Compressor device and compression method

Abstract

A compressor device for compressing a gas in at least one compression chamber in at least one compression cylinder is disclosed. In each of at least two drive cylinders, at least one drive piston is disposed, said at least one drive piston dividing each of the at least two drive cylinders into two drive chambers. The at least one first and second drive chamber, by way of a hydraulic fluid, are able to be periodically impinged with a fluid pressure in order for the respective drive piston to be moved. Each of the remaining drive chambers in the at least two drive cylinders, by way of a connection piece, are connected in a non-positive locking manner by a fluid. The movement of the drive pistons by way of at least one mechanical connection means is able to be transmitted to at least one compression piston.

Claims

1. A compressor device for compressing hydrogen gas in at least two compression chambers in at least two compression cylinders, wherein a) in each of at least two drive cylinders at least one drive piston is disposed, said at least one drive piston dividing each of the at least two drive cylinders into two drive chambers; b) at least one first drive chamber in a first drive cylinder of the at least two drive cylinders and at least one second drive chamber in a second drive cylinder of the at least two drive cylinders, by way of a hydraulic fluid, are configured to be periodically impinged with a fluid pressure in order for the respective drive piston to be moved; c) at least one third drive chamber in the first drive cylinder and at least one fourth drive chamber in the second drive cylinder are connected in a non-positive locking manner by a fluid directly by way of a connection piece; d) the movement of each of the at least one drive piston, by way of one assigned mechanical connection means of at least two mechanical connection means, is able to be transmitted to one assigned compression piston of at least two compression pistons which are disposed so as to be movable in the at least two compression cylinders, the at least two compression cylinders holding hydrogen, said compression pistons movably delimiting the at least two compression chambers in the at least two compression cylinders on one side such that movements of each of the at least two drive pistons are able to be converted to a volumetric variation of the respective at least one compression chamber; e) the at least two compression cylinders are disposed so as to be higher along a direction of gravity than the at least two drive cylinders and separated from the at least two drive cylinders by a spacing, wherein the spacing has at least the size of a maximum distance travelled by one of the at least one drive pistons in the assigned drive cylinder and at least the size of 5/18 of a height of the compressor device; and f) at least two connection chambers are filled with a functional gas and a first connection chamber of the at least two connection chambers is disposed between a first compression cylinder of the at least two compression cylinders and the first drive cylinder, and a second connection chamber of the at least two connection chambers is disposed between a second compression cylinder of the at least two compression cylinders and the second drive cylinder.

2. The compressor device as claimed in claim 1, wherein the at least two compression cylinders do not share any common wall with the at least two drive cylinders.

3. The compressor device as claimed in claim 1, wherein the at least two connection chambers are configured to be filled with the functional gas for purging the at least two connection chambers, for detecting leaks in the at least two connection chambers, and/or for blocking the at least two connection chambers.

4. The compressor device as claimed in claim 1, wherein at least one measuring device is provided, and wherein the at least one measuring device is configured to determine a position of at least one drive piston of the at least two drive pistons, at least one mechanical connection means of the at least two mechanical connection means, and/or at least one compression piston of the at least two compression pistons.

5. The compressor device as claimed in claim 1, wherein the at least two mechanical connection means are straight rods.

6. The compressor device as claimed in claim 1, wherein a seal is provided between at least one compression cylinder of the at least two compression cylinders and at least one compression piston of the at least two compression pistons and/or a seal is provided between at least one compression cylinder of the at least two compression cylinders and at least one mechanical connection means of the at least two mechanical connection means.

7. The compressor device as claimed in claim 1, wherein a cooling device, which discharges waste heat created in the operation of the at least one compression cylinder, is disposed on the at least one compression cylinder.

8. The compressor device as claimed in claim 1, wherein a compressed gas for forming a compression in multiple stages is configured to be directed as gas to be further compressed from a first compression chamber into at least one second compression chamber.

9. The compressor device as claimed in claim 1, further comprising a valve device for decoupling the movement of the drive pistons.

10. The compressor device as claimed in claim 1, further comprising a control system for controlling the impingement of the at least one first and second drive chamber with the hydraulic fluid via the valve device.

11. The compressor device as claimed in claim 1, wherein the fluid pressure between the at least one first and second drive chamber and each of the remaining drive chambers is configured to be synchronized via at least one synchronizing installation which bypasses the respective drive piston.

12. The compressor device as claimed in claim 2, wherein the at least one connection chamber is configured to be filled with the functional gas for purging the at least one connection chamber, for detecting leaks in the at least one connection chamber, and/or for blocking the at least one connection chamber.

13. The compressor device as claimed in claim 2, wherein at least one measuring device is provided, and wherein the at least one measuring device is configured to determine a position of the at least one drive piston, the at least one mechanical connection means, and/or the at least one compression piston.

14. The compressor device as claimed in claim 2, wherein the at least two drive cylinders are disposed below the at least one compression cylinder.

15. The compressor device as claimed in claim 1, wherein the at least one third drive chamber and the at least one fourth drive chamber are upper chambers, and the at least one first drive chamber and the at least one second drive chamber are lower chambers, and wherein the upper chambers are fluidly connected via the connection piece and the lower chambers are not fluidly connected.

16. The compressor device as claimed in claim 1, wherein the at least two drive cylinders are narrower than the at least two connection chambers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Exemplary embodiments will be illustrated in exemplary manner hereunder.

(2) FIG. 1 shows a first embodiment of a compressor device (single-action, single-stage, water-cooled, rod-proximal hydraulic coupling of the drive chambers);

(3) FIG. 2 shows a second embodiment of a compressor device (single-action, single-stage, air-cooled, rod-proximal hydraulic coupling of the drive chambers);

(4) FIG. 3 shows a third embodiment of a compressor device (single-action, single-stage, water-cooled, piston-proximal hydraulic coupling of the drive chambers);

(5) FIG. 4 shows a fourth embodiment of a compressor device (single-action, dual-stage, water-cooled, rod-proximal hydraulic coupling of the drive chambers);

(6) FIG. 5 shows a fifth embodiment of a compressor device (dual-action, four-stage water-cooled, rod-proximal hydraulic coupling of the drive chambers);

(7) FIG. 6a shows an embodiment of a compression device having a valve control system in a first position;

(8) FIG. 6b shows the embodiment according to FIG. 6a in a second position;

(9) FIG. 7 shows a schematic illustration of a further embodiment of a compression device having four-stage compression;

(10) FIG. 8A shows a schematic illustration of an alternative embodiment of a compression device having three dual-stage compressions;

(11) FIG. 8B shows a schematic illustration of an alternative embodiment of a compression device having four-stage compression;

(12) FIG. 8C shows a schematic illustration of an alternative embodiment of a compression device having four-stage compression and having alternative guiding of the gas to be compressed; and

(13) FIG. 8D shows a schematic illustration of an alternative embodiment of a compression device having three-stage compression.

DETAILED DESCRIPTION OF THE INVENTION

(14) An embodiment of a compressor device 100 which has one compression chamber 1a, 1b in in each case one compression cylinder 2a, 2b for a gas is illustrated in FIG. 1.

(15) The compression cylinders 2a, 2b here are disposed in a vertical manner so as to be mutually parallel, wherein the gas (to be compressed) entering from the compression chambers 1a, 1b, or the exiting (compressed) gas, respectively, is illustrated by double arrows at the end side of the compression cylinders. The compression chambers 1a, 1b have in each case one gas inlet 5a, 6a, and one gas outlet 5b, 6b. The gas inlet 5a, 6a and the gas outlet 5b, 6b, can be formed by gas valves (not illustrated).

(16) The volume of the compression chambers 1a, 1b by way of compression pistons 3a, 3b is periodically varied during the compression procedure.

(17) The compression pistons 3a, 3b, movably delimit in each case the compression chambers 1a, 1b in a downward manner in the compression cylinder 2a, 2b. The compression pistons 3a, 3b in the embodiment illustrated when in operation perform work only in a stroke, that is to say that said compression pistons 3a, 3b are single-action compression pistons.

(18) The compressor device 100 herein is aligned such that the force of gravity points downward. It is likewise conceivable and possible for the compressor device 100 to be aligned in an arbitrary manner in relation to the force of gravity. For example, the compressor device 100 can be aligned so as to be horizontal in relation to the force of gravity. The drive cylinders 12a, 12b are in each case disposed so as to be mutually coaxial below the at least one compression cylinder 2a, 2b. In other exemplary embodiments (not illustrated) the drive cylinders 12a, 12b are disposed above the at least one compression cylinder 12a, 12b.

(19) Drive pistons 13a, 13b which in the embodiment illustrated are disposed in the two drive cylinders 12a, 12b serve for driving the compression pistons 3a, 3b.

(20) The two drive pistons 13a, 13b subdivide in each case the internal chambers of the drive cylinders 12a, 12b into two drive chambers 11a, 11b, 11c, 11d. The volume of the drive chambers 11a, 11b, 11c, 11d can vary depending on the position of the drive pistons 13a, 13b within the drive cylinders 12a, 12b. The sum of the volumes of the drive chambers 11a, 11b, 11c, 11d in one drive cylinder 12a, 12b is in each case constant herein.

(21) The first and the second drive chamber 11a, 11b are periodically impinged with a hydraulic fluid. The entering and exiting hydraulic fluid is illustrated by double arrows (hydraulic fluid infeed 18a, 18b). For example, when hydraulic fluid is forced into the first drive chamber 11a the drive piston 13a moves upward. The movement takes place along the movement axes Ba, Bb.

(22) A third and a fourth drive chamber 11c, 11d is in each case indicated above the drive pistons 13a, 13b, said third and fourth drive chambers 11c, 11d being fluidically connected to one another by way of a connection piece (15).

(23) For example, when the first drive piston 13a moves upward the fluid situated in the third drive chamber 11c is forced into the fourth drive chamber 11. An exchange of fluid between the drive chambers 11c, 11d takes place on account of the fluidic coupling (hydraulic non-positive locking coupling).

(24) The drive pistons 13a, 13b are coupled to the compression pistons 3a, 3b by way of at least one mechanical connection means 20a, 20b, the latter here being a straight rod. In this embodiment, the drive cylinders 12a, 12b and the compression cylinders 2a, 2b lie in each case so as to be mutually aligned on top of one another.

(25) On account of the mechanical connection means 20a, 20b, a movement of the drive pistons 13a, 13b is able to be transmitted to the compression pistons 3a, 3b which are movably disposed in the compression cylinders 2a, 2b. Movements of the drive pistons 13a, 13b are thus able to be converted to a volumetric variation of the compression chambers 1a, 1b.

(26) The compression cylinders 2a, 2b in spatial terms herein are in each case disposed so as to be mutually separated from the two drive cylinders 12a, 12b by a spacing Da, Db. The risk of contaminations for example being carried from the drive cylinders 12a, 12b to the compression cylinders 13a, 13b is minimized by specifying said spacings Da, Db.

(27) The spacings Da, Db also have the effect that the compression cylinders 13a, 13b do not share any common wall with the drive cylinders 12a, 12b; the compression cylinders 2a, 2b and the drive cylinders 12a, 12b, are mutually separated in particular in spatial, fluidic and also thermal terms.

(28) In one embodiment, the spacing Da, Db can be chosen to be at least as long as the maximum distance travelled by one of the drive pistons 13a, 13b in the assigned drive cylinder 12a, 12b.

(29) At least one connection chamber 30a, 30b which for purging the at least one connection chamber 30a, 30b, for detecting a leak in the at least one connection chamber 30a, 30 and/or for blocking the at least one connection chamber 30a, 30b is able to be filled with a functional gas is disposed between the compression cylinders 2a, 2b, and the drive cylinders 12a, 12b in the embodiment illustrated according to FIG. 1. The at least one connection chamber 30a, 30b is surrounded by a connection housing 40a, 40b.

(30) The embodiment according to FIG. 1 furthermore has a cooling device 8a, 8b by way of which the compression cylinders 2a, 2b are able to be cooled in order for the waste heat created in the operation to be discharged. The cooling device in the embodiment illustrated is configured as a water-cooling system; the inflowing and outflowing water is illustrated by arrows. Water-cooling is expedient in particular in the case of compressors with a comparatively high output.

(31) A measuring device 17 by way of which the position of one of the drive pistons 13a, 13b is to be determined is schematically illustrated in FIG. 1. The measuring device 17 is formed by a position sensor.

(32) A stroke of 500 mm is able to be implemented using such a compressor device 100, for example. The overall height of the device in this instance would be approx. 1800 mm. In principle, other dimensions are also able to be implemented.

(33) The embodiment according to FIG. 1 thus represents a single-action, single-stage, water-cooled compressor device 100 having a rod-proximal hydraulic coupling. The term rod-proximal here refers to the relative disposal in relation to the mechanical connection means 20a, 20b (rod).

(34) Alternative construction modes for compression devices 100 will be illustrated in the figures hereunder, wherein reference is made to the description of the embodiment of FIG. 1 for the sake of brevity.

(35) A second embodiment which is likewise single-action, single-stage and hydraulically coupled in a rod-proximal manner, but has an air-cooling system, is illustrated in FIG. 2.

(36) Rib devices are disposed as a cooling device about the compression chambers 1a, 1b in this embodiment. The functional mode otherwise corresponds to that of the first embodiment.

(37) A third embodiment which represents a further variant of the embodiment of FIG. 1 is illustrated in FIG. 3.

(38) Like the first embodiment, said third embodiment has a water-cooling system. However, the hydraulic coupling takes place not in a rod-proximal manner but in a piston-proximal manner by way of the connection piece 15. Accordingly, the hydraulic fluid infeed lines 18a, 18b lie above the drive pistons 13a, 13b, that is to say proximal to the rod.

(39) Compressor devices of the type illustrated here can also be configured as dual-stage compressors.

(40) FIG. 4 thus shows a single-action, dual-stage, water-cooled variant having a rod-proximal hydraulic coupling. The fourth embodiment otherwise corresponds to the first embodiment. As an additional feature, a connection line 60 between the first compression chamber 1a and the second compression chamber 1b by way of which compression in two stages is optionally able to be implemented is illustrated here.

(41) A further variant is illustrated in FIG. 5. As in the first embodiment, a water-cooled compression device 100 is present, in which a rod-proximal hydraulic coupling of the drive chambers 11c, 11d is present.

(42) However, the compression chamber 1a, 1b in this embodiment is configured such that the compressor device 100 operates in a dual-action manner, that is to say that each stroke of the compression piston 3a, 3b performs work. Accordingly, the compression chambers 1a, 1b, 1c, 1d, 1e, 1f have in each case one inlet and one outlet.

(43) A further advantage of the compressor device 100 is derived from the hydraulically coupled drive cylinders 12a, 12b. On account of the fact that the two compression pistons 3a, 3b are in each case driven by a dedicated drive cylinder 12a, 12b, the stroke of a first cylinder can be varied independently of the second drive cylinder during the operation by way of the construction of a suitable hydraulic circuit. An embodiment to this end is illustrated in FIGS. 6a, 6b.

(44) This decoupling is above all highly advantageous when compressing gases to a constant output pressure at a sinking input pressure (for example when emptying bottles). In a dual-stage plant the intermediate pressure likewise sinks on account of the sinking input pressure since the two stages are designed with a view to only one specific type of application (tight range). A deviation from this design point is tolerated only to a minor extent, for example by way of an indicated pressure range at the gas input. Any excessive deviation leads to non-uniform and unfavorable compression ratios in one of the two stages, depending on whether the permissible range has been exceeded or undershot. This results in an excessive and unforeseen generation of heat which can cause damage to components. This principle in analogous manner also applies to filling containers, in which the output pressure varies and in particular increases.

(45) On account of the possibility of operating a variable stroke in one of the two drive cylinders 12a, 12b, the two stages can be adapted to variable operating conditions during the operation. Any unnecessary generation of heat on account of highly dissimilar compression ratios in the two stages is avoided on account thereof, and the input pressure can be operated in an optimal manner in a larger range (above all in low pressure ranges).

(46) This adjustment of stroke is achieved by a variation in the hydraulic management in the drive cylinders 12a, 12b.

(47) The hydraulic output 50 of the first drive cylinder 12a is blocked when the desired stroke is reached while the first drive piston 13a moves downward, while the hydraulic fluid (oil) of the upward moving second drive piston 13b is simultaneously discharged by way of an additional hydraulic fluid output 51.

(48) In this way, one of the drive pistons is stationary during the stroke; the drive piston coupled thereto can fully complete the stroke on account of the oil being diverted. The strokes of the two drive pistons 13a, 13b can thus be mutually decoupled by way of a suitable valve device 52.

(49) A pressure compensation line 16a, 16b is disposed at an end of the third and the fourth drive chamber 11c, 11d, where a reversal of the movement of the respective drive piston 13a, 13b takes place. The pressure compensation line 16a, 16b, in a position of the drive piston 13a, 13b at which the reversal of the movement takes place, bypasses the drive piston 13a, 13b such that the two drive chambers 11a, 11b, 11c, 11d of a drive cylinder 12a, 12b are able to be connected by way of the pressure compensation line 16a, 16b. The pressure compensation line 16a, 16b has a check valve 161a, 161b for controlling the connection between the drive chambers 11a, 11b, 11c, 11d.

(50) A modification of the embodiment according to FIG. 5 is illustrated in FIG. 7, so that reference can be made to the description above.

(51) Implemented here is a four-stage compression in which the first compression chamber 1a forms the first stage. The compressed gas is supplied to a second stage in the compression chamber 1b by way of the gas outlet 5b and the gas inlet 6a. The gas is then supplied to a third stage by way of the gas outlet 6b of this compression chamber 1b, said third stage being implemented in a third compensation chamber 1c. The gas is subsequently supplied back to the first compression cylinder in which a fourth compression stage is implemented in the compression chamber 1d. The flow of gas between the two compression cylinders is illustrated by arrows in FIG. 7. The size of the compression chambers 1a, 1b, 1c, 1d here is optionally to be adapted to the compression task.

(52) In an alternative embodiment according to FIG. 8A and FIG. 8B, compression in at least two stages is implemented in which the first compression chamber 1a and the fourth compression chamber 1d form the first stage. The gas to be compressed is in each case supplied to the first compression chamber 1a and to the fourth compression chamber 1d by one gas inlet 5a,5a. The gas to be compressed herein is in particular supplied in an alternating manner to the first compression chamber 1a and to the fourth compression chamber 1d. The compressed gas, as gas to be further compressed, is in each case supplied to a second stage in the compression chambers 1b, 1c by way of one gas outlet 5b, 5b. The gas to be further compressed is in each case supplied to the second compression chamber 1b and to the third compression chamber 1c by way of one gas inlet 6a, 6a. The gas from the first compression chamber 1a herein is supplied to the second compression chamber 1b, and the gas from the fourth compression chamber 1d is supplied to the third compression chamber 1c. The gas to be further compressed is guided onward from the second compression chamber 1b and from the third compression chamber 1c by way of a gas outlet 6b, 6b.

(53) According to FIG. 8A, the gas further compressed in the second stage is guided onward for further processing.

(54) According to FIG. 8B, the further compressed gas from the second compression chamber 1b and from the third compression chamber 1c is supplied to further compression stages.

(55) The compressor devices of FIG. 8A and FIG. 8B comprise four compression cylinders 2a, 2b, 2c, 2d. The compressor devices thus correspond substantially to the exemplary embodiment of FIG. 7, wherein the two compression cylinders 2c, 2d are upgraded. One cooling device 8c, 8d by way of which the compression cylinders 2c, 2d are able to be cooled is in each case disposed on the compression cylinders 2c, 2d. The movement of the drive pistons 13a, 13b by way of a mechanical connection means 20a, 20b is in each case able to be transmitted to four compression pistons 3a, 3b, 3c, 3d which are in each case disposed so as to be movable in a compression cylinder 2a, 2b, 2c, 2d. Two compression pistons 3a, 3b, 3c, 3d are disposed on each of the mechanical connection means 20a, 20b. In principle, the compression pistons 3a, 3b, 3c, 3d can in each case divide the compression cylinders 2a, 2b, 2c, 2d into two compression chambers in which gas can in each case be compressed in a mutually independent manner or in multiple stages. A sequence in which the gas is guided through the compression chambers of the compression device can be chosen in an arbitrary manner. Likewise, a number of stages of compression and/or a number of simultaneously operated, optionally multi-stage, compressions can be chosen in an arbitrary manner.

(56) In FIG. 8A, gas is compressed in the first compression chamber 1a and is then supplied to the second compression chamber 1b. Independently thereof, gas is compressed in a fifth compression chamber 1e of the third compression cylinder 2c. The gas to be compressed is supplied to the fifth compression chamber 1e by way of a gas inlet 7a. The compressed gas as gas to be further compressed is supplied to a further stage in a sixth compression chamber 1f by way of a gas outlet 7b. The gas to be further compressed is supplied to the sixth compression chamber 1f by way of a gas inlet 7a. The further compressed gas from the sixth compression chamber 1f is guided onward by way of a gas outlet 7b.

(57) Alternatively, the gas can likewise be compressed in more than two stages. A four-stage compressor device is illustrated in FIG. 8B. In contrast to the compressor device illustrated in FIG. 8A, gas is supplied to the gas inlet 7a of the fifth compression chamber 1e in that a third compression stage is implemented. The gas is then supplied to a fourth stage which is implemented in a sixth compression chamber 1f by way of a gas outlet 7b of the compression chamber 1e. The gas is supplied to the sixth compression chamber 1f by way of a gas inlet 7a. The gas compressed in the sixth compression chamber 1f is guided onward for further processing by way of a gas outlet 7b. The diameters of the drive pistons 3a, 3d are larger than the diameters of the drive pistons 3b, 3c. In principle, the size of the drive pistons 3a, 3b, 3c, 3d, like the size of the compression chambers 1a, 1b, 1c, 1d, is optionally to be adapted to the compression task.

(58) Alternative guiding of the gas through the compressor device is illustrated in FIG. 8C. The compressed gas herein as gas to be further compressed is supplied to a second stage in the compression chamber 1c by way of the gas outlets 5b, 5b. The gas to be further compressed is in each case supplied to the second compression chamber 1b and to the third compression chamber 1c by way of a gas inlet 6a, 6a. The further compressed gas from the third compression chamber 1c is supplied to the fifth compression chamber 1e. Thereafter, the gas is supplied to the fourth stage of the sixth compression chamber 1f.

(59) Alternatively, the gas, proceeding from the third stage, can be provided for further processing by the fifth compression chamber 1e, as is illustrated in FIG. 8D. The movement of the drive piston 13a by way of the mechanical connection means 20a herein is able to be transmitted to a compression piston 3a, wherein the movement of the drive piston 13b by way of the mechanical connection means 20b is able to be transferred to two compression pistons 3b, 3c. In principle, any arbitrary number of compression pistons connected to the mechanical connection means 20a, 20b, and any arbitrary guiding of the gas to be compressed, the compressed gas, and the gas to be further compressed in the compression chambers is conceivable and possible. The size of the compression chambers 1a, 1b, 1c, 1d, 1e, 1f herein is optionally to be adapted to the compression task.

(60) The above embodiments are merely preferred embodiments of the present disclosure. It should be set forth that, for a person skilled in the art, improvements and modifications may be made, with such improvements and modifications being deemed to be within the protection and scope of the present disclosure without departing away from the principles of the present disclosure.

LIST OF REFERENCE SIGNS

(61) 1a, 1b, 1c, 1d, 1e, 1f Compression chamber 2a, 2b, 2c, 2d Compression cylinder 3a, 3b, 3c, 3d Compression piston 5a, 6a, 5a, 6a, 7a, 7a Gas inlet 5b, 6b, 5b, 6b, 7b, 7b Gas outlet 8a, 8b, 8c, 8d Cooling device 11a, 11b, 11c, 11d Drive chamber 12a, 12b Drive cylinder 13a, 13b Drive piston 15 Connection piece 16a, 16b Pressure compensation line 161a, 161b Check valve 17 Measuring device 18a, 18b Hydraulic fluid infeed lines 20a, 20b Mechanical connection means 30a, 30b Connection chamber 40a, 40b Connection housing 50 Hydraulic output 51 Additional hydraulic fluid output 52 Valve device 100 Compressor device Ba, Bb Movement axis Da, Db Spacing