Purdue University Purdue e-Pubs International Compressor Engineering Conference School of Mechanical Engineering 1986 Single Stage, Oil-Free Screw Compressor with a Compression Ratio Eight H. Mori K. Kasuya Y. Takahashi A. Suzuki M. Aoki Follow this and additional works at: http://docs.lib.purdue.edu/icec Mori, H.; Kasuya, K.; Takahashi, Y.; Suzuki, A.; and Aoki, M., "Single Stage, Oil-Free Screw Compressor with a Compression Ratio Eight" (1986). International Compressor Engineering Conference. Paper 519. http://docs.lib.purdue.edu/icec/519 This document has been made available through Purdue e-Pubs, a service of the Purdue University Libraries. Please contact [email protected] for additional information. Complete proceedings may be acquired in print and on CD-ROM directly from the Ray W. Herrick Laboratories at https://engineering.purdue.edu/ Herrick/Events/orderlit.html SINGLE STAGE, OIL-FREE SCREW COMPRESSOR WITH A COMPRESSION RATIO OF EIGHT Hidetomo Moril, Katsuhlk o Kasuyal, Mitsuru Fuiiwar al, Katsumi Matsuba ral, Akira Suzuki2, and Masakazu Aoki2 !Mechan ical Engineer ing Research Laborato ry, Hitachi, Ltd.,Tsu chiura, Ibaragl, Japan 2Ebina Branch, Narashin o Works, Hitachi, Ltd., Ebina, Kanagawa , Japan ABSTRACT The developm ent of a series of sin~le-stage, oilfree screw air compress ors with a compress ion ratio of 8, previous ly obtainab le only with two-sta~e compress ors, is describe d. A new rotor profile , which reduces leakage loss to achieve higher efficien cy, and desig-ned for ease of manufac ture, is detailed . Addition ally, a new desig-n method for the clearanc e between rotors, to compens ate for rotor deforma tion due to thermal expansio n, is also introduc ed. This oil-free , screw air compres sor with a ratin? of 37-55 kW has been marketed since 1982 and 15-22 kW since 1984. INTRODUCTION Oil-fre e air compres sors having a dischar ge pressure of approxim ately 0.8 MPa (8 ata), and widely used in electric al, food and chemical industri es were traditio nally reciproc ating type compres sors. Recently, however, the advantag es of oi 1-free rotary screw compress ors have been reco~nized. These include mechanic al simplici ty, high reliabil ity,low noise and low vibratio n. Two-stag -e, oil-free screw air compress or use has predomi nated in the capacity range above 550 m3/h (motor power above 65 kW). Neverth eless, for compress or capacity below this range, where oil-free air is needed, this type of compress or was not availabl e. 105 tage, Due to the comp licate d const ructi on of two-s ght that oil-f ree screw comp resso rs, it was thou rocat ing they would not be econo mical , compa red to recip range the in nt opme devel if even oil-f ree comp resso rs, There fore, devel opme nt below 550 m3/h was possi ble. prefe rable of singl e-sta ge comp resso rs was consi dered antic ipate d and on ructi becau se of their simpl e const to ing relat ined, rema ems probl ral Seve low cost. comr highe the as such s, sever e opera ting cond ition eratu re press ion ratio and resul ting incre ase in temp these to ions solut given Even of the disch arge air. conwere y bilit relia and e rmanc perfo es, culti diffi use. nt warra to poor sider ed to be too le, Addre ssing these probl ems, a new rotor profi ratio n ressio comp high a at yield ing highe r effic iency n metho d was initi ally devel oped, follow ed by a new desig nt of accou into ·takes d metho This of the rotor cleara nce. durin g operrotor defor matio n due to therm al expan sion optim izati on This ation and optim izes clear ance . menta l funda These . iency effic great ly affec ts comp ressor e-sta ge, impro vemen ts enabl ed devel opme nt of a singl ratio of oil-f ree screw comp ressor with a comp ressio nattai nable dered consi Such a ratio was previ ously 8. Appl ying these only with two-s tage comp ressio n. comp ressor with screw ree ,oil-f devel opme nts, a pack aged senti ng the repre made, was kW 55 37 of g ratin a comp resso r. air screw ree oil-f lest first and smal ss of the proce ntal This paper descr ibes the devel opme new comp resso r. TECHNICAL OBJECTIVES disA screw comp resso r is a rotar y posi tive rotor e femal and male one g havin place ment comp ressor in a casin g. mesh ing with each othe r and hous ed rotor s and the the en betwe er chamb the into Air drawn Air n. motio rotor to due ressed casin g walls is comp en the betwe ance clear of t resul a as ing occur ge, leaka the casin g rotor s as well as betwe en the rotor s and nject ion Oil-i . iency effic walls , reduc es comp ress ion an oil with ances clear these seal rs resso comp screw resso rs comp ree Oil-f er. chamb n film in the comp ressio ge. leaka this nt preve to lack seali ng oil in the chamb er comThis is espe ciall y true with sing le-st age ly great and s, ratio n ressio comp r highe g havin press ors t. reduc ed effic iency as a resul 106 Fig.l shows how the clearance between rotors (interlobe clearanc e) of an oil-free , screw air compress or influence s the compressi on efficienc y by computer simulation . In this figure, volumetric and overall adiabatic efficiency at a male rotor tip speed of 100 m/s and a clearanc e ratio of 0.001 are taken as l. 0. Increasing rotor rot at ion speed is one solution to this problem, but not a satisfact ory one. The fundament al solution is to minimize clearance so as to lessen air leakage. Thus, the first technical problem was developme nt of a new rotor profile with minimum clearance for minimum air leakage, along with machining technology improveme nts enabling a high-prec ision rotor finish. · The second difficulty concerned is the air temper at ur e increase during compress ion and the resulting thermal ~xpansion of the rotor. Air tell'peratu re rises with Increase in the compressio n ratio. The lubricant in oil-inject ion screw compresso rs also functions as a coolant, permittinf ! the temperatu re rise to be controlled. In the case of oil-free rotary screw compress ors: (a) Hot air leaked fro~ the high-pres sure side can heat the low-press ure, low-tempe rature air. (b) The temperatu re of this heated air increases further after compressio n. (c) This air again leaks and heats up the low-tempe rature air. Thus, the air temperatu re progressiv ely rises. Heated by this air, the rotors expand. This reduces the rotor clearance to a critical degree. Contact between them causes compresso r darr.age or failure. Hence, conventional oil-free screw air compresso rs operating at a compressio n ratio above 4 had a two-stage design with an intercoole r. Fig.2 shovJS a comparison of operating conditions between a two-stage and a single-st age screw air compresso r at a discharge pressure of 0.8 MPa (8 ata). The compressi on ratio of each stage of the two-stag e co~pressor is 3 and the discharg e air temperatu re is less than 150°C. The compressio n ratio of the sinvlP-sta fe comrresso r is 8 and the discharge air temperatu re ~av be hipher than 300°C. The tePlreratu re difference implies very !'evere operatinv condition s for the sin?le-st are compresso r. Thus, the technical chAllen~e involves rlevelopme nt of a new sinple-sta ee, oil-free rotary screw compresso r with reduced internal air leakape and. opti~u~ cl~arance compensat ion for the theriT'a 1 ex pans ion of the rotors. 107 Furthe rmore , Fig.l indica tes that one perfor mance involv es chara cteris tics of oil-fr ee sere"'' compr essors . speed tip rotor r slowe with ency effici of lower ing be to need rotors essor compr There fore, srr,all. n highe r obtai Lo speed ion rotat r highe a at n drive The result ing rotor vibra tion increa se effici ency. The techn ical must be taken into consi derat ion. of a sophi stipment develo the in solved probie ms to be cated compr essor are sumar ized in Flg.3 . TECHNICAL SOLUTIONS In the light of the s e d i f f 1 c u l t i e s , inten sive R&D fundaeffor ts to develo p new techno lovy were made by these of Some ts. imen exper ment al analy sis and are outlin ed below . The rotor profi le of an oil-fr ee screw compr essor achiev ing is one of the most influe ntial factor s in such a for nts reme reaui The . highe r effic iency profi le are as follow s. (l) Seal lines to preve nt air leakag e betwe en rotors made. and betwe en rotors and casing walls should be should nce cleara the and short be These lines should e. be of a shape that funct ionall y preve nts leakag more is g sealin e surfac to e surfac As an examp le, effici ent than sharp edge sealin g. and (2) The cleara nce betwee n rotors arid betwee n rotors ndth casing walls should be smalle r than one thousa for of the rotor diame ter, resul ting in a need the ally, Basic ng. acturi super precis e rotoi:- manuf for rotor profl le shoul d be a shape suita ble manuf acturi ng. pin~ Giv~ri ~he time ~nd expen~e invol~~d in develo (CAD) design aided ter compu a a screw rotor profi le, The CAD system used to ststem can be v~ry us~ful. This shown in Fig.4 . is le profi rotor. develo p the new estim ates system is compo sed of two sub-sy st'ems , one lates screw compr essor perfor mance , and the other calcu les. rotor and cuttin g hob profi les Apply ing this CAD system , many rotor profi ee screw accep table for high compr ession ratio, oil-fr The most promi sing new compr essors were inves tigate d. 108 rotor profile is shown in Fig.S. This profile has the following advantage s over a conventio nal profile. (a) The respective lobe combinatio n of five for male and six for female rotors is sui table for h i g her compressi on ratio applicati ons, creating one more working chamber than the conventio nal profile. The addition al chamber reduces the pressure differenc e and compresse d air leakage between chambers. (b) The blow hole area is only 27 % of the conventio nal profile, and the seal line between rotors is 20 % shorter than the conventiona l one. Additiona lly, the new profile is created by continuou s, smooth curves. The smaller blow hole, shorter seal line and surface to surface sealing results in less air leakage. (c) The continuou s, smooth curves of the profile made it possible to machine rotors with higher precision by hobbing, resulting in smaller clearance between the rotors. As a result of computer simulatio n, the new rotor profile showed 7 %higher volumetric efficiency and 17 % higher overall adiabatic efficiency compared with the conventio nal rotor profile (Fig.6). Compensat ion for Rotor Thermal Expansion It is neccessary to know rotor temperatu res for optimizat ion of rotor clearance s. Fig. 7 shows rotor temperatu res of a prototype single-sta ge, oil-free air compresso r measured at a discharge pressure of 0.8 MPa (8 ata), compared with a caiculated rotor temperature. The discharge side rotor temperatu re was approximately 300 °C. This temperatu re was much higher than predicted beforehan d. A new design method was neccessary to minimize the ·rotor clearance along the whole rotor profile at such a high temperatu re. The fundament al desip:n concept of the new method is shown in Fig.S. ® is an initial profile of a male rotor at room temperatu re, from wh lch the heat-expan ded profile @ is obtained. Hith allowances for timing gear backlash and rotation reliabilit y, profile © is determine d. The heat-expan ded female rotor profile Q» is generated b_y_ © . The female rotor prof lle at room temperatu re © is obtained by contractin g @. _CuttinA hob profiles are transferr ed from rotor prof1les ® and @ . Applying this method, the rotor cleRrance is optimized at a higher operating temperatu re. The new design produced a 40-50 % smaller clearance compared with a conventio nal design. This is approxim ately equal to a 13 % higher overall adiabatic efficiency at a rotor tip speed of 100 m/s according to Fig.l. 109 PROTOTYPE COMPRESSOR , seve ral Follo wing this fund amen tal rese arch all being ~ade, were rs resso comp proto type sing le-st age Some of them_ had appl icabl e to the 37-55 klf' rat infs. the conv entio nal had rs othe while ile the new rotor prof one. Comp resso r Struc ture e-sta f!e Figur e 9 shows a cutaw ay viet.J of a nel.\1 singlradia lly s are rotor male and le Fema r. resso comp and axia lly by supo rted by cylin drica l rolle r beari ngs of timin g gears pair A ings. comb ined angu lar ball bear the clea ranc es at the end of roto r shaf ts adju sts efore , these Ther rs. roto the of betw een the lobe s n ?ear at the lobes do not conta ct one anoth er .. A pinio a large gear by drive end of the male rotor is drive n the comp resso r is cont aine d in a gear casin g on which The male rotor was teste d £lang -mou nted horiz onta lly. at up to 22,00 0 rpm. oil from Visc o-typ e seals preve nt the lubri cant n rings carbo while ber enter ing the comp ressio n cham roto r the in ent pres is hole oil An seal the air. is ng coati f proo heatial spec A shaf t for cooli n)l:. g of the casin The . aces surf r roto the to appl ied comp resso r is coole d by a wate r jack et. r Perfo rman ce Qi the Proto type Comp resso type comPerfo rman ce test resu lts of the proto adia batic all over The O. Fig.l in shown press ors are incre ase the and y ienc effic etric effic ienc y, the volum conv entio nal the of re eratu temp air e harg disc in of 8 (desi gn prof ile comp resso r at a comp ressio n ratio Volu metr ic 1.0. as comp ressi on ratio ) are taken y obtai ned ienc effic batic adia all over and y effic ienc impro ved, and with the new rotor prof ile are grea tly re is reduc ed. eratu the incre ase in disch arge air temp the high er the The high er the comp ressi on ratio , nt redu ction in ifica sign This indic ates impro veme nt. rotor prof ile. new the of s mean by loss air leaka ge the rela tive (8), ratio on ressi At the desig n comp entio nal to the conv the from nts veme impro y ienc effic etric effic ienc y new rotor prof iles are 27 'loin volum y. ienc effic and 38 % in over all adia batic new prof ile The perfo rman ce char acte risti cs of the show n in is ds spee tion rota us vario at r comp resso y curve ienc effic batic adia Fig. ll. A very flat over all l speed . iona rotat rotor of range wide a is seen over llO These test results allowed develop ment of a new machine able to deliver 0.8 MPa (8 ata) air by a single -stage compre ssion. Table 1 lists standar d specifi cations of a series of single- stage, oil-fre e screw air compre ssors. CONCLUSION The develop ment of a single- stage, oil-fre e screw air compre ssor was describ ed. This is the world' s first and smalles t single- stage compres sor operati ng at a compre ssion ratio of 8, previou sly obtaina ble only with two-sta ge compre ssion. As a result of intensi ve R&D effort, reliabl e and low cost oil-fre e screw compre ssors became availab le in the capacit y range from 120 to 455 m3jh. Formerl y, oil-fre e recipro cating compre ssors had predom inated in this range. ACKNOWLEDGMENTS The authors would like to thank their colleag ues at the Mechan ical Enginee ring Researc h Laborat ory and the Ebina Branch Works for their concern and coopera tion. REFERENCES [ 1] Trulsso n, I., "A New Develop ment in Rotary Screw Compre ssor Design ", Purdue Compre ssor Techno logy Confere nce, 1970. [2] Fujiwar a, M., Mori, H. and Suwama, T., "Predic tion of Oil-fre e Screw Compre ssor Perform ance Using Digital Comput er", Purdue Compre ssor Technol ogy Confere nce, 1974. [3] Fujiwa ra, M., and et al, "Comp uter Modeli ng for Perform ance Analys is of Rotary Screw Compre ssor", Purdue Compre ssor Technol ogy Confere nce, 1984. 111 1.2 0.6 SUCTION PRESSURE - lOlkPa (1.03ata) DISCHARGE PRESSURE - 0.8 MPa (8 ata) -~1.4( X\IJ~J) -~1.2 ~~0~£-0.8-~--~I0 Fig.l : INTERLOBE CLEARANCE TO RDTOR DIAMETER RATio obe Clearance and Compressor lnterl en Relat ion betwe metric effici ency Effic iency by Camputer Sfinulation (Volu rotor tip male a at ency effici atic adiab ll and overa ratio of nce cleara obe interl an and m/s speed of 100 1.0.) as taken are 0.001 ~ AFTERCOOLER 0 ~' ~ r.n r.n ~ ~ Fig.Z : '""' ou ~ r.n I ~ ~ !n I g ""' r.n ~i li jOQ JDO 2>0 200 l:;o ~' ~ ~ I <.:: ..... ~ r.n '"" en TWo-stage and Ganparison of Operating Conditions betweressor s (Discharge air Singl e-stag e, Oil-f ree, Screw Air Comp atic effici ency temperature is calcu lated assuming an adiab of 0.8.) 112 SINGLE-STAGE OIL-FREE I IROTARY SCREW OJMPRESSOR HIGHER OJMPRESSION RATIO I 'HIGHER DISCHARGE AIR TEMPERATURE I LARGER LEAKAGE LOSS 1HERMAL EXPANSION OF ROTORS I IJ..<I.RGER LOWER EFFICIENCY I -- I ROTOR ILARGER VIBRATIONS II.WER RELIABILITYj (TECHNICAL PJIDBLEMS) f--- - - - - - - ---~~, MINIMIZING AIR LEAKAGE •DEVELOPMENT OF HIGHLY EFFICIENT NEW ROTOR PROFILE •HIGH-PRECISION ROTOR MANUFAC1URING Fig.3: !HIGHER ROTATIONAL SPEED OPTIMUM ROTOR CLEARANCE • <XlMPENSATION FOR TERMAL EXPANSION OF ROTORS Technical Problems in the Development of a Single-stage O::mpressor Fig.4: CAD System to Develop a New Rotor Profile 113 I I I I CaY CONVENTIONAL ROToR PROFTLE (b)' NEw ROTOR PROFtLE Fig.S: NeW and~ Conventi"onal Rotor Profi!les SUCTION_ PRESSURE - iOlkPa (LCnata) SuCTION TEMPERATURf: = 2b""C MALE ROTOR TIP SPEED' - SO in! s INTERuDBE CLEARANCE RATIO ~ 0.67xlo-3 - -- -- -- --~ --- ....... NEW PROFILE t..:> ,......_0,~ ~ E:: ~~ 12 mNIJENnbNAL ~~ ~~ :$U __ .... __ _;_ PROFILE 10 ----~- ~--- - ........ ~ ~ ~!---+--+----:~:---+-COMPRESSION RATIO Efficiency between New and COnventional Fig.6: pdnparison of Cdmpressot ROtor Profil~s by Computer Sfinulation (Caripressor efficiencies with the conventional profile at the cowpression ratio of 0.8 are taken as 1.0.) 114 SUCTION SIDE MEASURED TEMPERATURE AT THE TOP OF THE IDBE AT 1HE OOTTCM OF THE rnooVE I CALCULATED SURFACE TEMPERATURE I I ~ I SUCTION PRESSURE ~ DISGlARGE PRESSURE lOlkPa (l.03ata) ~ 0.8 MPa (8 ata) 0~--------~~-----------~------0 1.0 DIMENSIONLESS ROTOR LENGHT Fig.7: Measured and Calculated Rotor Tanperatures of a Single-sta ge, Oil-free Screw Compressor (Rotors are non-cooled .) 115 ~ MALE ROTOR PROFILE AT ROOM TEMPERATURE HEAT-EXPANDED MALE ROTOR PROFILE PROFILE WITH AN ALLOWANCE FOR GEAR BACKLASH @ HEAT -EXPANDED FEMALE ROTOR PROFILE GENERATED BY @ FEMALE ROTOR PROFILE AT ROOM TEMPERATURE Fig.8: © Compensation for Rotor Thermal Expansion PINION GEAR MALE ROTOR TIMING GEARS WATER JACKET Fig.9: Prototy pe Compressor 116 r• '-'t I0 -o-o--a--o-o_o_ __ 6 _ _.t.___ o. ---n.---~---0.-- tO ,, u o I-......... <(f- l ~ cc« """' 0 >u "" ~t; ""- 12 <( ....!"-' 10 ...... lL E; tti us NEW PROFILE (WITH COMPENSATION FOR THERMAL EXPANSION) I.,.,....-- - o - o - - o-0 /0 - /0~-"'-"'-,-.. /~ \ CONVENTIONAL PROFILE (WITHOUT COMPENSATION FOR THERMAL EXPANSION) COMPRESSION RATIO SUCTION PRESSURE ~ lOlkPa (1.03ata ) SUCTION AIR TEMPERATURE ~ 20 °C Fig.lO: PerfoTinance Test Results (Efficie ncies and discharg e air tempera ture increase of the compressor with the conventi onal profile at the compression ratio of 8 are taken as 1.0.) 117 '[ I0 oe ~ 1.2 >- ~ 10 "' 1---' ..... O.B "" :r: "" o• ROTATIONAL SPEED OF MALE ROTOR (rpm) SUCTION PRESSURE - lOlkPa (1.03 ata) SUCTION AIR TEMPERATURE - 20 °C DISCHARGE PRESSURE - 0.8 MPa (8 ata) Fig.l l: the New Profi le Compressor Performance Char acter istics ofchara cteris tics at 15,000 rpm versu s Rotat ional Speed (The are taken as l.O.) Tabl e 1: MODEL MOTO!l POWER(kW) 3 CAPAC inim /h) Stand ard Spec ifica tions I\ DSP-SOWA DSP-60W A OSP-7SW A PSP-20C A PSP-JO CA DSP-201 /A DSP-30W 15 )20 22 ]5 22 37 45 55 J 80 J 20 )80 280 365 •ss " D.lSCHARGI!: PRESSURE (a ta) COOLING MET"OO DIMENSION (LxWx"J (nun) NET W£IGHT (k91 NOISE LEVEL dB (AI AIR COOLED J ,)OOx) 8. 7 ,]00><) ,)00 515 625 70 n 118 WATER COOLED 1,1 00x700 x) 1 ) 1, SSOx770M] 00 , ;i!OO 500 550 750 780 aoo 68 70 72 n 12 PERFORMANCE ANALYSIS OF OIF SINGLE SCREW COMPR ESSOR Tetsu o Hirai 1 , Sadaf umi Noda2 , Taiic hi Sagar a 2 , Kiyoh aru Tsuzi 2 1 centr al Resea rch Lab., Mitsu bishi Elec tric Corp ., 8-1-1 , Tsuka guchi honm achi, Amag asaki, Hyogo , 661 JAPAN 2Nag asaki Works , Mitsu bishi Elec tric Corp ., 517-7 , Ramad a-Go, Togit su-Ch o, Nishi sonog i-Gun , Naga saki, 851-2 1 JAPAN ABSTRACT This paper prese nts the perfo rman ce analy sis and the inter nal press ure measu remen t of the oil free singl e screw comp resso r. The geom etric injec tionshape of the singl e screw comp resso r and its theor etica l perfo rmanc e with the slide valve have been analy zed. The inter nal press ure has been measu red with piezo type press ure senso rs, and the press ure-v olum e diagr am has been obtai ned. The exper imen tal resul ts agree fairl y well with the theor etica l predi ction s, and the volum etric and adiab atic effic iency can be estim ated by this analy sis. SYMBOLS A cross secti onal area Dsg dista nce betwe en screw axis and gate rotor axis F coeff icien t of flow rate Gc mass of gas in the groov e G·l mass of gas which enter s the groov e Go mass of gas which comes out of the groov e 119
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