15T2半无油活塞式空气压缩机设计和开发
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摘要
本文是以南京英格索兰压缩机有限公司开发的一种活塞式压缩机作为研究对象,此开发的产品是一种新型号半无油活塞式压缩机。
为了保证半无油活塞式压缩机最终排出的压缩气体无油,在结构上进行了创新,采用中体和十字头结构,在十字头上安装刮油环,同时给中体通入一定压力的空气,来控制润滑油不串入压缩气腔。活塞式压缩机热力计算得到性价比最高的三级活塞式压缩机结构,同时进行气体损失分析,计算排气量和压缩机的轴功率和电动机功率。活塞式压缩机的动力计算得到压缩机的飞轮距,同时准确地分析压缩主机内部运动零件的受力情况,并在曲轴上增加适当重量的平衡块,平衡内部零件受力情况,基本消除压缩机机组的振动。使用有限元分析方法对连杆和活塞进行强度校核。
在工程试验阶段,根据国家压缩机标准的要求,对压缩机主机的排气量、排气温度、耗油量、振动和噪声等参数进行测量,并做了疲劳性试验。试验数据显示满足国家压缩机标准要求和设计输入要求。
The paper bases on a kind exploration of piston style compressor for Nanjing Ingersoll Compressor Company. The product is new type non-lubrication-oil piston style compressor.
In order to ensure non-lubrication-oil in final compressed air, there are two innovations for structure of non-lubrication-oil piston style compressor. There being the structure that has two key parts, guide and crosshead, in new machine. And oil scraper rings on the crosshead keep lubrication oil back to frame of compressor. The pressured air enters into guide in order to control lubrication oil not to penetrate cavity of compressed air. Through thermal calculation of piston compressor, the best cost-performance ratio machine is three-stage structure of compressor. In addition, Gas loss in compression process is analyzed and air displacement is calculated. And shaft power and motor power of compressor are counted out by way of thermal calculation. Moment of flywheel is calculated by dynamic calculation. Vibration of compressor is almost eliminated by these methods. Forces of movement parts of inside bare are accurately analyzed and calculated. And appropriate weight of balance block appends to crank surface. Intensity check of piston and connecting-rod are calculated by FEA.
During engineering test, several key parameters of non-lubrication-oil piston compressor, air displacement and exhaust temperature and lubrication-oil consumption and vibration and noise, are measured according to regulation of national standard of compressor. And fatigue test of new product is measured under requirement of national standard. All testing data tally with requirements of national standard and design input.
为了保证半无油活塞式压缩机最终排出的压缩气体无油,在结构上进行了创新,采用中体和十字头结构,在十字头上安装刮油环,同时给中体通入一定压力的空气,来控制润滑油不串入压缩气腔。活塞式压缩机热力计算得到性价比最高的三级活塞式压缩机结构,同时进行气体损失分析,计算排气量和压缩机的轴功率和电动机功率。活塞式压缩机的动力计算得到压缩机的飞轮距,同时准确地分析压缩主机内部运动零件的受力情况,并在曲轴上增加适当重量的平衡块,平衡内部零件受力情况,基本消除压缩机机组的振动。使用有限元分析方法对连杆和活塞进行强度校核。
在工程试验阶段,根据国家压缩机标准的要求,对压缩机主机的排气量、排气温度、耗油量、振动和噪声等参数进行测量,并做了疲劳性试验。试验数据显示满足国家压缩机标准要求和设计输入要求。
The paper bases on a kind exploration of piston style compressor for Nanjing Ingersoll Compressor Company. The product is new type non-lubrication-oil piston style compressor.
In order to ensure non-lubrication-oil in final compressed air, there are two innovations for structure of non-lubrication-oil piston style compressor. There being the structure that has two key parts, guide and crosshead, in new machine. And oil scraper rings on the crosshead keep lubrication oil back to frame of compressor. The pressured air enters into guide in order to control lubrication oil not to penetrate cavity of compressed air. Through thermal calculation of piston compressor, the best cost-performance ratio machine is three-stage structure of compressor. In addition, Gas loss in compression process is analyzed and air displacement is calculated. And shaft power and motor power of compressor are counted out by way of thermal calculation. Moment of flywheel is calculated by dynamic calculation. Vibration of compressor is almost eliminated by these methods. Forces of movement parts of inside bare are accurately analyzed and calculated. And appropriate weight of balance block appends to crank surface. Intensity check of piston and connecting-rod are calculated by FEA.
During engineering test, several key parameters of non-lubrication-oil piston compressor, air displacement and exhaust temperature and lubrication-oil consumption and vibration and noise, are measured according to regulation of national standard of compressor. And fatigue test of new product is measured under requirement of national standard. All testing data tally with requirements of national standard and design input.
引文
[1]郁永章等.容积式压缩机技术手册.第1版.北京：机械工业出版社,2005
[2]活塞式压缩机编写组.活塞式压缩机设计.第1版.北京：机械工业出版社,1974
[3]王迪生,杨乐之.活塞式压缩机结构.第1版.北京：机械工业出版社,1990
[4]林海,孙嗣莹.活塞式压缩机原理.第1版.北京：机械工业出版社,1987
[5]Ingersoll-Rand Company Mechanical Design Report.1st ed. Air Compressor Group. Davison Inngersoll-Rand Company,2004
[6]Ingersoll-Rand Air Compressor.1st ed. Air Compressor Group. New Jersey: Ingersoll-Rand Company,1983
[7]Heinz P. Bloch. Dynamic Compressor Technology.2nd ed. John Wiley & Sons, Inc., Publication,1983
[8]Heinz P. Bloch. A Practical Guide To Compressor Technology.2nd ed. John Wiley & Sons, Inc., Publication,1983
[9]Heinz P. Bloch. Shortcut Calculation and Graphical Compressor Selection Procedures. 2nd ed. John Wiley & Sons, Inc., Publication,1983
[10]Heinz P. Bloch. Properties of Common Gases.2nd ed. John Wiley & Sons, Inc., Publication,1983
[11]康书月.活塞式压缩机几种排气量调节方法.压缩机.2008(12)：82-84
[12]程言民.测算空压机排气量的几种简单方法.压缩机.2008(10)：94-96
[13]张火勇.活塞式压缩机压力比问题之简论.压缩机.2008(9)：78-80
[14]王晓忠.关于活塞式压缩机排气量问题的分析与故障对策.压缩机.2009(5)：76-78
[15]谭志模.活塞式和螺杆式空压机使用比较.压缩机.2008(6)：55-58
[16]压缩机网络论坛.浅谈国外空压机的控制系统.压缩机.2010(3)：98-103
[17]韩绿霞.活塞式压缩机计算方法的研究.郑州大学硕士学位论文.2005
[18]马东.活塞式压缩机机构平衡的研究.大连理工大学硕士学位论文.2005
[19]聂清风.空压机气阀运动规律及容积效率的研究.武汉理工大学硕士学位论文.2003
[20]杜红.往复式压缩机热力计算软件系统的研究.沈阳理工大学硕士学位论文.2006
[21]殷昌创.压缩机活塞杆的断裂失效研究.华东理工大学硕士学位论文.2005
[22]管宇辉.压缩机全量程可调气阀的理论与实践研究.浙江大学硕士学位论文.2006
[23]Derek Wollatt. Compressor Theory.1st ed. Davison:Ingersoll-Rand,2002
[24]Pado Bendirelli. Compressor Theory.1st ed. Davison:Ingersoll-Rand,2001
[25]Massimo Camattie. Very High Pressure Compressor.1st ed. Davison: Ingersoll-Rand,2004
[26]Harvey Nix. Compressor Analysis.1st ed. Davison:Ingersoll-Rand,2006
[27]Paul Hanlon. Reciprocating Compressor Sealing.1st ed. Davison: Ingersoll-Rand, 2002
[28]Hooshang Heshmat, H. Ming Chen. Principles of Bearing Design.1st ed. Davison: Ingersoll-Rand,1999
[29]Fred Heidrich. Compressor Performance-positive displacement.1st ed. Davison: Ingersoll-Rand,2001
[30]王蒙.基于分形的往复机械振动信号分析技术.大庆石油学院硕士学位论文.2004
[31]林清安.PRO-E Wildfire 3.0零件设计应用实例.第1版.北京：电子工业出版社,1990
[32]张智明,李预斌.精通PRO-E中文野火版.第1版.北京：中国青年出版社,2004
[33]万启超,魏田和.PRO-E Wildfire 3.0结构、热、运动分析基础与典型范例.第1版.北京：电子工业出版社,2008
[34]赵运才,何法江.机电工程专业英语.第1版.北京：北京大学出版社,2006
[35]成大先.机械设计手册(1、2、3、4、5卷).第4版.北京：化工工业出版社,2002
[36]全国压缩机标准化技术委员会编.中国机械工业标准汇编压缩机卷(上、下).第1版.北京：中国标准出版社,2004
[37]二代龙震工作室.PRO/MECHANICA 3.0/4.0结构和热力分析,第1版.北京：电子工业出版社,2008
[38]江苏大学数字化制造技术研究所.PRO/E3.0高级设计实例教程.第1版.北京：化工工业出版社，2007
[39]Baucer F. Value Losses in Reciprocating Compressors. Proceedings of ICEC-at Purdue (VOL. I),1988
[40]李映昕.化工用往复式压缩机的振动研究.压缩机.2009(2)：74-78
[41]曾亚男.空压机变频节能解决方案分析.压缩机.2009(11)：83-87
[42]周峰,李晓梅.空压机节能改造分析.压缩机.2009(12)：87-90
[43]刘海峰.浅议空气压缩机变频调速装置,压缩机.2009(12)：102-105
[44]孙品同,于克营.压缩比对往复式压缩机功耗的影响.压缩机技术.2008(5)：9-12
[45]王可,赵斌.单螺杆压缩机螺杆轴的有限元分析.压缩机技术.2008(6)：4-6
[46]Maclaren J. F. T., Tramschek A. B., Sanjines, A and Pastrana.O. P., 《Unsteady Flow in a Two-Stage Intercooled Reciprocating Compressor System, Vibration, and Noice in Pump, Fan and Compressor Installations》,1975
[47]Gibbs W C. Compressor Air and Gas Data (second) N. J. Ingersoll-Rand Company,1972
[48]S. Y. Sun, T. R. Ren. New Method of Thermodynamic Computation for a Reciprocating Compressor-Computer Simulation of Working Process. International Journal of Mechanical Sciences,1995
[2]活塞式压缩机编写组.活塞式压缩机设计.第1版.北京：机械工业出版社,1974
[3]王迪生,杨乐之.活塞式压缩机结构.第1版.北京：机械工业出版社,1990
[4]林海,孙嗣莹.活塞式压缩机原理.第1版.北京：机械工业出版社,1987
[5]Ingersoll-Rand Company Mechanical Design Report.1st ed. Air Compressor Group. Davison Inngersoll-Rand Company,2004
[6]Ingersoll-Rand Air Compressor.1st ed. Air Compressor Group. New Jersey: Ingersoll-Rand Company,1983
[7]Heinz P. Bloch. Dynamic Compressor Technology.2nd ed. John Wiley & Sons, Inc., Publication,1983
[8]Heinz P. Bloch. A Practical Guide To Compressor Technology.2nd ed. John Wiley & Sons, Inc., Publication,1983
[9]Heinz P. Bloch. Shortcut Calculation and Graphical Compressor Selection Procedures. 2nd ed. John Wiley & Sons, Inc., Publication,1983
[10]Heinz P. Bloch. Properties of Common Gases.2nd ed. John Wiley & Sons, Inc., Publication,1983
[11]康书月.活塞式压缩机几种排气量调节方法.压缩机.2008(12)：82-84
[12]程言民.测算空压机排气量的几种简单方法.压缩机.2008(10)：94-96
[13]张火勇.活塞式压缩机压力比问题之简论.压缩机.2008(9)：78-80
[14]王晓忠.关于活塞式压缩机排气量问题的分析与故障对策.压缩机.2009(5)：76-78
[15]谭志模.活塞式和螺杆式空压机使用比较.压缩机.2008(6)：55-58
[16]压缩机网络论坛.浅谈国外空压机的控制系统.压缩机.2010(3)：98-103
[17]韩绿霞.活塞式压缩机计算方法的研究.郑州大学硕士学位论文.2005
[18]马东.活塞式压缩机机构平衡的研究.大连理工大学硕士学位论文.2005
[19]聂清风.空压机气阀运动规律及容积效率的研究.武汉理工大学硕士学位论文.2003
[20]杜红.往复式压缩机热力计算软件系统的研究.沈阳理工大学硕士学位论文.2006
[21]殷昌创.压缩机活塞杆的断裂失效研究.华东理工大学硕士学位论文.2005
[22]管宇辉.压缩机全量程可调气阀的理论与实践研究.浙江大学硕士学位论文.2006
[23]Derek Wollatt. Compressor Theory.1st ed. Davison:Ingersoll-Rand,2002
[24]Pado Bendirelli. Compressor Theory.1st ed. Davison:Ingersoll-Rand,2001
[25]Massimo Camattie. Very High Pressure Compressor.1st ed. Davison: Ingersoll-Rand,2004
[26]Harvey Nix. Compressor Analysis.1st ed. Davison:Ingersoll-Rand,2006
[27]Paul Hanlon. Reciprocating Compressor Sealing.1st ed. Davison: Ingersoll-Rand, 2002
[28]Hooshang Heshmat, H. Ming Chen. Principles of Bearing Design.1st ed. Davison: Ingersoll-Rand,1999
[29]Fred Heidrich. Compressor Performance-positive displacement.1st ed. Davison: Ingersoll-Rand,2001
[30]王蒙.基于分形的往复机械振动信号分析技术.大庆石油学院硕士学位论文.2004
[31]林清安.PRO-E Wildfire 3.0零件设计应用实例.第1版.北京：电子工业出版社,1990
[32]张智明,李预斌.精通PRO-E中文野火版.第1版.北京：中国青年出版社,2004
[33]万启超,魏田和.PRO-E Wildfire 3.0结构、热、运动分析基础与典型范例.第1版.北京：电子工业出版社,2008
[34]赵运才,何法江.机电工程专业英语.第1版.北京：北京大学出版社,2006
[35]成大先.机械设计手册(1、2、3、4、5卷).第4版.北京：化工工业出版社,2002
[36]全国压缩机标准化技术委员会编.中国机械工业标准汇编压缩机卷(上、下).第1版.北京：中国标准出版社,2004
[37]二代龙震工作室.PRO/MECHANICA 3.0/4.0结构和热力分析,第1版.北京：电子工业出版社,2008
[38]江苏大学数字化制造技术研究所.PRO/E3.0高级设计实例教程.第1版.北京：化工工业出版社，2007
[39]Baucer F. Value Losses in Reciprocating Compressors. Proceedings of ICEC-at Purdue (VOL. I),1988
[40]李映昕.化工用往复式压缩机的振动研究.压缩机.2009(2)：74-78
[41]曾亚男.空压机变频节能解决方案分析.压缩机.2009(11)：83-87
[42]周峰,李晓梅.空压机节能改造分析.压缩机.2009(12)：87-90
[43]刘海峰.浅议空气压缩机变频调速装置,压缩机.2009(12)：102-105
[44]孙品同,于克营.压缩比对往复式压缩机功耗的影响.压缩机技术.2008(5)：9-12
[45]王可,赵斌.单螺杆压缩机螺杆轴的有限元分析.压缩机技术.2008(6)：4-6
[46]Maclaren J. F. T., Tramschek A. B., Sanjines, A and Pastrana.O. P., 《Unsteady Flow in a Two-Stage Intercooled Reciprocating Compressor System, Vibration, and Noice in Pump, Fan and Compressor Installations》,1975
[47]Gibbs W C. Compressor Air and Gas Data (second) N. J. Ingersoll-Rand Company,1972
[48]S. Y. Sun, T. R. Ren. New Method of Thermodynamic Computation for a Reciprocating Compressor-Computer Simulation of Working Process. International Journal of Mechanical Sciences,1995