Compressor system with internal air-water cooling

Abstract

A compressor system (01) with a system housing (02), in which are arranged heat generating system components (06) comprising at least one compressor stage (201) for compressing a gaseous medium, an air water cooler (12), a blower (15) which generates a cooling air flow (16), and air conducting elements. A cooling air channel (07) is configured which has an inlet opening (08) in the upper section of the system housing (02) and an outlet opening (09) in the lower section of the system housing (02), wherein upper air conducting elements (13) are positioned in order to conduct the cooling air flow (16) after flowing through the air water cooler (12) to the inlet opening (08), and lower air conducting elements (17) are positioned in order to conduct the cooling air flow (16) from the outlet opening (09) to the system components (06).

Claims

1. A compressor system with a system housing, in which the following are arranged: heat generating system components, including at least one compressor stage for compressing a gaseous medium; an air water cooler; a blower which generates a cooling air flow; and first air conductors, which conduct heated air from the heat generating system components to the air water cooler, wherein a cooling air channel includes a portion partitioned from the heat generating system components, the portion having an inlet opening in an upper section of the system housing and an outlet opening in a lower section of the system housing, wherein second air conductors are positioned in order to conduct the cooling air flow after flowing through the air water cooler to the inlet opening, and wherein third air conductors are positioned in order to conduct the cooling air flow from the outlet opening to the heat generating system components, and wherein the blower is positioned above the air water cooler in order to draw the cooling air flow through the air water cooler and supply it to the inlet opening of the cooling air channel.

2. The compressor system according to claim 1, wherein the portion of the cooling air channel runs at least in sections in a door sealing the system housing.

3. The compressor system according to claim 1, wherein the cooling air channel runs in sections in a bottom of the system housing and has a plurality of outlet openings.

4. The compressor system according to claim 1, wherein the heat generating system components comprise an electronic circuit assembly.

5. The compressor system according to claim 1, wherein the air water cooler is connected to an external cooling circuit having a heat recovery unit.

6. The compressor system according to claim 1, wherein the at least one compressor stage includes a first and a second compressor stage, wherein the first compressor stage compresses the gaseous medium and conducts it to the second compressor stage, which further compresses the medium; both compressor stages are driven separately from one another and are speed adjustable; and an exhaust valve is positioned at an outlet of the second compressor stage and opened when a volume flow removed from the second compressor stage falls below a predetermined minimum value, wherein the speed of at least the first compressor stage is reduced to a predetermined idling speed (V1L) in order to reduce the volume flow supplied from the first to the second compressor stage.

7. The compressor system according to claim 1, wherein the heat generating system components include a pulsation damper arranged in the system housing, which is arranged in terms of flow to a rear of the last compressor stage, the damper comprising: a damper housing extending along a central axis and having a media flow inlet and a media flow outlet; and a plurality of sleeve-like absorber elements, each consisting of sound-absorbing material and being arranged concentrically to one another in the damper housing, wherein each sleeve-like absorber element has an inlet region and an outlet region, which are positioned axially spaced from one another, the inlet region of a frontmost absorber element in terms of flow is connected to the media flow inlet of the damper housing, the outlet region of the frontmost absorber element in terms of flow is connected to the inlet region of a subsequent absorber element in terms of flow, and the outlet region of a rearmost absorber element terms of flow is connected to the media flow outlet of the damper housing, and a flow chamber for the media flow is positioned between respective radially adjacent wall sections of different absorber elements.

8. The compressor system according to claim 7, wherein the absorber elements of the pulsation damper are configured to be rotationally symmetrical and engage telescopically.

9. A compressor system with a system housing, in which the following are arranged: heat generating system components including at least one compressor stage for compressing a gaseous medium; an air water cooler; a blower which generates a cooling air flow; and first air conductors, which conduct heated air from the heat generating system components to the air water cooler, wherein a cooling air channel includes an inlet opening in an upper section of the system housing and an outlet opening in a lower section of the system housing, wherein second air conductors are positioned in order to conduct the cooling air flow after flowing through the air water cooler to the inlet opening, wherein third air conductors are positioned in order to conduct the cooling air flow from the outlet opening to the heat generating system components, and wherein the system housing is hermetically sealed from the environment, wherein one of the at least one compressor stage is connected to a suction support open to the environment.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantages and details of the invention arise from the following description of preferred embodiments in reference to the drawing. The figures show the following:

(2) FIG. 1 illustrates a partially opened view of an inventive compressor system;

(3) FIG. 2 illustrates a partially sectioned view of the compressor system with an indicated cooling air flow;

(4) FIG. 3 illustrates a longitudinal section of a pulsation damper which forms a system component;

(5) FIG. 4 illustrates a cross-section of the pulsation damper according to FIG. 3;

(6) FIG. 5 illustrates a simplified representation of the operating parameters in a screw compressor with two compressor stages during load operation;

(7) FIG. 6 illustrates a simplified representation of the operating parameters in the screw compressor during idling operation.

DETAILED DESCRIPTION

(8) Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways.

(9) FIG. 1 shows an inventive compressor system 01 in a partially opened, perspective view. The compressor system 01 has a closable system housing 02 whose sidewalls 03 are only partially shown. The system housing 02 comprises a bottom 04 and a door 05, which permits access to the system components 06 inside. The system components 06 generate heat during the operation of the compressor system and comprise at least one compressor stage for compression of a gaseous medium. The door 05 has a first section of a cooling air channel 07, which has an inlet opening 08 above and an outlet opening 09 on the bottom. A passage 11 is arranged in the bottom 04, which is coupled with the outlet opening 09 when the door 05 is closed in order to allow cooling air to flow into the bottom 04. The cooling air channel 07 is thus composes of the section running in the door, of sections in the bottom as well as sections within the system housing, which e.g. are formed by the air conducting elements.

(10) FIG. 2 shows the compressor system 01 in an opened view, wherein several of the system components are not shown. As a result, it becomes obvious that in the upper third of the system housing an air water cooler 12 is arranged, which is thus located above the system components 06 generating the heat. Several upper air conducting elements 13 are arranged in the system housing, said air conducting elements conducting the rising, heated airsymbolized by the warm air arrows 14to the air water cooler 12.

(11) A blower 15 is arranged above the air water cooler 12 for generation of a circulated cooling air flow. Said blower suctions the warm air through the air water cooler 12 and blows the cooled air there as a cooling air flow 16 to the inlet opening 08 of the cooling air channel 07. The cooling air flow 16 is conducted downward in the cooling air channel 07 and exits the outlet opening 09, in order to reach the bottom 04 via the passage 11. Lower air conducting elements 17 are arranged in the bottom 04 and, if necessary, also in the lower section of the system housing, in order to conduct the cooling air flow to the system components 06 to be cooled.

(12) FIG. 3 shows a simplified longitudinal section view of a pulsation damper 100, which is a system component of the previously described compressor system. FIG. 4 shows the cross-section of this pulsation damper. The sound damper 100 in this example has an essentially cylindrical damper housing 101 with an absorber element receiving region 102, a front plate 103 sealing the damper housing on the front side and a flange 104 axially opposing the front plate. The front plate 103 has a centrally arranged media flow inlet 106, via which a gaseous media flow 107 compressed by a compressor, in particular compressed air, is supplied.

(13) Several sleeve-like absorber elements 108 are arranged in the absorber element receiving region 102, in the example shown a front absorber element 108a in terms of flow, a central absorber element 108b in terms of flow and a rearmost absorber element 108c in terms of flow. The three absorber elements are inserted telescopically into one another and have essentially the same length in axial direction. All absorber elements consist of sound absorbing material, wherein the specific properties of the material can be selected differentiated between the individual absorber elements.

(14) The media flow inlet 106 flows into the centrally located inlet region of the front absorber element 108a, so that the media flow first flows in the interior of the front absorber element 108a and undergoes a damping through its material. The interior of the front absorber element 108a can be hollow or filled with gas-permeable material, wherein the flow resistance is to be kept low. An outlet region is provided on the end of the front absorber element 108a averted from the front plate 103 so that the media flow can escape from the front absorber element 108a. The media flow flows there in a first annular change region 110 to the inlet region of the central absorber element 108b, wherein there is a reversal of direction in the media flow 107. The central absorber element 108b annularly encompasses the front absorber element 108a in terms of flow, wherein a centering pin 111 provided on the central absorber element 108b acts as a fixture for the front absorber element 108a. The media flow 107 now flows through a first cylindrical flow chamber 112, which extends in axial direction between the front absorber element 108a and the central absorber element 108b.

(15) On the end of the central absorber element 108b directed toward the front plate 103 the media flow exits the first cylindrical flow chamber 112 via an outlet region and flows in a second annular change region 113 to the inlet region of the rear absorber element 108c. Now the media flow 107 flows through a second cylindrical flow chamber 114, which extends in axial direction between the central absorber element 108b and the rear absorber element 108c. The flow direction in the second flow chamber 114 is axially opposed to the flow direction in the first flow chamber 112.

(16) On the end of the rear absorber element 108c in terms of flow averted from the front plate 103 the media flow 107 exits the absorber element receiving region 102 via an outlet region of the rear absorber element 108c in terms of flow and then flows through a media flow outlet 116 in the flange 104 to the downstream units of the compressor. It is evident from the figures that the cross-section available for the media flow in each case significantly increases in the change regions and finally is significantly larger on the media flow outlet 116 than on the media flow inlet 106.

(17) It is also evident from the figures that all three absorber elements 108 each have several resonator chambers 117a, 117b or 117c in their walls.

(18) FIG. 5 shows the principle structure of a compressor system, which is used as a system component of a twin screw compressor 200. In addition to the individual elements of the twin screw compressor, typical parameters are moreover specified, as they occur in load operation when compressed air is discharged with a volume flow above a predetermined minimum value and not greater than a system-specific maximum value.

(19) A first compressor stage 201 has a first direct drive 202, which is speed controlled. The inlet of the first compressor stage 201, via which ambient air is suctioned, is coupled directly to a suction support 203 without interposition of a suction regulator, said suction support at which there is an ambient atmosphere with a pressure of 1.0 bar at a temperature of e.g. 20 C. Hence, on the inlet of the first compressor stage 201 there is a pressure of 1.0 bar.

(20) The first compressor stage 201 is for example operated at a speed of 15,500 min1 in order to compress the air. There is a pressure of 3.2 bar then at the outlet of the first compressor stage 201, so that the first compressor stage has a compression ratio of 3.2 in load operation. Due to the compression, the temperature of the medium (compressed air) increases to 170 C. The compressed air is conducted from the outlet of the first compressor stage 201 via an intercooler 204 to the inlet of a second compressor stage 206, which has a second, speed controlled direct drive 207. The heat accruing at the intercooler 204 must be discharged from the compressor system. The air circulating in the system housing 02 is cooled by the air water cooler 12. The cooling water flowing in the air water cooler can be conducted in a parallel branch or in series connection through the intercooler 204, if said intercooler has a water cooler. After the intercooler 204, on the inlet of the second compressor stage 206, the compressed air has a temperature of 30 C. and in addition a pressure of 3.2 bar. In load operation the second compressor stage 206 is operated at a speed of e.g. 22,000 min1, so that further compression can occur. The compressed air accordingly has a pressure of 10.2 bar and a temperature of 180 C. on the outlet of the second compressor stage 206. Hence, the second compressor stage 206 has a compression ratio of likewise about 3.2. The compressed air is conducted from the outlet of the second compressor stage 206 through an aftercooler 208 and is cooled there to about 35 C. The aftercooler 208 can also be integrated in the cooling water circuit, which supplies the air water cooler 12 and or the intercooler 204. Finally, an exhaust valve 209 is arranged on the outlet of the twin screw compressor 200, said exhaust valve being controlled by a control unit (not shown in the figure).

(21) The twin screw compressor 200 described by way of example shows at a maximum speed of the direct drives 202, 207 a power consumption of 150 kW and supplies compressed air with a maximum pressure of 12 bar and minimum pressure of 6 bar. The speed ratio between the compressor stages is about 1.4 in load operation.

(22) FIG. 6 shows the twin screw compressor 200 in idling operation, i.e. when basically no compressed air is being removed. Along with the elements of the twin screw compressor again typical parameters are specified, as they occur in idling operation. In order to enter into idling operation, the exhaust valve is opened and the speed of both compressor stages is reduced. The inlet of the first compressor stage 201, via which in addition ambient air is suctioned, even if in reduced quantity, is directly coupled to the suction support 203 without interposition of a suction regulator, at which there is ambient atmosphere with a pressure of 1.0 bar at a temperature of 20 C. Hence, at the inlet of the first compressor stage 201 a pressure of 1.0 is present, unaltered.

(23) The first compressor stage 201 is now operated with an idling speed V1L=2,500 min1, in order to compress the air. At the outlet of the first compressor stage 201 then there is a pressure of 1.5 bar, so that the first compressor stage has a compression ratio of 1.5 in idling operation. Through the reduced compression the temperature of the medium (compressed air) only rises to 90 C. The compressed air is conducted from the outlet of the first compressor stage 201 via the intercooler 204 to the inlet of the second compression stage 206. After the intercooler 204, on the inlet of the second compressor stage 206, the compressed air has a temperature of for example 30 C. while idling and in addition has a pressure of 1.5 bar (intermediate pressure). Hence, the necessary cooling capacity for the intermediate cooling is reduced in idling operation. In idling operation the second compressor stage 206 is operated at an idling speed V2L of 7,500 min1. The compressed air has, in comparison to the intermediate pressure, a lower pressure of about 1.2 bar and a temperature of 70 C. The second compressor stage hence has a compression ratio of about 0.8 (expansion). The compressed air is conducted from the outlet of the second compressor stage 206 through the aftercooler 208 and is cooled there to about 30 C.

(24) The twin screw compressor 200 described by way of example shows in idling operation a power consumption of 7 kW and supplies a maximum pressure of 1.2 bar. The speed ratio between the compressor stages is about 3.

REFERENCE LIST

(25) 01 Compressor system 02 System housing 03 Side walls 04 Bottom 05 Door 06 System components 07 Cooling air channel 08 Inlet opening 09 Outlet opening 10 11 Passage 12 Air water cooler 13 Upper air conducting elements 14 Warm air 15 Blower 16 Cooling air flow 17 Lower air conducting elements 100 Pulsation damper 101 Damper housing 102 Absorber element receiving region 103 Front plate 104 Flange 105 106 Media flow inlet 107 Media flow 108 Absorber elements 109 110 First change region 111 Centering pin 112 First flow chamber 113 Second change region 114 Second flow chamber 115 116 Media flow outlet 117 Resonator chamber 200 Twin screw compressor 201 First compressor stage 202 First direct drive 203 Suction support 204 Intercooler 205 206 Second compressor stage 207 Second direct drive 208 Aftercooler 209 Exhaust valve

(26) Various features and advantages of the disclosure are set forth in the following claims.