 50 Hz and 60 Hz. However, only a relatively limited control range can be implemented with the respective compressor due to the motor speeds specified in this process. Here, too, high engine speeds cause a high thermal load, particularly on oil-free sliding pairs, which significantly reduces the service life of a piston compressor. Although the solution is a simple approach to regulating the volume flow, the control spectrum is limited by the fixed motor speeds and, under certain operating conditions, the changeover cannot generate a sufficient volume flow.

Aus den Offenlegungsschriften der deutschen Patentanmeldungen DE 10 2013 113 555 und DE 10 2013 113 556 ist jeweils ein Kompressorsystem und ein Verfahren zum Betrieb des Kompressorsystems in Abhängigkeit vom Betriebszustand eines Schienenfahrzeugs bzw. in Abhängigkeit von der aktuellen Situation eines Schienenfahrzeugs bekannt, bei welchen ein Stellglied zur kontinuierlichen Beeinflussung der Drehzahl der elektrischen Antriebseinrichtung des Kolbenkompressors angeordnet ist, wobei die Ansteuerung des Stellglieds über eine Regelungseinrichtung erfolgt. Das Stellglied erlaubt es, den Betrieb der Antriebseinrichtung und damit des Kolbenkompressors durch unterschiedliche Drehzahlen an den aktuellen Betriebszustand bzw. an die aktuelle Situation des Schienenfahrzeugs anzupassen.From the published documents of the German patent applications DE 10 2013 113 555 and DE 10 2013 113 556 a compressor system and a method for operating the compressor system as a function of the operating state of a rail vehicle or as a function of the current situation of a rail vehicle are known, in which an actuator is arranged for continuously influencing the speed of the electric drive device of the piston compressor, the control of the Actuator takes place via a control device. The actuator allows the operation of the drive device and thus the piston compressor by different Adapt speeds to the current operating state or to the current situation of the rail vehicle.

Zudem offenbart die AT 135585 ein Verfahren zum Kühlen gasförmiger Mittel, gemäß welchem das Gas in zwei Stufen, gegebenenfalls unter Zwischenschaltung einer Kühleinrichtung, verdichtet wird, worauf das verdichtete Gas über eine Kühleinrichtung einer Entspannungsmaschine zuströmt.In addition, AT 135585 discloses a method for cooling gaseous media, according to which the gas is compressed in two stages, optionally with the interposition of a cooling device, whereupon the compressed gas flows to an expansion machine via a cooling device.

Die US 2005/0220628 A1 betrifft ein Verfahren zur Überprüfung eines Kompressorsystems auf Fehlfunktionen. Das hierzu angeführte Kompressorsystem umfasst zwei parallele Niederdruckzylinder, die einem Hochdruckzylinder vorgeschaltet sind.the US 2005/0220628 A1 relates to a method for checking a compressor system for malfunctions. The compressor system cited for this purpose comprises two parallel low-pressure cylinders which are connected upstream of a high-pressure cylinder.

Der Erfindung liegt daher die Aufgabe zugrunde, einen verbesserten Kolbenkompressor mit größerem Regelbereich der Lieferleistung unter Verbesserung der Energieeffizienz und Leistungsdichte zur Verfügung zu stellen.The invention is therefore based on the object of providing an improved reciprocating compressor with a larger control range of the delivery rate while improving the energy efficiency and power density.

Zur Lösung dieser Aufgabe wird ein Kolbenkompressor gemäß Anspruch 1 sowie ein Verfahren zum Steuern eines solchen Kolbenkompressors gemäß Anspruch 6 vorgeschlagen. Weiterbildungen der vorgeschlagenen Lösungen sind Gegenstand der jeweils abhängigen Ansprüche.To achieve this object, a piston compressor according to claim 1 and a method for controlling such a piston compressor according to claim 6 are proposed. Developments of the proposed solutions are the subject of the respective dependent claims.

Zur Lösung der Aufgabe wird ein Kolbenkompressor mit wenigstens einem Zylinder zum Verdichten von Luft mit einem darin bewegbar angeordneten Kolben in einem oberhalb des Kolbens im Zylinder angeordneten Verdichtungsraum vorgeschlagen. Der Verdichtungsraum weist einen Lufteinlass und einen Luftauslass auf und ist am Lufteinlass mit einer Einlassanordnung für zu verdichtende Luft verbunden und ist am Luftauslass mit einer Auslassanordnung für verdichtete Luft verbunden. Der Kolbenkompressor ist von einer ersten Antriebseinrichtung antreibbar. Die Einlassanordnung weist eine von einer zweiten Antriebseinrichtung mit veränderbarer Leistung antreibbare Vorverdichtungseinrichtung zum Erhöhen des Ansaugdrucks sowie und eine Kühleinrichtung zum Kühlen der zu verdichtenden Luft auf.To achieve the object, a piston compressor with at least one cylinder for compressing air with a piston arranged movably therein in a compression space arranged above the piston in the cylinder is proposed. The compression space has an air inlet and an air outlet and is connected at the air inlet to an inlet arrangement for air to be compressed and is connected to an outlet arrangement for compressed air at the air outlet. The piston compressor can be driven by a first drive device. The inlet arrangement has a pre-compression device, which can be driven by a second drive device with variable power, for increasing the intake pressure and a cooling device for cooling the air to be compressed.

Die vorgeschlagene Lösung ermöglicht es, durch den erhöhten Ansaugdruck und die reduzierte Ansaugtemperatur der Ansaugluft den Volumenstrom eines Kolbenkompressors zu erhöhen, wodurch dessen Lieferleistung steigt.The proposed solution makes it possible to increase the volume flow of a reciprocating compressor through the increased intake pressure and the reduced intake temperature of the intake air, whereby its delivery capacity increases.

Bei dem Kolbenkompressor handelt es sich um einen Kolbenkompressor bekannter Bauart mit einem Zylinder, in welchem ein darin angeordneter Kolben axial bewegbar ist und in einer Hubbewegung zu verdichtende Luft insbesondere über ein am Lufteinlass angeordnetes Einlassventil aus einer Einlassanordnung ansaugt, komprimiert und insbesondere über ein am Luftauslass angeordnetes Auslassventil gegen einen Druck in einer Auslassanordnung ausstößt. Der Kolbenkompressor ist dabei von einer ersten Antriebseinrichtung antreibbar. Abhängig von der Einsatzsituation des Kolbenkompressors ist die erste Antriebseinrichtung ein Verbrennungsmotor, eine elektrischen Antriebseinrichtung oder eine andere geeignete Antriebseinrichtung.The piston compressor is a known type of piston compressor with a cylinder in which a piston arranged therein is axially movable and in a reciprocating motion sucks in air to be compressed, in particular via an inlet valve arranged at the air inlet, compresses it from an inlet arrangement and in particular via an air outlet discharges arranged outlet valve against a pressure in an outlet arrangement. The piston compressor is one of the first Drive device drivable. Depending on the application of the piston compressor, the first drive device is an internal combustion engine, an electric drive device or another suitable drive device.

Bei einem erfindungsgemäßen Kolbenkompressor kann es sich sowohl um einen trockenlaufenden, also ölfreien Kolbenkompressor als auch um einen nicht ölfrei ausgeführten Kolbenkompressor handeln. Obwohl im Rahmen der Erfindung auch Vorteile oder Ausführungsformen beschrieben werden, welche für andere als trockenlaufende Kolbenkompressoren nicht anwendbar sind, so sind wiederum andere Vorteile und Ausführungsformen unabhängig davon auch für Kolbenkompressoren anwendbar, welche nicht trockenlaufend ausgeführt sind.A piston compressor according to the invention can be both a dry-running, that is to say oil-free, piston compressor and a piston compressor that is not designed to be oil-free. Although advantages or embodiments are also described within the scope of the invention which cannot be used for piston compressors other than dry running, other advantages and embodiments can also be used independently of this for piston compressors which are not running dry.

Beim vorgeschlagenen Kolbenkompressor weist die Einlassanordnung eine von einer zweiten Antriebseinrichtung mit veränderbarer Leistung antreibbare Vorverdichtungseinrichtung auf. Mit dieser Vorverdichtungseinrichtung kann der Ansaugdruck insbesondere am Lufteinlass durch die veränderbare Leistung variabel von einem Ausgangsdruck p0 auf bis zu einem Maximaldruck pmax erhöht werden. Durch den höheren Ansaugdruck des ersten Zylinders bei mehrstufigen Kolbenkompressoren bzw. dem einzigen Zylinder bei einstufigen Kolbenkompressoren wird eine Steigerung des Volumenstroms um ΔV erzielt, da der Verdichtungsraum des Zylinders mit einer unter höherem Druck stehenden zu verdichtenden Luft gefüllt wird.In the proposed piston compressor, the inlet arrangement has a pre-compression device that can be driven by a second drive device with variable power. With this pre-compression device, the intake pressure, in particular at the air inlet, can be increased variably from an output pressure p 0 up to a maximum pressure p max due to the variable power. The higher suction pressure of the first cylinder in multi-stage piston compressors or the single cylinder in single-stage piston compressors increases the volume flow by ΔV, since the compression chamber of the cylinder is filled with air that is to be compressed under higher pressure.

Auch die zweite Antriebseinrichtung, welche zum Antrieb der Vorverdichtungseinrichtung dient, kann abhängig von der Einsatzsituation eine elektrische Antriebseinrichtung oder eine andere geeignete Antriebseinrichtung sein. Ebenso kann die Antriebsleistung der zweiten Antriebseinrichtung auch von der ersten Antriebseinrichtung oder einer anderen verfügbaren Antriebseinrichtung auf diese übertragen werden, beispielsweise mittels eines Getriebes mit veränderbarer Übersetzung. Insbesondere ist von der zweiten Antriebseinrichtung übertragene Leistung variabel einstellbar.The second drive device, which is used to drive the pre-compression device, can also be an electric drive device or another suitable drive device, depending on the application. Likewise, the drive power of the second drive device can also be transferred to the first drive device or another available drive device, for example by means of a gear with a variable ratio. In particular, the power transmitted by the second drive device can be variably adjusted.

Bei der vorgeschlagenen Lösung weist die Einlassanordnung eine Kühleinrichtung auf, welche die zu verdichtende Luft, die durch die Einlassanordnung strömt, durch geeignete Maßnahmen kühlt. Dabei ist die Kühleinrichtung insbesondere in Strömungsrichtung der Ansaugluft nach der Vorverdichtungseinrichtung angeordnet, da sich die Luft durch die Vorverdichtung erwärmt. Es ist aber auch möglich, eine Kühleinrichtung in Strömungsrichtung vor der Vorverdichtungseinrichtung anzuordnen, insbesondere wenn dies aufgrund baulicher Gegebenheiten vorteilhaft ist. Bei dieser Anordnung ist eine größere Absenkung der Temperatur erforderlich, da sich die Lufttemperatur durch die Vorverdichtung wieder erhöht. Bei einer Ausführungsform des Kolbenkompressors kann auch vorgesehen sein, die Ansaugluft vor und nach der Vorverdichtung zu kühlen.In the proposed solution, the inlet arrangement has a cooling device through which the air to be compressed, which flows through the inlet arrangement suitable measures cool. In this case, the cooling device is arranged in particular in the flow direction of the intake air after the pre-compression device, since the air is heated by the pre-compression. However, it is also possible to arrange a cooling device upstream of the pre-compression device in the direction of flow, in particular if this is advantageous due to structural conditions. With this arrangement, a greater reduction in temperature is necessary, since the air temperature increases again as a result of the pre-compression. In one embodiment of the piston compressor it can also be provided that the intake air is cooled before and after the pre-compression.

Die Einlassanordnung weist insbesondere auch wenigstens eine Leitungseinrichtung auf, welche die Ansaugluft zur wenigstens einen Kühleinrichtung und zur wenigstens einen Verdichtungseinrichtung leiten und diese miteinander und/ oder mit dem Lufteinlass des Verdichtungsraums verbinden. Insbesondere kann eine Kühleinrichtung auch außen an einer Leitungseinrichtung angeordnet sein. Als geeignete Kühleinrichtungen der Einlassanordnung können beispielsweise Kühlmittelwärmetauscher oder Einrichtungen zur Vergrößerung der Außenfläche der Einlassanordnung bzw. einer Leitungseinrichtung wie Leitungsschleifen oder Kühlrippen sein, die beispielsweise in Verbindung mit Gebläsen eingesetzt werden, oder jede andere geeignete Art von Einrichtungen, mittels welcher der in der Einlassanordnung strömenden Ansaugluft Wärmeenergie entziehbar ist.The inlet arrangement in particular also has at least one conduit device which directs the intake air to the at least one cooling device and to the at least one compression device and connects them to one another and / or to the air inlet of the compression chamber. In particular, a cooling device can also be arranged on the outside of a line device. Suitable cooling devices of the inlet arrangement can be, for example, coolant heat exchangers or devices for enlarging the outer surface of the inlet arrangement or a line device such as line loops or cooling fins, which are used, for example, in connection with fans, or any other suitable type of device by means of which the flowing in the inlet arrangement Intake air heat energy can be withdrawn.

Die vorgeschlagene Lösung ermöglicht es, den Volumenstrom eines Kolbenkompressors um den Faktor p max p 0

Figure imgb0001
der Vorverdichtungseinrichtung zu erhöhen. Durch den erhöhten Ansaugdruck und die reduzierte Ansaugtemperatur der Ansaugluft steigt die Lieferleistung des Kolbenkompressors. Die veränderbare Leistung der Vorverdichtungseinrichtung ermöglicht in Verbindung mit der Leistungssteigerung des Kolbenkompressors ein nach oben hin breiteres Regelspektrum des Kolbenkompressors. So wird auch die Verwendung von Kolbenkompressoren mit insgesamt kleinerer Baugröße möglich, da durch den erhöhten Ansaugdruck höhere Volumenströme realisiert werden. Die vorgeschlagene Lösung ermöglicht einen geregelten Kompressorbetrieb mit kurzzeitig sehr hoher Leistung beim Auffüllbetrieb (großer Volumenstrom des Kolbenkompressors) und einen konstanter Betrieb mit niedriger Leistung (geringerer Volumenstrom des Kolbenkompressors) im Regelbetrieb. Damit besteht keine Gefahr von Vibrationen durch freie Massenkräfte bei niedrigen Drehzahlen und die maximalen Relativgeschwindigkeiten von insbesondere ölfreien Gleitpaarungen können eingehalten werden. Zudem kann durch die vorgeschlagene Lösung das Gesamttemperaturniveau eines Kolbenkompressors gesenkt werden.The proposed solution makes it possible to increase the volume flow of a reciprocating compressor by the factor p Max p 0
Figure imgb0001
to increase the pre-compression device. The delivery capacity of the piston compressor increases due to the increased intake pressure and the reduced intake temperature of the intake air. The variable output of the pre-compression device, in conjunction with the increase in output of the piston compressor, enables the piston compressor to have a broader control range towards the top. This also makes it possible to use piston compressors with a smaller overall size, since higher volume flows are achieved due to the increased suction pressure. The proposed solution enables regulated compressor operation with briefly very high performance in the filling operation (large volume flow of the piston compressor) and constant operation with low power (lower volume flow of the piston compressor) in normal operation. This means that there is no risk of vibrations due to free inertia forces at low speeds and the maximum relative speeds of, in particular, oil-free sliding pairs can be maintained. In addition, the proposed solution can lower the overall temperature level of a reciprocating compressor.

Die vorgeschlagene Lösung erhöht somit den Regelbereich des Volumenstroms und damit der Lieferleistung eines Kompressors, führt zur Senkung relevanter Temperaturniveaus und steigert gleichzeitig die Energieeffizienz und Leistungsdichte des Kolbenkompressors.The proposed solution thus increases the control range of the volume flow and thus the delivery capacity of a compressor, leads to a reduction in relevant temperature levels and at the same time increases the energy efficiency and power density of the piston compressor.

Der Kolbenkompressor wird über eine Kurbelwelle angetrieben, welche in einem Kurbelgehäuse drehbar gelagert ist. Ein oder mehrere jeweils mit einem Kolben verbundene Pleuel sind derart drehbar an einer exzentrischen Position der Kurbelwelle gelagert, dass deren Drehbewegung als Hubbewegung auf den sich in einem Zylinder axial bewegenden Kolben übertragen wird. Der Kolbenkompressor weist wenigstens einen Zylinder zum Komprimieren von Luft auf, kann aber auch zwei oder mehr, nacheinander oder parallel angeordnete Zylinder aufweisen, welche zum Komprimieren von Luft mittels jeweils eines darin bewegbar angeordneten Kolbens vorgesehen sind, so dass der Kolbenkompressor einstufig oder mehrstufig ausgebildet sein kann.The piston compressor is driven by a crankshaft which is rotatably mounted in a crankcase. One or more connecting rods, each connected to a piston, are rotatably mounted at an eccentric position of the crankshaft in such a way that their rotational movement is transmitted as a stroke movement to the piston moving axially in a cylinder. The piston compressor has at least one cylinder for compressing air, but can also have two or more cylinders arranged one after the other or in parallel, which are provided for compressing air by means of a piston movably arranged therein, so that the piston compressor can be designed in one or more stages can.

Der Kolbenkompressors weist zudem ein Kurbelgehäuse auf, in welchem eine Kurbelwelle angeordnet ist, an der wenigstens ein mit einem Kolben verbundener Pleuel drehbar gelagert ist, wobei die Ansaugluft des wenigstens einen Zylinders durch das Kurbelgehäuse geführt wird.The piston compressor also has a crankcase in which a crankshaft is arranged, on which at least one connecting rod connected to a piston is rotatably mounted, the intake air of the at least one cylinder being guided through the crankcase.

Hierdurch wird die Ansaugluft des wenigstens einen Zylinders durch das Kurbelgehäuse geführt, wobei es über die Elemente des Kurbeltriebs, im Wesentlichen die Kurbelwelle, die Pleuel, die Unterseite des oder der Kolben sowie die dazwischen angeordneten Lagerelemente strömt und diese dabei kühlt. Bei der Ansaugluft handelt es sich im Wesentlichen um die Luft, die später in den wenigstens einen Zylinder des Kolbenkompressors gesaugt und dort verdichtet wird.As a result, the intake air of the at least one cylinder is guided through the crankcase, flowing over the elements of the crank drive, essentially the crankshaft, the connecting rods, the underside of the piston or pistons and the bearing elements arranged in between, and cooling them in the process. The intake air is essentially the air that is later sucked into the at least one cylinder of the piston compressor and compressed there.

Bei einer Ausführungsform des Kolbenkompressors weist die Einlassanordnung eine Luftableiteinrichtung auf. Diese Ausführungsform ermöglicht es, einen größeren Volumenstrom durch das Kurbelgehäuse zu führen, als später als Ansaugluft in dem wenigstens einen Zylinder des Kolbenkompressors aufgenommen und dort verdichtet wird. So kann der Kühlluftvolumenstrom im Kurbelgehäuse erhöht werden und gleichzeitig die Erwärmung der Ansaugluft beim Durchströmen des Kurbelgehäuses vermindert werden.In one embodiment of the reciprocating compressor, the inlet arrangement has an air discharge device. This embodiment makes it possible to guide a larger volume flow through the crankcase than is later received as intake air in the at least one cylinder of the piston compressor and is compressed there. In this way, the volume flow of cooling air in the crankcase can be increased and, at the same time, the heating of the intake air as it flows through the crankcase can be reduced.

Die Luftableiteinrichtung kann beispielsweise in Form eines Rückschlagventils bzw. Überdruckventils ausgebildet sein, welches sich ab einem vorbestimmten Druck der Ansaugluft öffnet. Die Luftableiteinrichtung kann aber auch so ausgebildet sein, dass diese abhängig von vorbestimmten Parameterwerten offen- und schließbar ist, insbesondere durch eine Steuereinrichtung. Bei einer Ausführungsform einer Luftableiteinrichtung wird insbesondere überschüssige Ansaugluft aus der Einlassanordnung in die Umgebung abgeführt, bei einer anderen Ausführungsform einer Luftableiteinrichtung kann beispielsweise ein vorbestimmter Anteil des gekühlten Volumenstroms der Ansaugluft in das Kurbelgehäuse zurückgeführt werden.The air diverting device can be designed, for example, in the form of a check valve or pressure relief valve, which opens from a predetermined pressure of the intake air. The air discharge device can, however, also be designed in such a way that it can be opened and closed depending on predetermined parameter values, in particular by a control device. In one embodiment of an air discharge device, in particular excess intake air is discharged from the inlet arrangement into the environment; in another embodiment of an air discharge device, for example, a predetermined proportion of the cooled volume flow of the intake air can be returned to the crankcase.

Bei einer weiteren Ausführungsform des Kolbenkompressors ist eine Nachkühleinrichtung zum Kühlen der verdichteten Luft nach dem Durchlaufen des wenigstens einen Zylinders des Kolbenkompressors angeordnet. Insbesondere weist die Auslassanordnung eine Nachkühleinrichtung zum Kühlen der verdichteten Luft auf. Durch das Verdichten erwärmt sich die Luft im Zylinder, so dass die durch den Luftauslass aus dem Verdichtungsraum ausgestoßene verdichtete Luft eine erhöhte Temperatur aufweist. Ein Kühlen der verdichteten Luft nach dem Durchlaufen des wenigstens einen Zylinders mittels wenigstens einer Nachkühleinrichtung der Auslassanordnung vereinfacht beispielsweise ein nachfolgendes Speichern der Luft oder eine Weiterverarbeitung wie z. B. eine Entfeuchtung der Luft. Bei einer Ausführungsform des Kolbenkompressors wird die Nachkühleinrichtung der Auslassanordnung von einer Partition der Kühleinrichtung zum Kühlen der Ansaugluft der Einlassanordnung gebildet.In a further embodiment of the piston compressor, an after-cooling device is arranged for cooling the compressed air after it has passed through the at least one cylinder of the piston compressor. In particular, the outlet arrangement has an after-cooling device for cooling the compressed air. As a result of the compression, the air in the cylinder is heated, so that the compressed air expelled from the compression chamber through the air outlet has an increased temperature. Cooling the compressed air after it has passed through the at least one cylinder by means of at least one after-cooling device of the outlet arrangement simplifies, for example, a subsequent storage of the air or further processing such as e.g. B. dehumidifying the air. In one embodiment of the reciprocating compressor, the after-cooling device of the outlet arrangement is formed by a partition of the cooling device for cooling the intake air of the inlet arrangement.

Bei einer weiteren Ausführungsform weist der Kolbenkompressor eine Regelungseinrichtung auf, mit welcher die Leistung der Vorverdichtungseinrichtung und damit der Ansaugdruck am Lufteinlass insbesondere stufenlos regelbar ist. Die Regelungseinrichtung ist dabei mit der zweiten Antriebseinrichtung wirkverbunden, welche die Vorverdichtungseinrichtung mit veränderbarer Leistung antreibt. Die Regelungseinrichtung erhält dabei Signale und/ oder Messwerte, welche insbesondere mit der erforderlichen Lieferleistung des Kolbenkompressors im Zusammenhang stehen und mittels welcher die Regelungseinrichtung die Leistung der zweiten Antriebseinrichtung und damit der Vorverdichtungseinrichtung einstellt. Auf diese Weise wird der Vorverdichtungsgrad der durch die Einlassanordnung in den Zylinder strömenden Luft mittels der Vorverdichtungseinrichtung geregelt.In a further embodiment, the piston compressor has a regulating device with which the output of the pre-compression device and thus the suction pressure at the air inlet can be regulated, in particular continuously. The control device is operatively connected to the second drive device, which drives the pre-compression device with variable power. The control device receives signals and / or measured values which are in particular related to the required delivery capacity of the piston compressor and by means of which the control device adjusts the output of the second drive device and thus the pre-compression device. In this way, the degree of pre-compression of the air flowing through the inlet arrangement into the cylinder is regulated by means of the pre-compression device.

Zur Lösung der Aufgabe wird ferner ein Verfahren zum Steuern eines Kolbenkompressors der oben beschriebenen Art vorgeschlagen, wobei die Regelungseinrichtung die Leistung der Vorverdichtungseinrichtung zwischen einem maximalen Wert, der einem maximalen Ansaugdruck (pmax) am Lufteinlass entspricht und einem minimalen Wert, der dem durch die Kolbenhubbewegung im Zylinder erzeugten Ansaugdruck (p0) am Lufteinlass entspricht, regelt. Damit ist die Lieferleistung des Kolbenkompressors durch das erfindungsgemäße Verfahren in einem erweiterten Regelbereich zwischen einem maximalen Ansaugdruck und einem minimalen Ansaugdruck am Lufteinlass insbesondere stufenlos einstellbar. Auf diese Weise erweitert sich der Regelbereich des Volumenstroms des Kompressors, wobei die Energieeffizienz und die Leistungsdichte gesteigert werden.To achieve the object, a method for controlling a reciprocating compressor of the type described above is also proposed, wherein the regulating device adjusts the performance of the pre-compression device between a maximum value that corresponds to a maximum suction pressure (p max ) at the air inlet and a minimum value that corresponds to that caused by the Piston stroke movement in the cylinder corresponds to suction pressure (p 0 ) at the air inlet, regulates. The delivery performance of the piston compressor can thus be adjusted, in particular steplessly, by the method according to the invention in an extended control range between a maximum intake pressure and a minimum intake pressure at the air inlet. In this way, the control range of the volume flow of the compressor is expanded, whereby the energy efficiency and the power density are increased.

Bei einer Ausführungsform des Verfahrens zum Steuern des Kolbenkompressors ist die Regelungseinrichtung mit wenigstens einem Signalgeber und/ oder wenigstens einem Sensor signalverbunden, wobei die Regelungseinrichtung die Leistung der Vorverdichtungseinrichtung in Abhängigkeit von wenigstens einem Wert und/oder Signal von diesem wenigstens einen Signalgeber und/ oder Sensor regelt. Der Regelungseinrichtung werden dabei für die jeweils aktuell erforderliche Lieferleistung des Kolbenkompressors von wenigstens einem Sensor und/ oder wenigstens einem Signalgeber relevante Werte bzw. Signale übermittelt, woraus die Regelungseinrichtung den aktuell erforderlichen Volumenstrom ermittelt und die Leistung der Vorverdichtungseinrichtung entsprechend diesem Bedarf regelt. Auf diese Weise kann mittels der Regelungseinrichtung der Volumenstrom des Kolbenkompressors beispielsweise in Abhängigkeit von einer aktuellen Anforderung, vom Betriebszustand oder von der aktuellen Situation des den Kompressor aufweisenden Systems, wie beispielsweise eines Schienenfahrzeugs, angepasst werden.In one embodiment of the method for controlling the piston compressor, the regulating device is signal-connected to at least one signal transmitter and / or at least one sensor, the regulating device measuring the performance of the pre-compression device as a function of at least one value and / or signal from this at least one signal transmitter and / or sensor regulates. The control device receives relevant values or signals for the currently required delivery capacity of the piston compressor from at least one sensor and / or at least one signal transmitter, from which the control device determines the currently required volume flow and the output of the Pre-compression device regulates according to this need. In this way, the control device can be used to adapt the volume flow of the piston compressor, for example, depending on a current requirement, the operating state or the current situation of the system having the compressor, such as a rail vehicle.

Bei einer weiteren Ausführungsform des Verfahrens erhält die Regelungseinrichtung Werte von wenigstens einem Sensor. Für diesen Zweck ist der wenigstens eine Sensor aus einer Gruppe ausgewählt, welche insbesondere Drucksensoren, Temperatursensoren, Volumenstromsensoren, Drehzahlsensoren oder andere geeignete Sensoren aufweist. Diese Sensoren erfassen insbesondere für die Regelung der Vorverdichtungseinrichtung relevante Parameterwerte. Ein geeigneter Drucksensor erfasst beispielsweise den Druck im vom Kolbenkompressor belieferten Drucksystem. Dieser kann beispielsweise an der Auslassanordnung vor oder nach einer gegebenenfalls dort angeordneten Nachkühleinrichtung oder im Druckluftbehälter positioniert sein. Abhängig vom erfassten Druckwert im Druckluftsystem kann ein schnelles Auffüllen erforderlich sein, wobei eine hohe Lieferleistung des Kolbenkompressors erforderlich ist, oder ein Nachfüllen von geringeren Mengen entnommener Druckluft, was mit einer geringeren Lieferleistung wirtschaftlicher erfolgen kann.In a further embodiment of the method, the control device receives values from at least one sensor. For this purpose, the at least one sensor is selected from a group which in particular has pressure sensors, temperature sensors, volume flow sensors, speed sensors or other suitable sensors. These sensors record relevant parameter values in particular for the regulation of the pre-compression device. A suitable pressure sensor detects, for example, the pressure in the pressure system supplied by the piston compressor. This can be positioned, for example, on the outlet arrangement before or after an after-cooling device, which may be arranged there, or in the compressed air tank. Depending on the pressure value recorded in the compressed air system, it may be necessary to fill up quickly, with a high delivery rate of the reciprocating compressor being required, or to refill smaller amounts of extracted compressed air, which can be done more economically with a lower delivery rate.

Mittels eines Volumenstromsensors kann unmittelbar der aus dem Druckluftsystem entnommene Volumenstrom erfasst werden. Dieser Wert beeinflusst beispielsweise auch die erforderliche Druckluftmenge beim Nachfüllbetrieb des Kolbenkompressors. Mittels eines Drehzahlsensors, der die Drehzahl der Kurbelwelle an die Regelungseinrichtung übermittelt, kann beim Verfahren zum Steuern des Kolbenkompressors ein Wert für den Volumenstrom abgeleitet werden, welcher die Ansauganordnung durchströmt. Mit einem Temperatursensor ist beispielsweise die Lufttemperatur im Kurbelgehäuse, in der Einlassanordnung, in der Auslassanordnung oder im Druckluftsystem erfassbar, woraus ebenfalls unterschiedliche Anforderungen an die Lieferleistung des Kolbenkompressors ableitbar sind, die mit Hilfe der Regelungseinrichtung angepasst werden kann.The volume flow taken from the compressed air system can be recorded directly by means of a volume flow sensor. This value also influences, for example, the amount of compressed air required when the piston compressor is being refilled. By means of a speed sensor, which transmits the speed of the crankshaft to the regulating device, a value for the volume flow which flows through the intake arrangement can be derived in the method for controlling the piston compressor. With a temperature sensor, for example, the air temperature in the crankcase, in the inlet arrangement, in the outlet arrangement or in the compressed air system can be detected, from which different requirements for the delivery capacity of the piston compressor can also be derived, which can be adjusted with the help of the control device.

Bei einer Ausführungsform des Verfahrens zum Steuern eines Kolbenkompressors ist die Regelungseinrichtung mit wenigstens einem Signalgeber signalverbunden, der aus einer Gruppe ausgewählt ist, welche Betriebs-Management-Systeme, Steuerungseinrichtungen wie eine Steuerungseinrichtung der ersten Antriebseinrichtung oder andere geeignete Einrichtungen aufweist, welche Informationen verarbeiten, die für die Steuerung der Lieferleistung des Kolbenkompressors relevant sind. Aus einem Fahrzeugmanagementsystem erhält eine Regelungseinrichtung für einen Kolbenkompressor beispielsweise Werte betreffend den aktuellen Betriebszustand eines Fahrzeugs, wie die Fahrgeschwindigkeit, Bremsbetrieb oder Streckenbetrieb und dergleichen, aus welchen der momentane Druckluftverbrauch sowie der aktuell erforderliche Füllstand des Druckluftsystems ableitbar ist. Auch aufgrund von Signalen der Steuerungseinrichtung der ersten Antriebseinrichtung kann die Regelungseinrichtung Informationen bezüglich der aktuellen Betriebssituation sowie dem Betriebszustand des Systems ableiten, in welchem der Kolbenkompressor aktuell verwendet wird und kann hieraus Steuerwerte für den erforderlichen Volumenstrom des Kolbenkompressors ermitteln und anwenden.In one embodiment of the method for controlling a reciprocating compressor, the regulating device is signal-connected to at least one signal transmitter, which is selected from a group which has operating management systems, control devices such as a control device of the first drive device or other suitable devices that process information that are relevant for controlling the delivery capacity of the reciprocating compressor. From a vehicle management system, a control device for a reciprocating compressor receives, for example, values relating to the current operating state of a vehicle, such as the driving speed, braking operation or route operation and the like, from which the current compressed air consumption and the currently required level of the compressed air system can be derived. Based on signals from the control device of the first drive device, the control device can derive information regarding the current operating situation and the operating state of the system in which the piston compressor is currently being used and can determine and apply control values for the required volume flow of the piston compressor from this.

Bei einer Ausführungsform des Verfahrens zum Steuern eines Kolbenkompressors regelt die Regelungseinrichtung die Leistung der Kühleinrichtung unabhängig von der Leistung der Vorverdichtungseinrichtung. Die Sollwerte für die Leistung der Kühleinrichtung können dabei unmittelbar an die Regelungseinrichtung übertragen werden. Ebenso kann die Regelungseinrichtung den einzuregelnden Sollwert auch insbesondere abhängig von Sensor- oder Signalgeberwerten ermitteln, welche beispielsweise die Temperatur der Umgebung, im Kurbelgehäuse oder im Druckluftbehälter enthalten. Dabei kann eine stärkere oder geringere Kühlleistung der Kühleinrichtung unabhängig von der Leistung der Vorverdichtungseinrichtung erforderlich sein, um beispielsweise eine stärkere oder geringere Verdichtung der Luft im Kolbenkompressor zu bewirken, oder um das Temperaturniveau des Drucksystems durch eine geringere oder höhere Temperatur der Ansaugluft des Kolbenkompressors indirekt zu beeinflussen.In one embodiment of the method for controlling a reciprocating compressor, the regulating device regulates the output of the cooling device independently of the output of the pre-compression device. The setpoint values for the output of the cooling device can be transmitted directly to the control device. Likewise, the control device can also determine the setpoint to be adjusted, in particular as a function of sensor or signal transmitter values, which contain, for example, the temperature of the environment, in the crankcase or in the compressed air tank. A greater or lesser cooling capacity of the cooling device may be required, regardless of the capacity of the pre-compression device, for example to bring about greater or lesser compression of the air in the reciprocating compressor, or to indirectly increase the temperature level of the pressure system through a lower or higher temperature of the intake air of the reciprocating compressor influence.

Weitere Vorteile, Merkmale und Anwendungsmöglichkeiten der vorliegenden Erfindung ergeben sich aus der nachfolgenden Beschreibung im Zusammenhang mit den Figuren.

  • Fig. 1 zeigt eine schematische Darstellung einer ersten Ausführungsform eines beispielhaften erfindungsgemäßen Kolbenkompressors;
  • Fig. 2 zeigt eine schematische Darstellung einer zweiten Ausführungsform eines beispielhaften erfindungsgemäßen Kolbenkompressors; und
  • Fig. 3 zeigt ein Diagramm, in dem die Volumenstromänderung durch die Erhöhung des Eingangsdrucks dargestellt ist.
Further advantages, features and possible applications of the present invention emerge from the following description in connection with the figures.
  • Fig. 1 shows a schematic representation of a first embodiment of an exemplary piston compressor according to the invention;
  • Fig. 2 shows a schematic representation of a second embodiment of an exemplary piston compressor according to the invention; and
  • Fig. 3 shows a diagram in which the change in volume flow due to the increase in the inlet pressure is shown.

Fig. 1 zeigt eine schematische Darstellung einer ersten Ausführungsform eines beispielhaften erfindungsgemäßen Kolbenkompressors 10. Der im Ausführungsbeispiel ölfreie, also trockenlaufende Kolbenkompressor 10 weist ein Kurbelgehäuse 20 und eine darin angeordneten Kurbelwelle 21 auf, welche mit einer ersten Antriebseinrichtung 22 verbunden ist und von dieser angetrieben wird. Der im Ausführungsbeispiel einstufig dargestellte Kolbenkompressor 10 weist einen Zylinder 11 mit einem Verdichtungsraum 14 zum Komprimieren von Luft mittels eines im Zylinder 11 angeordneten Kolbens 12 auf, welcher über einen exzentrisch an der Kurbelwelle 21 drehbar gelagerten Pleuel 13 angetrieben wird. Fig. 1 3 shows a schematic representation of a first embodiment of an exemplary piston compressor 10 according to the invention. The piston compressor 10 shown in one stage in the exemplary embodiment has a cylinder 11 with a compression chamber 14 for compressing air by means of a piston 12 arranged in the cylinder 11, which is driven via a connecting rod 13 rotatably mounted eccentrically on the crankshaft 21.

Der Zylinder 11 weist einen Lufteinlass 30 auf, der mit einer Einlassanordnung 31 verbunden ist, welche zu verdichtende Luft zum Lufteinlass 30 des Verdichtungsraums 14 führt. Ferner weist der Zylinder 11 einen Luftauslass 33 auf, der mit einer Auslassanordnung 34 verbunden ist, welche verdichtete Luft aus dem Verdichtungsraum 14 aufnimmt. Die Kurbelwelle 21 bildet mit dem Pleuel 13 und den an diesen und zwischen diesen angeordneten Lagern den Kurbeltrieb 15, welcher sich im Betrieb des Kolbenkompressors 10 innerhalb des Kurbelgehäuses 20 erwärmt.The cylinder 11 has an air inlet 30, which is connected to an inlet arrangement 31, which guides air to be compressed to the air inlet 30 of the compression chamber 14. Furthermore, the cylinder 11 has an air outlet 33 which is connected to an outlet arrangement 34 which takes up compressed air from the compression chamber 14. The crankshaft 21, together with the connecting rod 13 and the bearings arranged on these and between them, forms the crankshaft drive 15, which heats up inside the crankcase 20 when the piston compressor 10 is in operation.

Das Kurbelgehäuse 20 der beispielhaften Ausführungsform ist über eine Luftzuführungsleitung 25 mit einem Luftfilter 26 verbunden, über welchen Umgebungsluft angesaugt und über die Luftzuführungsleitung 25 in das Kurbelgehäuse 20 geführt wird. An einem von Anschluss der Luftzuführungsleitung 25 entfernten Bereich des Kurbelgehäuses 20 ist die Einlassanordnung 31 angeordnet, so dass die von der Luftzuführungsleitung 25 in das Kurbelgehäuse 20 geführte Luft nach dem Durchströmen des Kurbelgehäuses 20 dieses durch die Einlassanordnung 31 wieder verlassen kann. Der dabei ausgebildete Luftstrom überströmt insbesondere die Elemente des Kurbeltriebs 15 und nimmt dabei bei gleichzeitiger Kühlung des Kurbeltriebs 15 Wärmeenergie auf.The crankcase 20 of the exemplary embodiment is connected via an air supply line 25 to an air filter 26, via which ambient air is sucked in and is fed into the crankcase 20 via the air supply line 25. The inlet arrangement 31 is arranged at a region of the crankcase 20 remote from the connection of the air supply line 25, so that the Air guided by the air supply line 25 into the crankcase 20 can leave the crankcase 20 again through the inlet arrangement 31 after flowing through the crankcase 20. The air flow formed in this way flows over in particular the elements of the crank drive 15 and absorbs thermal energy while cooling the crank drive 15 at the same time.

Die Einlassanordnung 31 weist eine Vorverdichtungseinrichtung 28 in Form eines externen Hochleistungsgebläses auf, das von einem Vorverdichterantrieb (zweite Antriebseinrichtung) 29 angetrieben wird. Durch die Wirkung der Vorverdichtungseinrichtung 28 wird Umgebungsluft durch den Luftfilter 26 in das Kurbelgehäuse 20 gesaugt, wo es über die Elemente des Kurbeltriebs 15 strömt und diesen dabei Wärmeenergie entzieht. Die Vorverdichtungseinrichtung 28 saugt die erwärmte Luft nach dem Durchströmen des Kurbelgehäuses 20 in die Einlassanordnung 31, verdichtet diese und baut dabei abhängig von der aktuellen Leistung des Vorverdichterantriebs 29 am Lufteinlass 30 vor dem Zylinder 11 einen gegenüber dem Umgebungsdruck erhöhten Druck auf. Durch diesen erhöhten Druck am Lufteinlass 30 kann während eines Ansaughubs des Kolbens 12 mehr Luft in den Verdichtungsraum 14 strömen, wodurch sich die Lieferleistung und Effizienz des Kolbenkompressors 10 erhöht.The inlet arrangement 31 has a pre-compression device 28 in the form of an external high-performance fan which is driven by a pre-compressor drive (second drive device) 29. As a result of the action of the pre-compression device 28, ambient air is sucked through the air filter 26 into the crankcase 20, where it flows over the elements of the crank drive 15 and thereby extracts thermal energy from them. The pre-compression device 28 sucks the heated air into the inlet arrangement 31 after it has flowed through the crankcase 20, compresses it and, depending on the current output of the pre-compressor drive 29, builds up a pressure that is higher than the ambient pressure at the air inlet 30 in front of the cylinder 11. As a result of this increased pressure at the air inlet 30, more air can flow into the compression chamber 14 during an intake stroke of the piston 12, as a result of which the delivery performance and the efficiency of the piston compressor 10 are increased.

Bei der beispielhaften Ausführungsform der Fig. 1 weist die Einlassanordnung 31 zwischen der Vorverdichtungseinrichtung 28 und dem Zylinder 11 eine Kühleinrichtung 32 auf, welche die durch die Einlassanordnung 31 strömende Luft kühlt. Sowohl beim Durchströmen des Kurbelgehäuses 20 als auch durch die Vorverdichtung in der Vorverdichtungseinrichtung 28 erwärmt sich die Ansaugluft, was zu einer Volumenvergrößerung führt, die eine Verringerung der während eines Ansaughubs in den Verdichtungsraum 14 aufnehmbaren Luftmenge bewirkt. Um diesem Effekt entgegen zu wirken, weist die Einlassanordnung 31 in Strömungsrichtung der Ansaugluft nach der Vorverdichtungseinrichtung 28 eine Kühleinrichtung 32 auf, welche die vorverdichtete Ansaugluft kühlt. Dadurch kann im Verdichtungsraum 14 eine größere Luftmenge aufgenommen werden. Durch diese Maßnahme wird die Lieferleistung und Effizienz des Kolbenkompressors 10 weiter erhöht.In the exemplary embodiment of Fig. 1 the inlet arrangement 31 has a cooling device 32 between the pre-compression device 28 and the cylinder 11, which cools the air flowing through the inlet arrangement 31. Both when flowing through the crankcase 20 and through the pre-compression in the pre-compression device 28, the intake air heats up, which leads to an increase in volume which causes a reduction in the amount of air that can be absorbed into the compression chamber 14 during an intake stroke. In order to counteract this effect, the inlet arrangement 31 has, in the flow direction of the intake air, after the pre-compression device 28, a cooling device 32 which cools the pre-compressed intake air. As a result, a larger amount of air can be taken up in the compression chamber 14. This measure further increases the delivery performance and efficiency of the reciprocating compressor 10.

Der Vorverdichterantrieb 29 ist bei der beispielhaften Ausführungsform des Kolbenkompressors 10 mit einer Regelungseinrichtung 40 verbunden, welche die Leistung der Vorverdichtungseinrichtung 28 und damit den Ansaugdruck am Lufteinlass 31 regelt. An der Einlassanordnung 31 und an der Auslassanordnung 34 des Kolbenkompressors 10 sind an geeigneten Stellen mehrere Drucksensoren 41a, 41b, 41c und mehrere Temperatursensoren 42a, 42b, 42c angeordnet, welche jeweils mit der Regelungseinrichtung 40 signalverbunden sind (nicht dargestellt). Die Drucksensoren 41a, 41b, 41c und die Temperatursensoren 42a, 42b, 42c übermitteln die jeweils herrschende Lufttemperatur bzw. den Druck an deren jeweiligen Position an der Einlassanordnung 31 bzw. an der Auslassanordnung 34 an die Regelungseinrichtung 40.In the exemplary embodiment of the piston compressor 10, the pre-compressor drive 29 is connected to a control device 40 which regulates the output of the pre-compression device 28 and thus the suction pressure at the air inlet 31. Several pressure sensors 41a, 41b, 41c and several temperature sensors 42a, 42b, 42c are arranged at suitable points on the inlet arrangement 31 and on the outlet arrangement 34 of the reciprocating compressor 10, each of which is signal-connected to the control device 40 (not shown). The pressure sensors 41a, 41b, 41c and the temperature sensors 42a, 42b, 42c transmit the respective prevailing air temperature or the pressure at their respective position on the inlet arrangement 31 or on the outlet arrangement 34 to the control device 40.

Ferner ist die Regelungseinrichtung 40 mit einem Vorrichtungsmanagementsystem 45 signalverbunden, welches weitere für die Druckluftversorgung des Kolbenkompressors 10 relevante Daten an die Regelungseinrichtung 40 übermittelt. Aus den Daten, welche die Regelungseinrichtung 40 insbesondere von den Drucksensoren 41a, 41b, 41c, den Temperatursensoren 42a, 42b, 42c und vom Vorrichtungsmanagementsystem 45 erhält, ermittelt die Regelungseinrichtung 40 den aktuellen Bedarf des Druckluftversorgungssystems und damit die erforderliche Lieferleistung des Kolbenkompressors 10. Mit der hieraus folgenden Bedarfsanforderung passt die Regelungseinrichtung 40 durch eine geeignete Regelung des Vorverdichterantriebs 29 den Grad der Vorverdichtung der Ansaugluft am Lufteinlass 31 mittels der Vorverdichtungseinrichtung 28 entsprechend an.Furthermore, the control device 40 is signal-connected to a device management system 45, which transmits further data relevant to the compressed air supply to the reciprocating compressor 10 to the control device 40. From the data that the control device 40 receives, in particular from the pressure sensors 41a, 41b, 41c, the temperature sensors 42a, 42b, 42c and from the device management system 45, the control device 40 determines the current requirement of the compressed air supply system and thus the required delivery capacity of the piston compressor 10 The control device 40 adapts the degree of pre-compression of the intake air at the air inlet 31 by means of the pre-compression device 28 to the demand requirement resulting therefrom by suitable regulation of the pre-compressor drive 29.

Bei einer weiteren, nicht dargestellten beispielhaften Ausführungsform des erfindungsgemäßen Kolbenkompressors 10 ist auch eine Leistungssteuerung der Kühleinrichtung 32 sowie der Nachkühleinrichtung 35 mit der Regelungseinrichtung 40 verbunden. Dabei kann dann auch die Kühlleistung der beiden Kühleinrichtungen 32, 35 mittels der Regelungseinrichtung 40 auf eine insbesondere jeweils ermittelte erforderliche Kühlleistung geregelt werden.In a further exemplary embodiment, not shown, of the piston compressor 10 according to the invention, a power control of the cooling device 32 and of the post-cooling device 35 is also connected to the regulating device 40. In this case, the cooling output of the two cooling devices 32, 35 can then also be regulated by means of the regulating device 40 to a required cooling output, in particular determined in each case.

Fig. 2 zeigt eine schematische Darstellung einer zweiten Ausführungsform eines beispielhaften erfindungsgemäßen Kolbenkompressors 10. Der Kolbenkompressor 10 aus Fig. 2 entspricht weitgehend dem in Fig. 1 dargestellten und hierzu beschriebenen Kolbenkompressor 10, so dass gleiche Elemente der Kolbenkompressoren 10 mit gleichen Bezugszeichen bezeichnet werden. Im Folgenden werden lediglich die Unterschiede zwischen den beiden schematisch dargestellten Kolbenkompressoren 10 erläutert. Fig. 2 shows a schematic representation of a second embodiment of an exemplary piston compressor 10 according to the invention. The piston compressor 10 the end Fig. 2 largely corresponds to that in Fig. 1 piston compressor 10 illustrated and described for this purpose, so that the same elements of the piston compressors 10 are denoted by the same reference numerals. In the following, only the differences between the two piston compressors 10 shown schematically are explained.

Der in Fig. 2 gezeigte Kolbenkompressor 10 weist gegenüber dem Kolbenkompressor 10 aus Fig. 1 eine an der Einlassanordnung 31 angeordnete Luftableiteinrichtung 36 in Form eines Überdruckventils auf. Bei der gezeigten Ausführungsform öffnet sich das Überdruckventil der Luftableiteinrichtung 36, sobald der Druck in der Einlassanordnung 31 in Strömungsrichtung der Ansaugluft nach der Kühleinrichtung 32 einen vorbestimmten Wert übersteigt und führt die überschüssige Ansaugluft in der Einlassanordnung 31 an die Umgebung des Kolbenkompressors 10 ab. Auf diese Weise kann der Volumenstrom von Luft zur Kühlung des Kurbelgehäuses 20 größer sein als die Lieferleistung des Kolbenkompressors 10, da die überschüssige Luft nach dem Durchströmen des Kurbelgehäuses 20 und nach der Vorverdichtung aus der Einlassanordnung 31 abgeführt werden kann.The in Fig. 2 The piston compressor 10 shown has opposite the piston compressor 10 Fig. 1 an air discharge device 36 arranged on the inlet arrangement 31 in the form of a pressure relief valve. In the embodiment shown, the pressure relief valve of the air discharge device 36 opens as soon as the pressure in the inlet arrangement 31 in the flow direction of the intake air after the cooling device 32 exceeds a predetermined value and discharges the excess intake air in the inlet arrangement 31 to the surroundings of the reciprocating compressor 10. In this way, the volume flow of air for cooling the crankcase 20 can be greater than the delivery rate of the reciprocating compressor 10, since the excess air can be discharged from the inlet arrangement 31 after flowing through the crankcase 20 and after the pre-compression.

Bei dieser beispielhaften Ausführungsform ist ein weitgehend beliebig großer Luftvolumenstrom durch das Kurbelgehäuse 20 realisierbar, wobei die Kühleinrichtung 32 möglicherweise gegenüber dem Kolbenkompressor 10 aus Fig. 1 für den vergrößerten Volumenstrom größer auszulegen ist. Bei im Vergleich mit dem Kolbenkompressor 10 aus Fig. 1 gleicher Lieferleistung steigt auch die Menge der durch den Luftfilter 26 angesaugten Luftmenge.In this exemplary embodiment, a largely arbitrarily large air volume flow through the crankcase 20 can be achieved, the cooling device 32 possibly being off opposite the reciprocating compressor 10 Fig. 1 is to be designed larger for the increased volume flow. When compared with the piston compressor 10 from Fig. 1 With the same delivery rate, the amount of air drawn in through the air filter 26 also increases.

Fig. 3 zeigt ein Diagramm, das die Änderung des vom Kolbenkompressor 10 geförderten Volumenstroms aufgrund einer Vorverdichtung und Kühlung der Ansaugluft beim Durchströmen der Einlassanordnung 31 veranschaulicht. Im Diagramm ist der Druck der Ansaugluft am Lufteinlass 30 über dem vom Kolbenkompressor 10 geförderten Volumenstrom dargestellt. Fig. 3 FIG. 8 shows a diagram which illustrates the change in the volume flow delivered by the reciprocating compressor 10 due to a precompression and cooling of the intake air as it flows through the inlet arrangement 31. The diagram shows the pressure of the intake air at the air inlet 30 over the volume flow conveyed by the piston compressor 10.

Der von einem Kolbenkompressor 10 gemäß dem Stand der Technik geförderte Volumenstrom 51 ist durch eine gestrichelt dargestellte Kurve gezeigt. Der von einem erfindungsgemäßen Kolbenkompressor 10 geförderte Volumenstrom 52 ist durch eine durchgehend dargestellte Kurve veranschaulicht.The volume flow 51 conveyed by a piston compressor 10 according to the prior art is shown by a curve shown in dashed lines. The one from one The volume flow 52 conveyed by the piston compressor 10 according to the invention is illustrated by a curve shown continuously.

Wie aus dem Diagramm ablesbar ist, wird durch die Erhöhung des Ansaugdrucks pe0 um Δpe auf pe1 durch die Vorverdichtung und Kühlung der Ansaugluft eine Steigerung des Volumenstroms um ΔV auf V1 erzielt, da das Hubvolumen des Verdichtungsraums V0 mit einer größeren Luftmenge als bei einem Kolbenkompressor 10 gemäß dem Stand der Technik gefüllt wird.As can be seen from the diagram, increasing the intake pressure p e0 by Δp e to p e1 increases the volume flow by ΔV to V 1 through the pre-compression and cooling of the intake air, since the displacement of the compression chamber V 0 with a larger amount of air than is filled in a piston compressor 10 according to the prior art.

Die in der vorstehenden Beschreibung, in den Zeichnungen sowie in den Ansprüchen offenbarten Merkmale der Erfindung können sowohl einzeln als auch in beliebiger Kombination für die Verwirklichung der Erfindung wesentlich sein.The features of the invention disclosed in the above description, in the drawings and in the claims can be essential for realizing the invention both individually and in any combination.

BEZUGSZEICHENLISTEREFERENCE LIST

1010
KolbenkompressorReciprocating compressor
1111
Zylindercylinder
1212th
KolbenPistons
1313th
PleuelConnecting rod
1414th
VerdichtungsraumCompression space
1515th
KurbeltriebCrank drive
2020th
KurbelgehäuseCrankcase
2121
Kurbelwellecrankshaft
2222nd
erste Antriebseinrichtungfirst drive device
2525th
LuftzuführungsleitungAir supply line
2626th
LuftfilterAir filter
2828
VorverdichtungseinrichtungPre-compression device
2929
VorverdichterantriebPre-compressor drive
3030th
LufteinlassAir inlet
3131
EinlassanordnungInlet arrangement
3232
KühleinrichtungCooling device
3333
LuftauslassAir outlet
3434
AuslassanordnungOutlet arrangement
3535
NachkühleinrichtungPost-cooling device
3636
LuftableiteinrichtungAir deflector
4040
RegelungseinrichtungControl device
41a, b, c41a, b, c
DrucksensorPressure sensor
42a, b, c42a, b, c
TemperatursensorTemperature sensor
4545
VorrichtungsmanagementsystemDevice management system
5151
Volumenstrom eines Kolbenkompressors des Stands der TechnikVolume flow of a piston compressor of the prior art
5252
Volumenstrom eines erfindungsgemäßen KolbenkompressorsVolume flow of a piston compressor according to the invention

Claims (9)

  1. Piston compressor comprising at least one cylinder (11) for compressing air with a piston (12), which is arranged movably therein, in a compression chamber (14) arranged above the piston (12) in the cylinder (11), wherein the compression chamber (14) has an air inlet (30) and an air outlet (33) and is connected at the air inlet (30) to an inlet arrangement (31) for air to be compressed and is connected at the air outlet (33) to an outlet arrangement (34) for compressed air, wherein the piston compressor (10) is drivable by a first drive device (22), characterized in that the inlet arrangement (31) has a pre-compression device (28), which is drivable with variable power by a second drive device (29), for increasing the intake pressure, and a cooling device (32) for cooling the air to be compressed, and wherein the piston compressor comprises a crankcase (22) in which a crankshaft (21) is arranged, on which at least one connecting rod (13) which is connected to a piston (12) is rotatably mounted, wherein the intake air of the at least one cylinder (11) is guided through the crankcase (20) .
  2. Piston compressor according to Claim 1, characterized in that the inlet arrangement (31) has an air-diverting device (36).
  3. Piston compressor according to either of the preceding claims, characterized by an after-cooling device (35) for cooling the compressed air after passage through the at least one cylinder (11) of the piston compressor (10).
  4. Piston compressor according to one of the preceding claims, characterized by a regulating device (40) with which the power of the pre-compression device (28) and thus the intake pressure at the air inlet (30) can be regulated.
  5. Method for controlling a piston compressor according to Claim 4, characterized in that the regulating device (40) regulates the power of the pre-compression device (28) between a maximum value, which corresponds to a maximum intake pressure (pmax) at the air inlet (30), and a minimum value, which corresponds to the intake pressure (p0), which is produced by the piston stroke movement in the cylinder (11), at the air inlet (30).
  6. Method for controlling a piston compressor according to Claim 5, characterized in that the regulating device (40) is connected in terms of signalling to at least one signal transmitter (45) and/or at least one sensor (41a, 41b, 41c, 42a, 42b, 42c), wherein the regulating device (40) regulates the power of the pre-compression device (28) depending on at least one value and/or signal from said at least one signal transmitter (45) and/or sensor (41a, 41b, 41c, 42a, 42b, 42c).
  7. Method for controlling a piston compressor according to Claim 6, characterized in that the at least one sensor (41a, 41b, 41c, 42a, 42b, 42c) is selected from a group which in particular comprises pressure sensors (41a, 41b, 41c), temperature sensors (42a, 42b, 42c), volumetric flow sensors and rotational speed sensors.
  8. Method for controlling a piston compressor according to Claim 6 or 7, characterized in that the at least one signal transmitter (45) is selected from a group which in particular comprises operating management systems (45) or control devices.
  9. Method for controlling a piston compressor according to one of Claims 5 to 8, characterized in that the regulating device (40) regulates the power of the cooling device (32) independently of the power of the pre-compression device (28).
EP17712994.7A 2016-03-21 2017-03-23 Reciprocating compressor with an extended control range Not-in-force EP3601797B1 (en)

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DE102016105145.4A DE102016105145A1 (en) 2016-03-21 2016-03-21 Piston compressor with extended control range
PCT/EP2017/056908 WO2017186415A1 (en) 2016-03-21 2017-03-23 Piston compressor with enlarged regulating region

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EP (1) EP3601797B1 (en)
JP (1) JP6771579B2 (en)
KR (2) KR102353258B1 (en)
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DE (1) DE102016105145A1 (en)
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JP6771579B2 (en) 2020-10-21
EP3601797A1 (en) 2020-02-05
KR20190123665A (en) 2019-11-01
US11041490B2 (en) 2021-06-22
CN109072897A (en) 2018-12-21
KR102275455B1 (en) 2021-07-09
JP2019510919A (en) 2019-04-18
DE102016105145A1 (en) 2017-09-21
KR20210107704A (en) 2021-09-01
WO2017186415A1 (en) 2017-11-02
WO2017186415A8 (en) 2018-05-17
CN109072897B (en) 2021-06-08
KR102353258B1 (en) 2022-01-18
US20190048865A1 (en) 2019-02-14
RU2703046C1 (en) 2019-10-15

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