Ingersoll-rand Company

Other

William H Harden

John T Gunn

Daniel T Martin

Don John Gerhardt

Dale R Herbstritt

Devin D Biehler

Dilip K Mistry

A method for optimizing the operating efficiency of a compressor having a compression module for compressing a fluid, the compression module including an inlet for receiving the fluid and an outlet for discharging compressed fluid, the compressor including a prime mover for driving the compression module and a rotatable fan for drawing ambient air into the compressor. The compressor includes a first temperature sensor for sensing the temperature of compressed fluid discharged from the compression module, a second temperature sensor for sensing the temperature of a coolant circulating through the prime mover, a third temperature sensor for sensing the temperature of the fluid entering the compression module, and a fourth temperature sensor for sensing the temperature of a lubricant mixed with the fluid as the fluid is compressed in the compression module. The compressor includes an electronic control module (ECM) electrically connected to the four temperature sensors for receiving signals therefrom. The ECM includes a non-volatile memory containing empirical data relating to optimal operating set points of the compressor and a logic routine for controlling the rotational speed of the fan and the volume of the lubricant mixed with the fluid so as to optimize the efficiency of the compressor. The method includes the steps of executing a temperature sensing subroutine whereby the first, second, third and fourth temperature sensors collect temperature data and relay the temperature data to the ECM, executing a fan speed subroutine whereby the ECM generates signals in response to the temperature data received by the ECM for controlling the rotational speed of the fan, and executing a lubricant volume control subroutine whereby the ECM generates signals in response to the temperature data received by the ECM for controlling the volume of the lubricant mixed with the fluid in the compression module.

Compressor control system and method

A gas compressor includes a compression module, an adjustable inlet valve for precisely controlling the supply of a compressible gas to the compression module, and a pressure sensor for sensing a pressure of the gas discharged from the compression module. The gas compressor also includes an internal combustion engine for driving the compression module, the internal combustion engine having a cooling system including an engine coolant, a coolant sensor for sensing a temperature of the engine coolant, the coolant sensor being in signal sending relation with the electronic control module, a fuel control device for controlling the amount of fuel supplied to the internal combustion engine and an electronic control module (ECM) having a memory and a logic routine for controlling operation of the compressor. The ECM has a set point speed for the engine and a set point minimum coolant temperature for the engine stored in the memory. The ECM is in communication with the coolant sensor for receiving the sensed temperature of the engine coolant. The ECM is also in communication with the pressure sensor for receiving the sensed discharge pressure and comparing the discharge pressure to a set point discharge pressure range stored in the memory. The ECM generates a signal for positioning the adjustable inlet valve so that the discharge pressure remains within the set point pressure range. A method for controlling the gas compressor includes executing a compressor start routine including the steps of opening the fuel control device for supplying fuel to the engine, and accelerating the engine to the set point speed stored in the memory of the electronic control module. After the internal combustion engine reaches the set point speed, the ECM executes the compressor load routine including sensing an actual temperature of the engine coolant and comparing the actual temperature of the engine coolant to the set point minimum coolant temperature; and opening the adjustable inlet valve after the actual engine coolant temperature is at least equal to the set point minimum coolant temperature, wherein the position of the adjustable inlet valve is controlled by the ECM.

A method for controlling compressor discharge pressure in a compressor. The compressor comprising a compression module driven by a prime mover, the compression module having a discharge port through which a compressed fluid is discharged with a discharge pressure, and an inlet through which uncompressed fluid is flowed into the compression chamber, the flow of fluid through the inlet controlled by an inlet valve repositionable by an actuator driven by a motor. The method comprising the steps of running a discharge pressure control routine, comprising the steps of: calculating the difference between the actual discharge pressure and a predetermined setpoint discharge pressure; computing the required change in valve position to achieve the setpoint discharge pressure, the period of time the motor means must be energized to produce the change in valve position, and the direction the valve must be moved to produce the setpoint discharge pressure. The method including the additional steps of running an actuator position control routine, comprising the steps of: energizing the motor in the required direction for the computed period of time; and braking the motor by energizing the motor in a direction different than the required direction for a braking time interval.

Method for controlling compressor discharge pressure

An apparatus for electronically controlling the flow of low pressure gas to a compressor and preventing backflow from the compressor, the apparatus including a housing in fluid communication with the compressor, where the housing has a chamber, a housing inlet for receiving a low pressure gas, and a housing discharge port for flowing the low pressure gas to the compressor and through which backflow gas flows from the compressor. A valve member having a contact end is movable within the chamber along a predetermined path. The apparatus also includes a drive for moving an actuator along an axis. The actuator has an extension with an end adapted to abut the contact end of the valve member to thereby move the valve member along the path toward the housing inlet. The valve member is movable along the path and away from the inlet, when the actuator is retracted, by the flow of low pressure gas through the inlet. Upon compressor shutdown, the back pressure moves the valve member to a substantially occluding position relative to the inlet position to prevent backflow from flowing outward from the compressor.

Apparatus and method for electronically controlling inlet flow and

An air cooling system for an engine driven, multi-stage compressor is provided which includes a fan means for providing a cooling airstream to the air cooling system and an engine radiator. An intercooler has a predetermined height dimension and receives heated, compressed, interstage air. An oil cooler has a predetermined height dimension which is substantially less than the height dimension of the intercooler. An aftercooler receives hot, compressed, final stage air. The intercooler, the oil cooler, the radiator, and the aftercooler are arranged in two banks, each bank comprising two cooling cores juxtaposed one to each other. The intercooler and the engine radiator define the first bank which is positioned substantially adjacent to the fan means to receive the coolest cooling airstream. The oil cooler and the aftercooler define the second bank which receives warmer cooling air which has first passed through the first bank. The oil cooler is positioned behind the intercooler and the aftercooler is positioned behind the radiator.

Cooling system for engine-driven multi-stage centrifugal compressor

A portable compressed air system includes a housing, and a diesel engine having a predetermined torsional inertia, a predetermined cranking speed, and a predetermined idle speed. A centrifugal compressor is flexibly coupled in motive force receiving relation to the diesel engine. The flexible coupling has a predetermined spring rate which places the torsional interia of the compressor above a highest predetermined cranking speed and below the predetermined idle speed of the diesel engine. A microprocessor-based electronic controller controls compressor operation. A receiver stores compressed air. A cooling means cools the portable compressed air system. The cooling means has a fan, an intercooler, an oil cooler, an engine radiator, and an aftercooler. The intercooler, the oil cooler, the radiator, and the aftercooler are arranged in two banks, and each bank is defined by two cooling cores juxtaposed one to each other.

Portable diesel-driven centrifugal air compressor

An apparatus for loading a compressor includes a microprocessor based electronic controller, a pneumatically driven, spring loaded open first valve, and a normally open, electrically driven second valve flow connected in series with the first valve. The first valve and the second valve are fluidly disposed intermediate a receiver tank and the compressor. The second valve is disposed in signal receiving relation to the controller. An orifice and muffler combination is flow connected intermediate the first valve and the second valve. The orifice has a predetermined inside diameter dimension suitably sized to establish a pressure signal to close the first valve to thereby load the compressor. During operation, at a predetermined time, the controller closes the second valve thereby directing a predetermined volume of fluid to be compressed through the orifice and muffler combination to cause fluid pressure to rise to a predetermined magnitude, at which time sufficient actuation pressure is available for control of the spring loaded first valve.

Bootstrap method of loading a compressor having a spring loaded blowoff

A method and apparatus for controlling working fluid surge in a centrifugal compressor include preventing surge by using a variable-speed prime-mover to achieve a minimum desired surge margin. Surge prevention is also accomplished by continuously modulating a blowoff valve to maintain an actual compressor pressure ratio at a predetermined target maximum value. Surge detection is accomplished by monitoring the time rate of change of the final stage discharge pressure.

Surge control and recovery for a centrifugal compressor

A compressor, used for compressing a working fluid to be discharged into a reservoir, includes at least one compressor element. A prime driver, capable of operating at varying angular velocities, applies motive force to the compressor. A ratio maintaining device, disposed between each compressor element and the prime driver, ensures that a ratio defined as an angular velocity of the compressor element divided by the angular velocity of the prime driver remains constant. The prime driver is typically internal combustion engine powered. A controllable fuel valve is in communication with the prime driver and is positionable for controlling a fuel flow to the prime driver. A controller positions the fuel valve based upon a combination of parameters including a variable setpoint reservoir pressure, ambient pressure and ambient temperature, wherein the prime driver is operated at an angular velocity at which the actual pressure at the reservoir can be maintained at the setpoint reservoir pressure. The controller is microprocessor or microcomputer based.

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Yadkinville, NC, United States of America

William H Harden