The main purpose of this article is to describe gas or air compressors and various types of air compressors. Compressors are needed in almost every industry.
What is a compressor?
A machine that is mechanically driven to increase the pressure of a liquid by reducing the volume of the liquid is called a compressor. When a compressor uses gas as hydraulic fluid, it is called a gas compressor. However, if the compressor uses air as the hydraulic fluid, it is called an air compressor. Naturally, in a compressor, compressed air gas raises the temperature.
Air compressors are also a special type of machine powered by compressed air and are used in a variety of industries. Air compressors have been recognized worldwide since they were discovered in 1875.
With an air compressor, you can save time and money on almost any job. It turns out that these devices have had a major impact on people’s lives. Those who were able to reduce their work have taken on a lot of work, which has resulted in a significant increase in their productivity and productivity levels. This is the main reason for the increasing demand for compressors.
The operation of the compressor is similar to the operation of the pump. But his job is a little different. However, the mechanical devices of pumps and compressors increase the pressure of the liquid.
How does the compressor work?
The basic operating principle of a gas or air compressor is easy to understand. It basically works by changing the amount of gas or air. Use a piston or diffuser to increase the pressure of the hydraulic fluid.
When the hydraulic fluid enters the diffuser, the speed of the hydraulic fluid is converted to pressure energy.
Therefore, the compressor compresses gas or air. After the compression process, the compressed air becomes a storage tank. Compressors are used in many industries to increase production, which has led to the development of many new industries.
Today, many companies manufacture and supply air compressors for a variety of industries. Originally made of wood, these machines are now manufactured with many of the latest technologies and materials.
Many countries use air compressors for their benefit. They use these machines to save valuable time, energy and money.
Types of air compressors
The most well-known types of air compressors are listed below.
There are two main types of air compressors:
1. Volumetric compressor
2. Dynamic compressor
These two types are subdivided into different types listed below.
1) Volumetric air compressor
The most famous type of air compressor. The principle of operation of a reciprocating compressor is simple.
These compressors reduce the volume of the compression chamber by feeding air into the compression chamber through the intake air. Compress the air until it reaches the air pressure you need. Compressed air at rated pressure is then blown out of the valve to ensure air flow.
Other definition of PD compressor is a compressor that works by extracting a certain amount of gas or air from the inlet of the compressor and forcibly releasing it from the outlet of the compressor, called positive displacement (PD) compressor.
There are the following types of reciprocating compressors.
1.1) Reciprocating compressor
These types of air compressors use pistons or plungers that are pushed by the crankshaft. This piston or plunger moves at a constant speed, sucking in and compressing air. Normally, one stroke of the piston draws air into the cylinder, and the other stroke compresses it.
The power of a small reciprocating compressor ranges from 5 to 30 horsepower, which is mainly used in automotive applications and is often used for intermittent work.
Large reciprocating compressors are over 1000 horsepower and are commonly used in the oil and large industries. In major industries, they are used in applications such as chemical plants, industry, oil refining, natural gas processing and supply.
1.2) Screw compressor
These are the most common types of air compressors in use today. In a rotary screw compressor, air enters the compressor, the holes are closed, and the air is compressed by two continuously rotating rotors passing through the cavity. With each revolution, the air pressure gradually increases until it reaches the desired pressure.
The classification of screw compressors depends on the type of gearbox, cooling method and stage. These types of air compressors are usually built dry and filled with water and oil.
The efficiency of a rotary compressor is highly dependent on the air dryer. The screw compressor consists of several components, high efficiency, large capacity, simple structure, voltage peaks and low vibration, and can run at low speed for power regulation.
1.3) Ion type air compressor
Ion compressors are also known as ionic liquid piston pumps. This is a liquid ion hydrogen reciprocating compressor, not a metal piston like a reciprocating compressor with a metal diaphragm.
Advantages of ion compressor:
• No seals or bearings required
• Has a long shelf life
• This type reduces power consumption
• Minimal maintenance required
1.4) Rotary vane compressor
The rotary air compressor is also a famous compressor. This compressor uses two asymmetric rotors (also known as helical screws) to compress the air.
The rotary vane gas compressor consists of a rotor with a large number of blades or vanes. These blades are secured in the radial slots of the rotor. The rotor is secured to a casing with a more rounded or more complex design. As the rotor rotates, the blades move in and out of the slots and touch the casing on the outside of the wall. Therefore, the rotor blades create a set of volumes that are maximized and minimized. This compressor is the oldest compressor technology.
They are used in tire and wheel shop applications such as tire expansion, dry cleaning and paint pumps.
Advantages and disadvantages of vane compressors:
Pros and cons
It is a lightweight design. Used for limited purposes.
It’s very efficient. Produces high vibrations in
work
The initial cost is low. There are many of this compressor
Rotating parts.
It is a compact size. Because there are many moving parts
High maintenance costs.
Simple structure.
1.5) Roller piston compressor
The rotating piston of this type of air compressor acts as a gap between the impeller and the vane. This piston pushes the gas towards the fixed blade. Two of these compressors can be mounted on the same shaft to reduce noise and vibration and improve performance. The spring less version is known as a rotary compressor.
This gas compressor is more efficient than a reciprocating compressor because there is less wasted space between the piston and the compressor housing.
With given performance, the volume of the reciprocating compressor is reduced by 40-50% and the weight is increased. There is less vibration and less detail. It is more reliable than the reciprocating compressor.
1.6) Scroll Compressor
Scroll compressors are also known as scroll vacuum pumps or scroll pumps. These types of air compressors use two offset helical vanes to compress or pump various fluids such as air, gas, and liquids. The blade shape can be a mixed curve or an Archimedes spiral.
These types of compressors operate smoothly with lower capacity limits than other types of compressors. It is quieter and more reliable.
Typically, one roller is equipped and the other is eccentric and does not rotate, pump, restrict or compress the air pockets present between the rollers.
They are used in homes, air conditioners, shipping containers, fruits, food refrigerators, vacuum pumps, trucks and more.
Advantages and disadvantages of scroll compressors:
1.7) Diaphragm compressor
This type of air compressor is a conservative piston type compressor. In these compressors, the gas or air is compressed by the movement of the flexible diaphragm rather than the inlet component.
Reciprocating movement of the diaphragm handle using a crank mechanism. If gas compression is required, only the compressor housing and diaphragm will be in contact with the gas. The degree of bending and the material of the membrane affect the life of the device.
Compressors with a rubber or silicone diaphragm can withstand very large deflection depths. However, the low resistance of these compressors limits their use at low pressure and must be replaced if the plastic becomes brittle. They are used in many applications such as compressed natural gas (CNG) and hydrogen plants.
Advantages and disadvantages of diaphragm compressors:
Types of dynamic air compressors
2.1) Centrifugal compressor
Centrifugal compressors are among the best known types of air compressors. Use a rotating impeller or housing disc to supply gas or air to the impeller blades. The impeller blades increase the speed of the gas. The diffuser converts the energy of the gas velocity into pressure. The gas is then pumped to the right place.
These compressors are mainly used in some stationary applications in industries such as petrochemical plants, gas, chemical and oil refineries. Its application ranges from 100 horsepower to thousands of horsepower. Various modifications allow high outlet pressures in excess of 6.9 MPa (1000 psi) to be achieved.
2.2) Axial air compressor
Axial compressors are a type of dynamic compressors. These are very famous types of air compressors. They are used where compact design or high flow rates are required. Axial compressors use a series of fan-shaped air blades to progressively compress a fluid.
In this type, the wings are arranged in pairs, one in a fixed row and the other in a rotating row. A rotating vane of air, also known as a rotor, accelerates the fluid. The fixed vanes (also known as vanes or stators) slow down the speed, deflect the fluid flow, and position the rotor blades for the next pitch.
How to use the air compressor?
Air compressor operators need basic skills and training to operate them. First, read the instruction manual and follow the manufacturer’s instructions to create a maintenance checklist. Then chart the usage of the air compressor and operate accordingly.
Below are the basic steps to help you use an air compressor.
1. Ensure safe operation
2. Tighten the loose part.
3. Wear PPE
4. Check fuel pump oil level.
5. Connect the pneumatic tool
6. Remove water from air receiver.
7. Check the oil level in the tank.
8. Fill the air reservoir
9. Adjust check valve
10. Provide more checks
1) Ensure safe operation
It is very important to keep the electrical components of the air compressor out of and away from water. There is a risk of electric shock.
As a general rule, the operator keeps the electric relief valve away from wet surfaces. When a pneumatic air compressor is running, changing and refilling the oil can cause safety issues. Also, use it while it cools down.
Also, do not forget to connect the compressor to a socket equipped with a lightning rod. The fire extinguisher should also be placed in an important place near the equipment.
Inlet pressure should not exceed 90 psi unless internal compressor pressure is high. This high air pressure can affect the performance of the air tool. Therefore, it is very important to understand the air requirements of air distribution systems, dryers, tools, and other equipment.
2) Tighten the loose part
Check and tighten loose parts of connections and connectors, as they can become loose due to vibrations from the compression system. Vibrations often loosen nuts, bolts, and nuts. So check these details and tighten if they are loose.
3) Wear PPE (Personal Protective Equipment)
Always wear personal protective equipment (PPE) before operating the air compressor. Before working on the equipment, the operator must wear boots, goggles, a helmet and gloves.
In the event of an accident at work, personal protective equipment can prevent serious injuries to workers. Proper personal protective equipment also reduces the risk of environmental damage.
4) Check the oil level of the air compressor pump.
It is very important to check the oil level before running the oil-lube compressor. This will prevent equipment damage.
On the other hand, if you are using an oil-free air compressor, you do not need to perform regular lubrication checks. Make sure the power is off before removing the oil filter plug.
5) Pneumatic tool connection
If using a quick connect fitting, pull on the spring clip to release it and secure it to the compressor.
Make sure the air tool is properly connected to the compressor air hose. Check for air leaks from the air tool inlet valve.
6) Drain the water from the receiver.
Compression traps vapors when the tank is wet from the atmosphere. This situation is typical for air compressors in humid climates. Therefore, for the correct operation of the equipment, it is necessary to drain the moisture from the air reservoir.
When the job is completed, the operator can unlock the drain valve under the receiver to remove moist air. Before regularly draining the water, it is necessary to bleed the pneumatics in the tank.
7) Check oil level
Check and change compressor lubricant after each use. Oil is very important for equipment pistons. This oil helps the piston move forward and backward.
If the piston is not properly lubricated, it may be damaged. The manufacturer also recommends that the driver refuel the oil pump after 500-1000 hours of operation.
8) Fill the air tank
Almost all compressors have a drain valve to release air or gas. So, check the air compressor drain valve. If you also have a drain valve, close it with a wrench before filling the air reservoir. After closing, turn on the power. Instead of using the compressor right away, run the pump for a few minutes.
Check the air pressure gauge to make sure the compressor shuts off automatically when the air pressure reaches 115 psi. Extreme operating pressure may vary depending on the air compressor model. The maximum pressure rating for some DEWALT products is 150 psi.
9) Adjust air control valve
You can adjust the air valve adjuster to suit your needs with the Pneumatic Tool Pneumatic. Generally, turning the air control valve clockwise increases the air pressure. This control valve is mainly used to stop, decrease or increase pneumatic or gas pressure.
