US20100303658A1 - Water-Cooled Oil-Free Air Compressor - Google Patents
Water-Cooled Oil-Free Air Compressor Download PDFInfo
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- US20100303658A1 US20100303658A1 US12/707,429 US70742910A US2010303658A1 US 20100303658 A1 US20100303658 A1 US 20100303658A1 US 70742910 A US70742910 A US 70742910A US 2010303658 A1 US2010303658 A1 US 2010303658A1
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- Prior art keywords
- aftercooler
- intercooler
- cooling water
- pressure stage
- compressed air
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component 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
- F04B39/06—Cooling; Heating; Prevention of freezing
- F04B39/064—Cooling by a cooling jacket in the pump casing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01C—ROTARY-PISTON OR OSCILLATING-PISTON MACHINES OR ENGINES
- F01C21/00—Component parts, details or accessories not provided for in groups F01C1/00 - F01C20/00
- F01C21/007—General arrangements of parts; Frames and supporting elements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C23/00—Combinations of two or more pumps, each being of rotary-piston or oscillating-piston type, specially adapted for elastic fluids; Pumping installations specially adapted for elastic fluids; Multi-stage pumps specially adapted for elastic fluids
- F04C23/001—Combinations of two or more pumps, each being of rotary-piston or oscillating-piston type, specially adapted for elastic fluids; Pumping installations specially adapted for elastic fluids; Multi-stage pumps specially adapted for elastic fluids of similar working principle
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
- F04C28/02—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids specially adapted for several pumps connected in series or in parallel
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C29/00—Component parts, details or accessories of pumps or pumping installations, not provided for in groups F04C18/00 - F04C28/00
- F04C29/04—Heating; Cooling; Heat insulation
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C18/00—Rotary-piston pumps specially adapted for elastic fluids
- F04C18/08—Rotary-piston pumps specially adapted for elastic fluids of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing
- F04C18/12—Rotary-piston pumps specially adapted for elastic fluids of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type
- F04C18/14—Rotary-piston pumps specially adapted for elastic fluids of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type with toothed rotary pistons
- F04C18/16—Rotary-piston pumps specially adapted for elastic fluids of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type with toothed rotary pistons with helical teeth, e.g. chevron-shaped, screw type
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2240/00—Components
- F04C2240/70—Use of multiplicity of similar components; Modular construction
Definitions
- the present invention relates to water-cooled oil-free air compressors and more particularly to air compressors which use a cooling device for cooling the air compressed in multiple stages.
- the compressors as described in JP-A No. H8-61271 and JP-A No. H11-22688 are known as water-cooled two-stage compressors having an intercooler and an aftercooler.
- cooling water is first to the aftercooler and then to the intercooler, and in the compressor as described in JP-A No. H11-22688, the cooling water path is branched into a cooling water path for cooling the intercooler and a cooling water path for cooling the aftercooler and after cooling the intercooler and aftercooler, the paths join together to discharge cooling water.
- These compressors have one intercooler and one aftercooler.
- JP-A No. 2002-130172 and JP-A 2006-249934 are known as compressors designed for compactness.
- the intercooler and aftercooler are integral with each other and a cooling water inlet port is located on the aftercooler side and a cooling water outlet port is located on the intercooler side.
- JP-A 2006-249934 discloses that the compressor uses a plate type heat exchanger for a cooler with focus on heat exchanger size reduction.
- a compressors uses one intercooler and one aftercooler like those as described in JP-A No. H8-61271 and JP-A No. H11-22688 and is large in size, its intercooler and aftercooler must be large.
- the space occupied by the coolers and cooler inlet and outlet pipes in the compressor package must be large, which is an impediment to compressor size reduction.
- the intercooler and aftercooler shell diameter and length must be large enough to secure the required cooling capacity. This means that the cooler volume must be large and it is difficult to reduce the overall compressor size.
- the intercooler and aftercooler are integral with each other so that a certain degree of cooler compactness can be achieved.
- the intercooler and aftercooler are located opposite to each other, which constitutes a restriction on the arrangement of the coolers. Therefore, when the cooler size is increased in order to achieve higher putout (larger air volume) of the air compressor, it may be difficult to reduce the overall compressor size because the coolers are integral with each other.
- JP-A 2006-249934 is designed for cooler compactness, it also offers no solution to the problem that the cooler size must be increased to cope with higher compressor output (larger air volume). Therefore, a solution to the problem has been anticipated.
- the present invention has been made in view of the above circumstances and has an object to provide an air compressor which features compressor package compactness and ensures improved productivity and maintainability.
- a water-cooled oil-free air compressor which includes a low pressure stage compressor body, an intercooler for water-cooling compressed air discharged from the low pressure stage compressor body, a high pressure stage compressor body for further compressing the compressed air cooled by the intercooler, and an aftercooler for water-cooling air discharged from the high pressure stage compressor body.
- the compressor has the following features:
- the intercooler and the aftercooler are arranged so as to make a flow direction of compressed air flowing in the intercooler and a flow direction of compressed air flowing in the aftercooler opposite to each other, a flow direction of compressed air flowing in the intercooler and a flow direction of cooling water flowing in the intercooler are opposite to each other and a flow direction of compressed air flowing in the aftercooler and a flow direction of cooling water flowing in the aftercooler are opposite to each other, and a cooling water pipe for connecting a cooling water outlet of one aftercooler unit and a cooling water inlet of one intercooler unit and a cooling water pipe for connecting a cooling water outlet of another aftercooler unit and a cooling water inlet of another intercooler unit are provided.
- the cooling water pipe for connecting the cooling water outlet of one aftercooler unit and the cooling water inlet of one intercooler unit and the cooling water pipe for connecting a cooling water outlet of another aftercooler unit and the cooling water inlet of another intercooler unit be arranged symmetrically.
- the compressor includes a motor for driving the low pressure stage compressor body and the high pressure stage compressor body, a plurality of gears for transmitting power of the motor to the low pressure stage compressor body and the high pressure stage compressor body, a gear casing for housing the gears, and a cooler rack located opposite to the gear casing with respect to the motor to hold the intercooler and the aftercooler in a higher position than the motor, it is preferable that the positional relation be as follows:
- the aftercooler is placed above the intercooler.
- coolers can be simplified and it is possible to provide a water-cooled two-stage oil-free air compressor which features compactness and ensures improved productivity and maintainability.
- FIG. 1 is a schematic diagram showing a water-cooled two-stage oil-free screw compressor according to an embodiment of the present invention
- FIG. 2 shows the configuration of the water-cooled two-stage oil-free screw compressor
- FIG. 3 shows the configuration of a cooling system
- FIG. 4 is a sectional view of a cooler unit.
- a preferred embodiment of the present invention assumes a multistage air compressor which includes: a low pressure stage compressor body 1 ; an intercooler 3 for water-cooling the compressed air discharged from the low pressure stage compressor body 1 ; a high pressure stage compressor body 2 for further compressing the compressed air cooled by the intercooler 3 ; and an aftercooler 4 for water-cooling the air discharged from the high pressure stage compressor body 2 .
- the air compressor is characterized by adopting a so-called one-pass system in which two intercooler units and two aftercooler units are provided to ensure compactness of the intercooler 3 and the aftercooler 4 .
- This embodiment offers the following four advantageous effects, which will be explained in detail later.
- the intercooler 3 and aftercooler 4 each include two units so that maintainability of the coolers 3 and 4 is improved and the compressor package can be compact. In addition, even if a cooler breakdown occurs, leakage of compressed air is reduced due to the compactness of the cooler units.
- this embodiment is advantageous as follows.
- one check valve is provided for one compressor as suggested in JP-A No. 2002-130172.
- the check valve size must be larger. If that is the case, the check valve cost is higher and it is less easy to simplify the check valve installation structure and improve maintainability.
- a plurality of cooler units are used and the path for compressed air flowing into the coolers is branched off so that two check valves can be provided.
- two check valves 13 are installed at the inlets of the two aftercooler units 4 a and 4 b respectively so that the check valves 13 are small, the compressor package is compact and the installation structure of the check valves 13 is simplified and maintainability is improved.
- the check valves 13 are so located that they can be easily accessed from outside.
- the embodiment is also advantageous as follows.
- compressed air flows into plural cooler units, which means that the air path is branched off.
- one cooler head is provided at each of the inlets and outlets of the coolers, not a few pipes will be required for the inlets and outlets.
- a common header is provided at each or either of the inlet and outlet in the two intercooler units 3 a and 3 b and the two aftercooler units 4 a and 4 b to decrease the number of cooler inlet and outlet pipes for simplicity.
- one cooler 3 ( 4 ) includes plural cooler units, in this case 3 a and 3 b ( 4 a and 4 b ), productivity and maintainability can be improved.
- the intercooler and aftercooler are different in size and shape (JP-A No. H8-61271 and JP-A No. H11-22688) or integral with each other (JP-A No. 2002-130172 and JP-A No. 2006-249934), so when assembling the compressor or cleaning or replacing a cooler, it is necessary to prepare different parts for the intercooler and aftercooler.
- the intercooler units and aftercooler units are all common and their parts are interchangeable, leading to improvement in productivity and maintainability.
- cooling water pipes are disposed in parallel and symmetrically for the intercooler 3 and aftercooler 4 which constitute two cooler sets, each set consisting of an intercooler unit and an aftercooler unit, so that equal amounts of cooling water flow into the two intercooler units 3 a and 3 b and the two aftercooler units 4 a and 4 b , and the intercooler units (aftercooler units) are equal in cooling capacity.
- the cooling water flow system is specially designed to address this need. More specifically, it is designed so that the aftercooler 4 is first cooled and the intercooler 3 is cooled by the cooling water used for the aftercooler 4 , which has a temperature higher than before. The cooling capacity of the intercooler 3 and that of the aftercooler 4 are thus controlled.
- the cooling capacity can be controlled by making the number of cooler units of the intercooler 3 and that of the aftercooler 4 different (for example, three aftercooler units and two intercooler units are used). This means that common parts can be used and the cooling capacity can be easily controlled, contributing to improvement in productivity.
- the inlet and outlet ports for compressed air as a hot fluid are opposite to those for cooling water as a cool fluid and their flow directions are opposite or they flow as counterflows.
- the intercooler 3 and aftercooler 4 it is desirable that cooling water be made to flow first for higher temperature compressed air. Therefore, the aftercooler 4 and intercooler 3 are arranged in parallel as mentioned above and since cooling water is to be supplied first to the aftercooler 4 and then to the intercooler 3 , the outlet for cooling water from the aftercooler 4 is located near the inlet for cooling water into the intercooler 3 in order to shorten the cooling water pipe and simplify the piping.
- the piping is arranged so that the flow direction of compressed air in the aftercooler 4 is opposite to that in the intercooler 3 (at the same time, the flow directions of cooling water in the coolers are also opposite to each other), so the cooling water pipe is shortened, the structure is simplified and productivity is improved.
- FIG. 1 is a schematic diagram showing a water-cooled two-stage oil-free screw compressor 30 having a low pressure stage compressor body 1 and a high pressure stage compressor body 2 .
- the low pressure stage compressor body 1 and high pressure stage compressor body 2 each include a pair of rotors, i.e. a male rotor and a female rotor.
- the compressor according to this embodiment is a screw air compressor which compresses air by rotation of the male and female rotors.
- Pinion gears 21 are fitted to the axial ends of the male rotors of the low pressure stage compressor body 1 and high pressure stage compressor body 2 . These pinion gears 21 are engaged with a bull gear 23 fitted to one end of a driving shaft inside a gear casing 28 so that motor power is transmitted to the low pressure stage compressor body 1 and high pressure stage compressor body 2 .
- FIG. 1 shows that the bull gear 23 is located on the output shaft of a motor 26 and engaged with the pinion gears 21 at the axial ends of the male rotors, instead an intermediate shaft may be located between the motor output shaft and the male rotors. If an intermediate shaft is provided, the power of the motor 26 is transmitted to the low pressure stage compressor body 1 and high pressure stage compressor body 2 through the intermediate shaft.
- An intake throttle valve 12 which regulates the flow rate of air taken into the low pressure stage compressor body 1 is located on the intake side of the low pressure stage compressor body 1 .
- the air, from which foreign matter is removed by a filter (not shown), is passed through the intake throttle valve 12 and introduced into the low pressure stage compressor body 1 and compressed to a prescribed pressure level and discharged through the outlet of the low pressure stage compressor body 1 .
- the compressed air discharged from the low pressure stage compressor body 1 is led into an intermediate discharge pipe A.
- the air compressed by the low pressure stage compressor body 1 and led into the intermediate discharge pipe A is cooled by the intercooler 3 .
- the intermediate discharge pipe A is branched into plural pipes upstream of the cooler headers 6 which serve as holes to introduce air into the intercooler 3 .
- the discharge pipe A is bifurcated at the inlets of the cooler headers 6 and the two flows of compressed air are introduced in parallel into the two intercooler units 3 a and 3 b located in the air path between the low pressure stage compressor body 1 and high pressure stage compressor body 2 to be cooled there.
- the two flows of compressed air cooled by the intercooler 3 comprised of two intercooler units, join together at a cooler header 7 attached to the outlet side of the intercooler 3 before being led into an intermediate discharge pipe B.
- the compressed air cooled by the intercooler 3 and led into the intermediate discharge pipe B is taken into the high pressure stage compressor body 2 located downstream thereof.
- the compressed air further compressed by the high pressure stage compressor body 2 is discharged from the high pressure stage compressor body 2 and led into a high pressure stage discharge pipe C.
- the discharge pipe C which connects the high pressure stage compressor body 2 and the aftercooler 4 , is branched into plural pipes upstream of cooler headers 8 of the aftercooler 4 .
- a check valve 13 is installed in each flow path downstream of the branching point of the discharge pipe C, in which the check valves 13 are located upstream of the aftercooler headers 8 .
- the compressed air discharged into the high pressure stage discharge pipe C is divided into two flows at a point midway in the discharge pipe C and the flows of compressed air pass through the two check valves 13 located downstream thereof before being taken in parallel into the aftercooler 4 , comprised of two aftercooler units 4 a and 4 b , and being cooled there.
- the flows of compressed air cooled by the aftercooler 4 join together in a cooler header 9 attached to the outlet side of the aftercooler 4 before being exhausted through a compressed air outlet port.
- cooler header 6 is attached to the inlet side of each of the intercooler units 3 a and 3 b of the intercooler 3 and one cooler header 8 is attached to the inlet side of each of the aftercooler units 4 a and 4 b of the aftercooler 4
- only one cooler header is attached to the outlet sides of the two intercooler units 3 a and 3 b and also only one cooler header is attached to the outlet sides of the two aftercooler units 4 a and 4 b so that the two flows of compressed air join together at each outlet side, and the flows of compressed air join together in the outlet side.
- the high pressure stage compressor body 2 and the low pressure stage compressor body 1 generate heat due to compression heat.
- the compressed air has a high temperature and is too hot for a consumer to use.
- the overall efficiency of the oil-free screw compressor 30 is improved.
- cooling water is supplied to various parts of the oil-free compressor 30 .
- the cooling water is routed as follows.
- the path for cooling water cooled by a cooling tower is branched at the cooling water inlet port into a cooling water path for the aftercooler 4 and intercooler 3 and a cooling water path for the oil cooler 10 , blower cooler 11 , high pressure stage compressor body 2 , and low pressure stage compressor body 1 .
- the cooling water path for the aftercooler 4 and intercooler 3 first leads to the aftercooler 4 to cool the air discharged from the high pressure stage compressor body 2 , then reaches the intercooler 3 to cool the air discharged from the low pressure stage compressor body 1 before returning the cooling water to the cooling tower or the like through a cooling water outlet port.
- the flow direction of cooling water is opposite to the flow direction of compressed air to make it a counterflow and in both the intercooler 3 and aftercooler 4 , cooling water is supplied from the bottom of the shell and drained from its top.
- the intercooler 3 and aftercooler 4 each have two units (intercooler units 3 a and 3 b and aftercooler units 4 a and 4 b ) and the cooling water pipe in the path for cooling them is bifurcated at the inlet of the aftercooler 4 into a pipe for cooling one cooler set, i.e. the aftercooler unit 4 a and intercooler unit 3 a and a pipe for cooling the other cooler set, i.e. the aftercooler unit 4 b and intercooler unit 3 b .
- the two cooling water pipes join together and lead to a cooling water outlet port. (Hereinafter, they may be called the “first cooling water path” and “second cooling water path” respectively.)
- cooling water in the path for cooling the oil cooler 10 , blower cooler 11 , high pressure stage compressor body 2 and low pressure stage compressor body 1 is first led to the oil cooler 10 to cool lubricating oil, then led to the blower cooler 11 to cool the air released during no-load operation.
- the cooling water is led to a cooling jacket provided on the casing of the high pressure stage compressor body 2 to cool the high pressure stage compressor body 2 , then led to a cooling jacket provided on the casing of the low pressure stage compressor body 1 to cool the low pressure stage compressor body 1 before returning to the cooling tower through the cooling water outlet port.
- a valve is attached to the inlet of the cooling water path for the oil cooler 10 .
- a valve is used to regulate the cooling water ratio between the path for the aftercooler 4 and intercooler 3 and the path for the oil cooler 10 , blower cooler 11 and high pressure stage compressor body 2 , and low pressure stage compressor body 1 .
- the lubricating oil cooled by the oil cooler 10 lubricates the bearings and pinion gears of the low pressure stage compressor body 1 and high pressure stage compressor body 2 , the timing gears and the bearings of the intermediate shaft in the gear casing 28 , the pinion gears and bull gear fitted to the intermediate shaft and the bull gear fitted to the rotation shaft of the motor and so on before being stored in an oil reservoir at the bottom of the gear casing 28 . Then, the oil is led by an oil pump into the oil cooler 10 and cooled by cooling water. The lubricating oil circulates in this way.
- the compressed air path is branched into two paths upstream of the intercooler 3 and after the compressed air is cooled by the intercooler 3 , the paths join together.
- the compressed air path is branched upstream of the aftercooler 4 .
- the paths join together after the compressed air is cooled by the aftercooler 4 to supply the compressed air to the outside.
- the cooling water path is branched into a first cooling water path and a second cooling water path which are independent of each other. More specifically, after the path is branched into two paths before supplying cooling water to the aftercooler 4 , the flows of cooling water in the two paths cool the aftercooler 4 and then go to the intercooler 3 respectively without joining together. Therefore, it is desirable to supply an equal amount of cooling water to both the paths to ensure uniformity in cooling performance. Therefore, it is desirable that the first cooling water path and cooling water path be the same or mutually symmetrical in terms of shape.
- FIG. 2 shows the configuration of the water-cooled two-stage oil-free screw compressor, in which parts other than substantial ones are omitted.
- a pedestal on which the motor 26 and gear casing 28 are mounted is placed on the base and adjacent to the pedestal is a cooler rack 18 on which the coolers 3 and 4 are mounted. Power from the motor 26 is transmitted through various gears in the gear casing 28 to the low pressure stage compressor body 1 and high pressure stage compressor body 2 .
- the gear casing 28 is located on the output shaft side of the motor 26 and the low pressure stage compressor body 1 and high pressure stage compressor body 2 are placed side by side in a way to protrude over the motor 26 from above the gear casing 28 . In other words, both the compressor bodies 1 and 2 lie over the motor 26 .
- the cooler rack 18 is located opposite to the gear casing 28 (front left in the figure) with respect to the motor 26 .
- the cooler rack 18 has legs and the cooler rest is in a higher position than the motor 26 . This arrangement facilitates heat radiation of the motor 26 because the space on the side of the motor 26 which is opposite to the gear casing 28 is open.
- the intercooler 3 and aftercooler 4 are placed on the cooler rest of the cooler rack 18 .
- the low pressure stage compressor body 1 lies over the motor 26 and compressed air discharged from the low pressure stage compressor body 1 flows into the discharge pipe A and enters the intercooler 3 . Since the distance between the low pressure stage compressor body 1 and intercooler 3 is short, the air path can be short and the intermediate discharge pipe A can be simplified.
- the intercooler 3 in this embodiment is explained below. As shown in FIG. 2 , the intercooler 3 is mounted on the cooler rack 18 .
- the intercooler 3 includes two intercooler units 3 a and 3 b which are placed on the cooler rack 18 side by side by cooler supporting members.
- the two units of the aftercooler 4 are placed side by side like the intercooler 3 , over the intercooler 3 . Since the aftercooler 4 lies over the intercooler 3 , the check valves 13 can be accessed easily and installed easily, contributing to easy maintenance.
- the cooler headers 6 and 7 are attached to the compressed air inlet and outlet sides of the two intercooler units 3 a and 3 b of the intercooler 3 which are located side by side.
- the discharge pipe A is branched upstream of the cooler headers 6 so that compressed air flows through two air paths into the intercooler units 3 a and 3 b where it is cooled.
- the cooler header 7 in this embodiment has a structure which allows the flows of compressed air from the units to meet and the combined compressed air flow in the cooler header 7 goes through the discharge pipe B into the high pressure stage compressor body 2 .
- both the compressor bodies 1 and 2 protruding over the motor 26 from the top of the gear casing 28 , are arranged so as to simplify the piping. More specifically, the low pressure stage compressor body 1 is on the same side as the inlet of the intercooler 3 (front in the figure) and the high pressure stage compressor body 2 is on the same side as the outlet of the intercooler 3 (back in the figure).
- the discharge pipe B as the path for the air cooled by the intercooler 3 is also simplified.
- the compressed air further compressed by the high pressure stage compressor body 2 is discharged into the high pressure stage discharge pipe C.
- the discharge pipe C extends upward and, on the downstream, extends toward the aftercooler 4 .
- the aftercooler 4 is comprised of two aftercooler units 4 a and 4 b like the intercooler 3 , and has cooler headers 8 and 9 on the compressed air inlet and outlet sides respectively.
- the discharge pipe C is branched upstream of the cooler headers 8 and each branch pipe has a check valve 13 .
- Each of these branch pipes is connected with the cooler header 8 provided on each of the cooler units 4 a and 4 b.
- compressed air after being branched through the discharge pipe C, passes through the check valve 13 in each branch pipe and is introduced into the cooler header 8 .
- the compressed air flowing from the cooler header 8 into the aftercooler 4 is cooled by the aftercooler 4 before joining the other flow of compressed air in the cooler header 9 on the outlet side and flowing out of the compressor package.
- the flow direction of compressed air in the intercooler 3 is opposite to that in the aftercooler 4 so that the discharge pipe is simplified due to the positional relation with the compressor bodies 1 and 2 .
- the cooling water pipe for the path for cooling the intercooler units 3 a and 3 b and aftercooler units 4 a and 4 b is branched before the inlet of the aftercooler 4 into a pipe for cooling one set of cooler units, the aftercooler unit 4 a and intercooler unit 3 a , and a pipe for cooling the other set, the aftercooler unit 4 b and intercooler unit 3 b .
- the cooling water in the coolers flows in a direction opposite to the flow of compressed air to make a counterflow, so the flow direction of cooling water in the intercooler 3 is opposite to that in the aftercooler 4 . Therefore, the cooling water pipe through which the cooling water used to cool the compressed air in the aftercooler 4 flows into the intercooler 3 can be shortened to simplify the structure. More specifically, the cooling water outlet of the aftercooler 4 as designated by reference numeral 17 in FIG. 2 and the cooling water inlet of the intercooler 3 as designated by reference numeral 16 can be close to each other, largely contributing to compactness from the viewpoint of the cooling water path.
- FIG. 3 shows the configuration of the cooling system which includes the intercooler 3 and aftercooler 4
- FIG. 4 is a sectional view of a cooler.
- the shell 5 which forms the outside of the cooling part has the same dimensions.
- the intercooler 3 and aftercooler 4 each have two cooler units placed side by side on the cooler rack 18 in which the aftercooler 4 is in the upper position and the intercooler 3 is in the lower position.
- the cooler units are fixed on the cooler rest of the cooler rack 18 by supporting members. They are thus arranged with the required spacing between cooler units (between the cooler units 3 a and 3 b and between the cooler units 4 a and 4 b ) and the required spacing between the coolers (between the intercooler 3 and aftercooler 4 ).
- cooling water is supplied into the cooler shell (explained later) from the cooling water inlet 16 (upper right in the figure) of the aftercooler 4 to cool high-pressure compressed air and then discharged through the outlet 17 (upper left in the figure). After that, it is supplied through the cooling water inlet 16 (lower left in the figure) into the intercooler 3 to cool middle-pressure compressed air and then discharged through the cooling water outlet 17 (lower right in the figure).
- This configuration makes it possible that all cooler components including the cooling water paths are arranged in a compressor unit in a compact manner.
- the entire coolers including the check valves 13 can be removed from the compressor unit.
- cooler maintenance including cleaning and replacement is easy.
- FIG. 4 Details of the inside of each unit of the intercooler 3 and aftercooler 4 are shown in FIG. 4 .
- the intercooler 3 and aftercooler 4 adopt a so-called one-pass shell and tube heat exchanger.
- one-pass means that the inlet and outlet for compressed air are in different positions and there is no reciprocating path. More specifically, air which flows in from one side is discharged at the other side and cooling water which flows in from the side where air is discharged is discharged at the side where air flows in.
- the plurality of heat transfer tubes 14 installed inside the intercooler 3 and aftercooler 4 are all the same in terms of shape and the number of such tubes is almost equal for the coolers, and the heat transfer tubes 14 are disposed at regular intervals in the cooler shell 5 .
- pipe plates 15 are disposed in a staggered pattern at a plurality of points in the cooler unit axial direction.
- intercooler and aftercooler each use two units.
- the invention is not limited thereto and three or more intercooler and/or aftercooler units may be used without departing from the scope of the invention.
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- Compressor (AREA)
Abstract
A water-cooled oil-free air compressor which features compactness and ensures improved productivity and maintainability. The compressor is an oil-free screw compressor which includes a low pressure stage compressor body, an intercooler for water-cooling the compressed air discharged from the low pressure stage compressor body, a high pressure stage compressor body for further compressing the compressed air cooled by the intercooler, and an aftercooler for water-cooling the air discharged from the high pressure stage compressor body. The intercooler and aftercooler each have a plurality of units, all of which are almost equal in shape. A cooler header on each or either of the inlet and outlet sides for compressed air is shared by the units of each cooler.
Description
- The present invention relates to water-cooled oil-free air compressors and more particularly to air compressors which use a cooling device for cooling the air compressed in multiple stages.
- Most conventional two-stage oil-free screw compressors which have a low pressure stage compressor body and a high pressure stage compressor body use an intercooler for cooling the air compressed by the low pressure stage compressor body and an aftercooler for cooling the air compressed by the high pressure stage compressor body.
- The compressors as described in JP-A No. H8-61271 and JP-A No. H11-22688 are known as water-cooled two-stage compressors having an intercooler and an aftercooler. In the compressor as described in JP-A No. H8-61271, cooling water is first to the aftercooler and then to the intercooler, and in the compressor as described in JP-A No. H11-22688, the cooling water path is branched into a cooling water path for cooling the intercooler and a cooling water path for cooling the aftercooler and after cooling the intercooler and aftercooler, the paths join together to discharge cooling water. These compressors have one intercooler and one aftercooler.
- The compressors as described in JP-A No. 2002-130172 and JP-A 2006-249934 are known as compressors designed for compactness. In the compressor as described in JP-A No. 2002-130172, the intercooler and aftercooler are integral with each other and a cooling water inlet port is located on the aftercooler side and a cooling water outlet port is located on the intercooler side. JP-A 2006-249934 discloses that the compressor uses a plate type heat exchanger for a cooler with focus on heat exchanger size reduction.
- In recent years, with growing demand for compressed air, there has been a trend toward large size compressors that provide high output and deal with large volumes of air. As compressors provide higher output and deal with larger volumes of air, the coolers used therein tend to be larger in size.
- If a compressors uses one intercooler and one aftercooler like those as described in JP-A No. H8-61271 and JP-A No. H11-22688 and is large in size, its intercooler and aftercooler must be large. In such a compressor, the space occupied by the coolers and cooler inlet and outlet pipes in the compressor package must be large, which is an impediment to compressor size reduction. More specifically, when a large compressor deals with a large volume of air, the intercooler and aftercooler shell diameter and length must be large enough to secure the required cooling capacity. This means that the cooler volume must be large and it is difficult to reduce the overall compressor size.
- Furthermore, since the intercooler and aftercooler lie in the compressed air discharge route, there is high pressure air in the air paths inside the coolers. A large compressor which deals with a large volume of air has a problem that the cooler volume must be large enough as mentioned above, and if a cooler breakdown occurs, its influence will be serious. Another problem is that as the cooler size is larger, the cooler maneuverability and working efficiency in maintenance including cleaning deteriorate.
- In the compressor as described in JP-A No. 2002-130172, the intercooler and aftercooler are integral with each other so that a certain degree of cooler compactness can be achieved. However, the intercooler and aftercooler are located opposite to each other, which constitutes a restriction on the arrangement of the coolers. Therefore, when the cooler size is increased in order to achieve higher putout (larger air volume) of the air compressor, it may be difficult to reduce the overall compressor size because the coolers are integral with each other.
- Although the compressor as described in JP-A 2006-249934 is designed for cooler compactness, it also offers no solution to the problem that the cooler size must be increased to cope with higher compressor output (larger air volume). Therefore, a solution to the problem has been anticipated.
- The present invention has been made in view of the above circumstances and has an object to provide an air compressor which features compressor package compactness and ensures improved productivity and maintainability.
- In order to achieve the above object, according to one aspect of the present invention, there is provided a water-cooled oil-free air compressor which includes a low pressure stage compressor body, an intercooler for water-cooling compressed air discharged from the low pressure stage compressor body, a high pressure stage compressor body for further compressing the compressed air cooled by the intercooler, and an aftercooler for water-cooling air discharged from the high pressure stage compressor body.
- The compressor has the following features:
-
- The intercooler includes a plurality of intercooler units;
- The aftercooler includes a plurality of aftercooler units;
- The intercooler units each have a cooling water inlet and a cooling water outlet;
- The aftercooler units each have a cooling water inlet and a cooling water outlet; and
- A first cooling water path is provided to supply cooling water first to one aftercooler unit, then to one intercooler unit and a second cooling water path is provided to supply cooling water first to another aftercooler unit, then to another intercooler unit.
- Preferably the above compressor is characterized as follows:
- (a) The first cooling water path and the second cooling water path are symmetrical to each other in shape.
- (b) The intercooler and the aftercooler each have a cooler header covering a compressed air inlet side and a cooler header covering a compressed air outlet side and a cooler header on either or each of the compressed air inlet side and outlet side of the intercooler or the aftercooler is shared by the intercooler units or the aftercooler units.
- (c) Upstream of the aftercooler, a discharge pipe for compressed air flowing into the aftercooler is branched into a plurality of pipes leading to the aftercooler units and a check valve is provided in each branch discharge pipe.
- (d) The intercooler units and the aftercooler units have the same shape.
- More preferably, the intercooler and the aftercooler are arranged so as to make a flow direction of compressed air flowing in the intercooler and a flow direction of compressed air flowing in the aftercooler opposite to each other, a flow direction of compressed air flowing in the intercooler and a flow direction of cooling water flowing in the intercooler are opposite to each other and a flow direction of compressed air flowing in the aftercooler and a flow direction of cooling water flowing in the aftercooler are opposite to each other, and a cooling water pipe for connecting a cooling water outlet of one aftercooler unit and a cooling water inlet of one intercooler unit and a cooling water pipe for connecting a cooling water outlet of another aftercooler unit and a cooling water inlet of another intercooler unit are provided.
- In the above compressor, it is preferable that the cooling water pipe for connecting the cooling water outlet of one aftercooler unit and the cooling water inlet of one intercooler unit and the cooling water pipe for connecting a cooling water outlet of another aftercooler unit and the cooling water inlet of another intercooler unit be arranged symmetrically.
- Furthermore, if the compressor includes a motor for driving the low pressure stage compressor body and the high pressure stage compressor body, a plurality of gears for transmitting power of the motor to the low pressure stage compressor body and the high pressure stage compressor body, a gear casing for housing the gears, and a cooler rack located opposite to the gear casing with respect to the motor to hold the intercooler and the aftercooler in a higher position than the motor, it is preferable that the positional relation be as follows:
- (a) The low pressure stage compressor body and the high pressure stage compressor body are placed side by side, protruding over the motor from the gear casing.
- (b) The low pressure stage compressor body is located on a compressed air inlet side of the intercooler and the high pressure stage compressor body is located on a compressed air inlet side of the aftercooler to make the flow direction of compressed air flowing in the intercooler and the flow direction of compressed air flowing in the aftercooler opposite to each other.
- In the above case, on the cooler rack, the aftercooler is placed above the intercooler.
- According to the present invention, coolers can be simplified and it is possible to provide a water-cooled two-stage oil-free air compressor which features compactness and ensures improved productivity and maintainability.
- Embodiments of the present invention will be described in detail based on the following figures, wherein:
-
FIG. 1 is a schematic diagram showing a water-cooled two-stage oil-free screw compressor according to an embodiment of the present invention; -
FIG. 2 shows the configuration of the water-cooled two-stage oil-free screw compressor; -
FIG. 3 shows the configuration of a cooling system; and -
FIG. 4 is a sectional view of a cooler unit. - As shown in
FIG. 1 andFIG. 2 , a preferred embodiment of the present invention assumes a multistage air compressor which includes: a low pressurestage compressor body 1; anintercooler 3 for water-cooling the compressed air discharged from the low pressurestage compressor body 1; a high pressurestage compressor body 2 for further compressing the compressed air cooled by theintercooler 3; and anaftercooler 4 for water-cooling the air discharged from the high pressurestage compressor body 2. According to this embodiment, the air compressor is characterized by adopting a so-called one-pass system in which two intercooler units and two aftercooler units are provided to ensure compactness of theintercooler 3 and theaftercooler 4. - This embodiment offers the following four advantageous effects, which will be explained in detail later.
- First, as compared with the conventional techniques (for example, those described in JP-A No. H8-61271 and JP-A No. H11-22688 in which one cooler head is provided on each of the inlet and outlet sides of an intercooler and an aftercooler, this embodiment is advantageous in the following point.
- In the conventional techniques, which use one intercooler and one aftercooler, when the compressor is large and provides high output with a large volume of air, the intercooler and aftercooler must be large as well. As a consequence, working efficiency in maintenance including cleaning the cooler inside deteriorates and the space occupied by the coolers and cooler inlet and outlet pipes in the compressor package is large, constituting a bottleneck in the effort to reduce the compressor size.
- By contrast, in this embodiment, the
intercooler 3 andaftercooler 4 each include two units so that maintainability of thecoolers - Second, concerning check valves provided in the compressed air paths, this embodiment is advantageous as follows. In the conventional techniques which use one intercooler and one aftercooler (for example, those described in JP-A No. H8-61271 and JP-A No. H11-22688), one check valve is provided for one compressor as suggested in JP-A No. 2002-130172. In this case, as the compressor provides higher output and deals with a larger volume of air, the check valve size must be larger. If that is the case, the check valve cost is higher and it is less easy to simplify the check valve installation structure and improve maintainability.
- In this embodiment, a plurality of cooler units are used and the path for compressed air flowing into the coolers is branched off so that two check valves can be provided. As shown in
FIG. 1 , twocheck valves 13 are installed at the inlets of the twoaftercooler units check valves 13 are small, the compressor package is compact and the installation structure of thecheck valves 13 is simplified and maintainability is improved. In addition, for further improvement in productivity and maintainability, thecheck valves 13 are so located that they can be easily accessed from outside. - Third, concerning the compressed air paths, the embodiment is also advantageous as follows. In this embodiment, compressed air flows into plural cooler units, which means that the air path is branched off. In this case, if one cooler head is provided at each of the inlets and outlets of the coolers, not a few pipes will be required for the inlets and outlets. In this embodiment, instead a common header is provided at each or either of the inlet and outlet in the two
intercooler units aftercooler units - Fourth, since one cooler 3 (4) includes plural cooler units, in this
case - When the
intercooler 3 andaftercooler 4 have more than one unit, for example, twounits intercooler units aftercooler units intercooler 3 andaftercooler 4 which constitute two cooler sets, each set consisting of an intercooler unit and an aftercooler unit, so that equal amounts of cooling water flow into the twointercooler units aftercooler units - Although the units of the
intercooler 3 andaftercooler 4 are common in this embodiment, for the sake of drain reduction theintercooler 3 must be lower in cooling capacity than theaftercooler 4. In this embodiment, the cooling water flow system is specially designed to address this need. More specifically, it is designed so that theaftercooler 4 is first cooled and theintercooler 3 is cooled by the cooling water used for theaftercooler 4, which has a temperature higher than before. The cooling capacity of theintercooler 3 and that of theaftercooler 4 are thus controlled. - Alternatively, the cooling capacity can be controlled by making the number of cooler units of the
intercooler 3 and that of theaftercooler 4 different (for example, three aftercooler units and two intercooler units are used). This means that common parts can be used and the cooling capacity can be easily controlled, contributing to improvement in productivity. - For the purpose of improvement in the cooling capacity of a cooler, it is effective that the inlet and outlet ports for compressed air as a hot fluid are opposite to those for cooling water as a cool fluid and their flow directions are opposite or they flow as counterflows. For both the
intercooler 3 andaftercooler 4, it is desirable that cooling water be made to flow first for higher temperature compressed air. Therefore, theaftercooler 4 andintercooler 3 are arranged in parallel as mentioned above and since cooling water is to be supplied first to theaftercooler 4 and then to theintercooler 3, the outlet for cooling water from theaftercooler 4 is located near the inlet for cooling water into theintercooler 3 in order to shorten the cooling water pipe and simplify the piping. In other words, the piping is arranged so that the flow direction of compressed air in theaftercooler 4 is opposite to that in the intercooler 3 (at the same time, the flow directions of cooling water in the coolers are also opposite to each other), so the cooling water pipe is shortened, the structure is simplified and productivity is improved. - As described above, according to this embodiment, space for the
coolers - The first embodiment of the present invention will be described in detail referring to the accompanying drawings. The description will be given below by taking as an example a screw compressor which compresses air by rotation of male and female rotors.
-
FIG. 1 is a schematic diagram showing a water-cooled two-stage oil-free screw compressor 30 having a low pressurestage compressor body 1 and a high pressurestage compressor body 2. The low pressurestage compressor body 1 and high pressurestage compressor body 2 each include a pair of rotors, i.e. a male rotor and a female rotor. The compressor according to this embodiment is a screw air compressor which compresses air by rotation of the male and female rotors. - Pinion gears 21 are fitted to the axial ends of the male rotors of the low pressure
stage compressor body 1 and high pressurestage compressor body 2. These pinion gears 21 are engaged with abull gear 23 fitted to one end of a driving shaft inside agear casing 28 so that motor power is transmitted to the low pressurestage compressor body 1 and high pressurestage compressor body 2. AlthoughFIG. 1 shows that thebull gear 23 is located on the output shaft of amotor 26 and engaged with the pinion gears 21 at the axial ends of the male rotors, instead an intermediate shaft may be located between the motor output shaft and the male rotors. If an intermediate shaft is provided, the power of themotor 26 is transmitted to the low pressurestage compressor body 1 and high pressurestage compressor body 2 through the intermediate shaft. - Next, the structure of the water-cooled two-stage oil-free screw compressor according to this embodiment will be explained, paying attention to flows of air compressed by the compressor.
- An
intake throttle valve 12 which regulates the flow rate of air taken into the low pressurestage compressor body 1 is located on the intake side of the low pressurestage compressor body 1. The air, from which foreign matter is removed by a filter (not shown), is passed through theintake throttle valve 12 and introduced into the low pressurestage compressor body 1 and compressed to a prescribed pressure level and discharged through the outlet of the low pressurestage compressor body 1. The compressed air discharged from the low pressurestage compressor body 1 is led into an intermediate discharge pipe A. - The air compressed by the low pressure
stage compressor body 1 and led into the intermediate discharge pipe A is cooled by theintercooler 3. In this embodiment, the intermediate discharge pipe A is branched into plural pipes upstream of thecooler headers 6 which serve as holes to introduce air into theintercooler 3. - As shown in
FIG. 1 , the discharge pipe A is bifurcated at the inlets of thecooler headers 6 and the two flows of compressed air are introduced in parallel into the twointercooler units stage compressor body 1 and high pressurestage compressor body 2 to be cooled there. The two flows of compressed air cooled by theintercooler 3, comprised of two intercooler units, join together at acooler header 7 attached to the outlet side of theintercooler 3 before being led into an intermediate discharge pipe B. - The compressed air cooled by the
intercooler 3 and led into the intermediate discharge pipe B is taken into the high pressurestage compressor body 2 located downstream thereof. The compressed air further compressed by the high pressurestage compressor body 2 is discharged from the high pressurestage compressor body 2 and led into a high pressure stage discharge pipe C. The discharge pipe C, which connects the high pressurestage compressor body 2 and theaftercooler 4, is branched into plural pipes upstream ofcooler headers 8 of theaftercooler 4. Acheck valve 13 is installed in each flow path downstream of the branching point of the discharge pipe C, in which thecheck valves 13 are located upstream of theaftercooler headers 8. - Therefore, as shown in
FIG. 1 , the compressed air discharged into the high pressure stage discharge pipe C is divided into two flows at a point midway in the discharge pipe C and the flows of compressed air pass through the twocheck valves 13 located downstream thereof before being taken in parallel into theaftercooler 4, comprised of twoaftercooler units aftercooler 4 join together in acooler header 9 attached to the outlet side of theaftercooler 4 before being exhausted through a compressed air outlet port. - It should be noted that whereas one
cooler header 6 is attached to the inlet side of each of theintercooler units intercooler 3 and onecooler header 8 is attached to the inlet side of each of theaftercooler units aftercooler 4, only one cooler header is attached to the outlet sides of the twointercooler units aftercooler units - Next, the structure of the water-cooled two-stage oil-free screw compressor according to this embodiment will be explained, paying attention to the compressor cooling mechanism.
- In an oil-free screw compressor, since there is no cooling means in the process of compressing air as working gas, the high pressure
stage compressor body 2 and the low pressurestage compressor body 1 generate heat due to compression heat. The compressed air has a high temperature and is too hot for a consumer to use. In addition, by cooling the gas compressed by the low pressurestage compressor body 1 and supplying it to the high pressurestage compressor body 2, the overall efficiency of the oil-free screw compressor 30 is improved. For the above reasons, cooling water is supplied to various parts of the oil-free compressor 30. The cooling water is routed as follows. - The path for cooling water cooled by a cooling tower (not shown) is branched at the cooling water inlet port into a cooling water path for the
aftercooler 4 andintercooler 3 and a cooling water path for theoil cooler 10,blower cooler 11, high pressurestage compressor body 2, and low pressurestage compressor body 1. The cooling water path for theaftercooler 4 andintercooler 3 first leads to theaftercooler 4 to cool the air discharged from the high pressurestage compressor body 2, then reaches theintercooler 3 to cool the air discharged from the low pressurestage compressor body 1 before returning the cooling water to the cooling tower or the like through a cooling water outlet port. In theintercooler 3 andaftercooler 4, the flow direction of cooling water is opposite to the flow direction of compressed air to make it a counterflow and in both theintercooler 3 andaftercooler 4, cooling water is supplied from the bottom of the shell and drained from its top. - In this embodiment, the
intercooler 3 andaftercooler 4 each have two units (intercooler units aftercooler units aftercooler 4 into a pipe for cooling one cooler set, i.e. theaftercooler unit 4 a andintercooler unit 3 a and a pipe for cooling the other cooler set, i.e. theaftercooler unit 4 b andintercooler unit 3 b. After leaving theintercooler 3, the two cooling water pipes join together and lead to a cooling water outlet port. (Hereinafter, they may be called the “first cooling water path” and “second cooling water path” respectively.) - On the other hand, cooling water in the path for cooling the
oil cooler 10,blower cooler 11, high pressurestage compressor body 2 and low pressurestage compressor body 1 is first led to theoil cooler 10 to cool lubricating oil, then led to the blower cooler 11 to cool the air released during no-load operation. Next, the cooling water is led to a cooling jacket provided on the casing of the high pressurestage compressor body 2 to cool the high pressurestage compressor body 2, then led to a cooling jacket provided on the casing of the low pressurestage compressor body 1 to cool the low pressurestage compressor body 1 before returning to the cooling tower through the cooling water outlet port. - A valve is attached to the inlet of the cooling water path for the
oil cooler 10. In this embodiment, since the cooling water pipe from the cooling water inlet port is bifurcated into a pipe for the cooling water path for compressed air and a pipe for the cooling water path for oil and the compressor bodies, a valve is used to regulate the cooling water ratio between the path for theaftercooler 4 andintercooler 3 and the path for theoil cooler 10,blower cooler 11 and high pressurestage compressor body 2, and low pressurestage compressor body 1. - The lubricating oil cooled by the
oil cooler 10 lubricates the bearings and pinion gears of the low pressurestage compressor body 1 and high pressurestage compressor body 2, the timing gears and the bearings of the intermediate shaft in thegear casing 28, the pinion gears and bull gear fitted to the intermediate shaft and the bull gear fitted to the rotation shaft of the motor and so on before being stored in an oil reservoir at the bottom of thegear casing 28. Then, the oil is led by an oil pump into theoil cooler 10 and cooled by cooling water. The lubricating oil circulates in this way. - In this embodiment, the compressed air path is branched into two paths upstream of the
intercooler 3 and after the compressed air is cooled by theintercooler 3, the paths join together. After air is further compressed by the high pressurestage compressor body 2, the compressed air path is branched upstream of theaftercooler 4. The paths join together after the compressed air is cooled by theaftercooler 4 to supply the compressed air to the outside. On the other hand, the cooling water path is branched into a first cooling water path and a second cooling water path which are independent of each other. More specifically, after the path is branched into two paths before supplying cooling water to theaftercooler 4, the flows of cooling water in the two paths cool theaftercooler 4 and then go to theintercooler 3 respectively without joining together. Therefore, it is desirable to supply an equal amount of cooling water to both the paths to ensure uniformity in cooling performance. Therefore, it is desirable that the first cooling water path and cooling water path be the same or mutually symmetrical in terms of shape. - Next, the internal arrangement of the air compressor package according to this embodiment will be described referring to
FIG. 2 .FIG. 2 shows the configuration of the water-cooled two-stage oil-free screw compressor, in which parts other than substantial ones are omitted. - As shown in
FIG. 2 , a pedestal on which themotor 26 andgear casing 28 are mounted is placed on the base and adjacent to the pedestal is acooler rack 18 on which thecoolers motor 26 is transmitted through various gears in thegear casing 28 to the low pressurestage compressor body 1 and high pressurestage compressor body 2. In this embodiment, as shown in the figure, thegear casing 28 is located on the output shaft side of themotor 26 and the low pressurestage compressor body 1 and high pressurestage compressor body 2 are placed side by side in a way to protrude over themotor 26 from above thegear casing 28. In other words, both thecompressor bodies motor 26. - The
cooler rack 18 is located opposite to the gear casing 28 (front left in the figure) with respect to themotor 26. Thecooler rack 18 has legs and the cooler rest is in a higher position than themotor 26. This arrangement facilitates heat radiation of themotor 26 because the space on the side of themotor 26 which is opposite to thegear casing 28 is open. - The
intercooler 3 andaftercooler 4 are placed on the cooler rest of thecooler rack 18. As mentioned above, the low pressurestage compressor body 1 lies over themotor 26 and compressed air discharged from the low pressurestage compressor body 1 flows into the discharge pipe A and enters theintercooler 3. Since the distance between the low pressurestage compressor body 1 andintercooler 3 is short, the air path can be short and the intermediate discharge pipe A can be simplified. - The
intercooler 3 in this embodiment is explained below. As shown inFIG. 2 , theintercooler 3 is mounted on thecooler rack 18. Theintercooler 3 includes twointercooler units cooler rack 18 side by side by cooler supporting members. The two units of theaftercooler 4 are placed side by side like theintercooler 3, over theintercooler 3. Since theaftercooler 4 lies over theintercooler 3, thecheck valves 13 can be accessed easily and installed easily, contributing to easy maintenance. - The
cooler headers intercooler units intercooler 3 which are located side by side. In this embodiment, the discharge pipe A is branched upstream of thecooler headers 6 so that compressed air flows through two air paths into theintercooler units - The flows of compressed air cooled by the
intercooler units cooler header 7 at the outlet side. Thecooler header 7 in this embodiment has a structure which allows the flows of compressed air from the units to meet and the combined compressed air flow in thecooler header 7 goes through the discharge pipe B into the high pressurestage compressor body 2. - As shown in
FIG. 2 , both thecompressor bodies motor 26 from the top of thegear casing 28, are arranged so as to simplify the piping. More specifically, the low pressurestage compressor body 1 is on the same side as the inlet of the intercooler 3 (front in the figure) and the high pressurestage compressor body 2 is on the same side as the outlet of the intercooler 3 (back in the figure). The discharge pipe B as the path for the air cooled by theintercooler 3 is also simplified. - The compressed air further compressed by the high pressure
stage compressor body 2 is discharged into the high pressure stage discharge pipe C. The discharge pipe C extends upward and, on the downstream, extends toward theaftercooler 4. - Like the
intercooler 3, theaftercooler 4 is comprised of twoaftercooler units intercooler 3, and hascooler headers cooler headers 8 and each branch pipe has acheck valve 13. Each of these branch pipes is connected with thecooler header 8 provided on each of thecooler units - Therefore, compressed air, after being branched through the discharge pipe C, passes through the
check valve 13 in each branch pipe and is introduced into thecooler header 8. The compressed air flowing from thecooler header 8 into theaftercooler 4 is cooled by theaftercooler 4 before joining the other flow of compressed air in thecooler header 9 on the outlet side and flowing out of the compressor package. The flow direction of compressed air in theintercooler 3 is opposite to that in theaftercooler 4 so that the discharge pipe is simplified due to the positional relation with thecompressor bodies - Next, the cooling water paths in this embodiment will be briefly described. As mentioned above, in this embodiment, the cooling water pipe for the path for cooling the
intercooler units aftercooler units aftercooler 4 into a pipe for cooling one set of cooler units, theaftercooler unit 4 a andintercooler unit 3 a, and a pipe for cooling the other set, theaftercooler unit 4 b andintercooler unit 3 b. This means that the flows of cooling water branched before being cooled by the coolers do not join together until they are cooled. - As mentioned above, the cooling water in the coolers flows in a direction opposite to the flow of compressed air to make a counterflow, so the flow direction of cooling water in the
intercooler 3 is opposite to that in theaftercooler 4. Therefore, the cooling water pipe through which the cooling water used to cool the compressed air in theaftercooler 4 flows into theintercooler 3 can be shortened to simplify the structure. More specifically, the cooling water outlet of theaftercooler 4 as designated byreference numeral 17 inFIG. 2 and the cooling water inlet of theintercooler 3 as designated byreference numeral 16 can be close to each other, largely contributing to compactness from the viewpoint of the cooling water path. - Next, the structures of the
intercooler 3 andaftercooler 4 will be described in detail. As mentioned above, theintercooler 3 andaftercooler 4 in this embodiment each use two cooler units. The structure of the coolers is shown inFIGS. 3 and 4 .FIG. 3 shows the configuration of the cooling system which includes theintercooler 3 andaftercooler 4 andFIG. 4 is a sectional view of a cooler. For both theintercooler 3 andaftercooler 4, theshell 5 which forms the outside of the cooling part has the same dimensions. - As shown in
FIG. 3 , theintercooler 3 andaftercooler 4 each have two cooler units placed side by side on thecooler rack 18 in which theaftercooler 4 is in the upper position and theintercooler 3 is in the lower position. The cooler units are fixed on the cooler rest of thecooler rack 18 by supporting members. They are thus arranged with the required spacing between cooler units (between thecooler units cooler units intercooler 3 and aftercooler 4). - The inlets and outlets of the
aftercooler 4 andintercooler 3 for air and cooling water are oriented in opposite directions to make counterflows as mentioned above. In the example ofFIG. 3 , cooling water is supplied into the cooler shell (explained later) from the cooling water inlet 16 (upper right in the figure) of theaftercooler 4 to cool high-pressure compressed air and then discharged through the outlet 17 (upper left in the figure). After that, it is supplied through the cooling water inlet 16 (lower left in the figure) into theintercooler 3 to cool middle-pressure compressed air and then discharged through the cooling water outlet 17 (lower right in the figure). - This configuration makes it possible that all cooler components including the cooling water paths are arranged in a compressor unit in a compact manner. In addition, by removing the pipes connected to the coolers and the bolts on the
cooler rack 18, the entire coolers including thecheck valves 13 can be removed from the compressor unit. Furthermore, since all the cooler parts are common to the coolers, cooler maintenance including cleaning and replacement is easy. - Details of the inside of each unit of the
intercooler 3 andaftercooler 4 are shown inFIG. 4 . Theintercooler 3 andaftercooler 4 adopt a so-called one-pass shell and tube heat exchanger. Here, “one-pass” means that the inlet and outlet for compressed air are in different positions and there is no reciprocating path. More specifically, air which flows in from one side is discharged at the other side and cooling water which flows in from the side where air is discharged is discharged at the side where air flows in. - The plurality of
heat transfer tubes 14 installed inside theintercooler 3 andaftercooler 4 are all the same in terms of shape and the number of such tubes is almost equal for the coolers, and theheat transfer tubes 14 are disposed at regular intervals in thecooler shell 5. In order to hold theseheat transfer tubes 14 stably inside thecooler shell 5 and form a cooling water path,pipe plates 15 are disposed in a staggered pattern at a plurality of points in the cooler unit axial direction. - The above explanation of the embodiment of the present invention assumes that the intercooler and aftercooler each use two units. However, the invention is not limited thereto and three or more intercooler and/or aftercooler units may be used without departing from the scope of the invention.
- Although the above embodiment concerns a two-stage compressor, the same configuration can be applied to a multistage compressor which has three or more pressure stages and even in that case, the same advantageous effects can be achieved.
- It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof.
Claims (11)
1. A water-cooled oil-free air compressor comprising:
a low pressure stage compressor body;
an intercooler for water-cooling compressed air discharged from the low pressure stage compressor body;
a high pressure stage compressor body for further compressing the compressed air cooled by the intercooler; and
an aftercooler for water-cooling air discharged from the high pressure stage compressor body,
wherein the intercooler includes a plurality of intercooler units;
wherein the aftercooler includes a plurality of aftercooler units;
wherein the intercooler units each have a cooling water inlet and a cooling water outlet;
wherein the aftercooler units each have a cooling water inlet and a cooling water outlet; and
wherein a first cooling water path is provided to supply cooling water first to one aftercooler unit, then to one intercooler unit and a second cooling water path is provided to supply cooling water first to another aftercooler unit, then to another intercooler unit.
2. The water-cooled oil-free air compressor according to claim 1 , wherein the first cooling water path and the second cooling water path are symmetrical to each other in shape.
3. The water-cooled oil-free air compressor according to claim 1 ,
wherein the intercooler and the aftercooler each have a cooler header covering a compressed air inlet side and a cooler header covering a compressed air outlet side; and
wherein a cooler header on either or each of the compressed air inlet side and outlet side of the intercooler or the aftercooler is shared by the intercooler units or the aftercooler units.
4. The water-cooled oil-free air compressor according to claim 1 ,
wherein upstream of the aftercooler, a discharge pipe for compressed air flowing into the aftercooler is branched into a plurality of pipes leading to the aftercooler units; and
wherein a check valve is provided in each branch discharge pipe.
5. The water-cooled oil-free air compressor according to claim 1 , wherein the intercooler units and the aftercooler units have the same shape.
6. The water-cooled oil-free air compressor according to claim 1 ,
wherein the intercooler and the aftercooler are arranged so as to make a flow direction of compressed air flowing in the intercooler and a flow direction of compressed air flowing in the aftercooler opposite to each other;
wherein a flow direction of compressed air flowing in the intercooler and a flow direction of cooling water flowing in the intercooler are opposite to each other and a flow direction of compressed air flowing in the aftercooler and a flow direction of cooling water flowing in the aftercooler are opposite to each other; and
wherein a cooling water pipe for connecting a cooling water outlet of one of the aftercooler units and a cooling water inlet of one of the intercooler units and a cooling water pipe for connecting a cooling water outlet of another of the aftercooler units and a cooling water inlet of another of the intercooler units are provided.
7. The water-cooled oil-free air compressor according to claim 6 , wherein the cooling water pipe for connecting the cooling water outlet of the one aftercooler unit and the cooling water inlet of the one intercooler unit and the cooling water pipe for connecting the cooling water outlet of the another aftercooler unit and the cooling water inlet of the another intercooler unit are arranged symmetrically.
8. The water-cooled oil-free air compressor according to claim 6 , further comprising:
a motor for driving the low pressure stage compressor body and the high pressure stage compressor body;
a plurality of gears for transmitting power of the motor to the low pressure stage compressor body and the high pressure stage compressor body;
a gear casing for housing the gears; and
a cooler rack located opposite to the gear casing with respect to the motor to hold the intercooler and the aftercooler in a higher position than the motor,
wherein the low pressure stage compressor body and the high pressure stage compressor body are placed side by side, protruding over the motor from the gear casing; and
wherein the low pressure stage compressor body is located on a compressed air inlet side of the intercooler and the high pressure stage compressor body is located on a compressed air inlet side of the aftercooler to make the flow direction of compressed air flowing in the intercooler and the flow direction of compressed air flowing in the aftercooler opposite to each other.
9. The water-cooled oil-free air compressor according to claim 7 , further comprising:
a motor for driving the low pressure stage compressor body and the high pressure stage compressor body;
a plurality of gears for transmitting power of the motor to the low pressure stage compressor body and the high pressure stage compressor body;
a gear casing for housing the gears; and
a cooler rack located opposite to the gear casing with respect to the motor to hold the intercooler and the aftercooler in a higher position than the motor,
wherein the low pressure stage compressor body and the high pressure stage compressor body are placed side by side, protruding over the motor from the gear casing; and
wherein the low pressure stage compressor body is located on a compressed air inlet side of the intercooler and the high pressure stage compressor body is located on a compressed air inlet side of the aftercooler to make the flow direction of compressed air in the intercooler and the flow direction of compressed air flowing in the aftercooler opposite to each other.
10. The water-cooled oil-free air compressor according to claim 8 , wherein on the cooler rack, the aftercooler is placed above the intercooler.
11. The water-cooled oil-free air compressor according to claim 9 , wherein on the cooler rack, the aftercooler is placed above the intercooler.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2009129801A JP2010275939A (en) | 2009-05-29 | 2009-05-29 | Water-cooled oil-free air compressor |
JP2009-129801 | 2009-05-29 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20100303658A1 true US20100303658A1 (en) | 2010-12-02 |
Family
ID=43220449
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/707,429 Abandoned US20100303658A1 (en) | 2009-05-29 | 2010-02-17 | Water-Cooled Oil-Free Air Compressor |
Country Status (3)
Country | Link |
---|---|
US (1) | US20100303658A1 (en) |
JP (1) | JP2010275939A (en) |
CN (1) | CN101900101B (en) |
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Also Published As
Publication number | Publication date |
---|---|
CN101900101A (en) | 2010-12-01 |
JP2010275939A (en) | 2010-12-09 |
CN101900101B (en) | 2013-03-13 |
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Owner name: HITACHI INDUSTRIAL EQUIPMENT SYSTEMS CO., LTD., JA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ITO, YUJI;SUZUKI, TOMOO;OHTA, HIROSHI;REEL/FRAME:024239/0747 Effective date: 20100210 |
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Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |