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HYDRAULICS & PNEUMATICS
Presented by: Dr. Abootorabi
Compressed AirSource of Pneumatic
Power
1
Basic Source of System Air
The source of air used in pneumatic systems is the
atmosphere.
2
The gases in atmospheric air are:
Nitrogen (79%)
Oxygen (20%)
Other gases (1%)
Basic Source of System Air
Composition of atmospheric air
3
Basic Source of System Air
In addition to gases, the atmosphere contains water
vapor and entrapped dirt.
Both of these influence air compression and the final
quality of the system air.
4
The weight of the gases in the atmosphere exerts
pressure.
Atmospheric pressure is 14.7 pounds per square inch at
sea level.
Basic Source of System Air
Atmospheric pressure varies by elevation
5
Pneumatic System Compressed Air
Atmospheric air is typically referred to as free air.
Free air must be conditioned before it can be used in a
pneumatic system.
Certain locations require considerable preparation of
free air to make it usable in a pneumatic system.6
Pneumatic System Compressed Air
The conditioning of compressed air for use in pneumatic
systems involves:
Removal of entrapped dirt
Removal of water vapor
Removal of heat
Incorporation of lubricants
7
Pneumatic System Compressed Air
The amount of water vapor air can hold depends on the
temperature of the air:
The higher the temperature, the greater the
amount of water that can be retained by the air
Saturation is reached when air holds the maximum
amount of water for the given temperature
8
Pneumatic System Compressed Air
Water legs are used to collect
and remove liquid water from
pneumatic lines.
9
Pneumatic System Compressed Air
Relative humidity expresses the percentage of water in
the air compared to the maximum amount that can be
held at the specified temperature.
Dew point is the temperature at which water vapor in
the saturated air begins to be released in liquid form.
10
Pneumatic System Compressed Air
Dry compressed air contains water vapor, but the relative
humidity is sufficiently low to prevent the formation of liquid
water at the ambient temperature of the workstation.
11
A lubricant is added to dry compressed air distributed
by the pneumatic system workstation. This is for
protection of system components.
Pneumatic System Compressed Air
A lubricator for a
pneumatic workstation:
12
Compression and Expansion of Air
In an operating pneumatic system, the continuous
interaction of temperature, pressure, and volume
changes make calculations complex.
13
Engineering data are available from component
manufacturers and data handbooks that can be used to
estimate performance from compressors and other
system components.
Reaction of Air to Temperature, Pressure, and Volume
When air is compressed, there are changes in
temperature, pressure, and volume that follow the
relationships expressed by the general gas law:
(P1 V1) T1 = (P2 V2) T2
Specific system pressure, temperature, and volume
changes may be difficult to verify
14
Compressed-Air Unit
The source of compressed air for a pneumatic system is
the compressed-air unit:
Prime mover
Compressor
Other components to condition and store the
pressurized air used by the system workstations
Compressed air units vary in size.
15
Compressed-Air Unit
Very small packages may produce only a fraction of a cubic
foot of air per minute (cfm).
1 ft3 ≈ 0.028 m3
16
Compressed-Air Unit
Large, industrial units may produce thousands of cfm.
17
Compressed-Air Unit
Compressed-air units can be classified as portable units
or central air supplies:
Physical size is not the only factor in placing a unit
in one of these classes
Easy transport of a unit from one location to
another is a more important factor
Many portable units have a larger capacity than
many stationary central air supplies18
Compressed-Air Unit
A portable unit may be large or small.
19
Compressed-Air Unit
Portable units allow the compressor to be moved to the work site.
20
Compressed-Air Unit
A compressed-air unit consists of:
Prime mover
Compressor
Coupling
Receiver
Capacity-limiting system
Safety valve
Air filter
May have a cooler and dryer21
Compressed-Air Unit
The prime mover in a compressed-air unit may be:
Electric motor
Internal combustion engine
Steam or gas turbine
A coupling connects the prime mover to the compressor
22
Compressed-Air Unit
Belt coupling:
23
DeVilbiss Air Power Company
Compressed-Air Unit
Mechanical coupling:
24
DeVilbiss Air Power Company
Basic Compressor Design
A variety of designs are used for air compressors in the
compressed-air unit:
Reciprocating piston
Rotary, sliding vane
Rotary screw
Dynamic
25
Basic Compressor Design
Reciprocating-piston compressors are the most common.
Rotary screw compressors are popular in new installations.
26
Basic Compressor Design
The basic operation of any compressor includes three
phases:
Air intake
Air compression
Air discharge
Component parts and physical operation varies between
compressor designs.
27
Basic Compressor Classifications
Compressors are classified as:
Positive or non-positive displacement
Reciprocating or rotary
Positive-displacement compressors mechanically reduce
the compression chamber size to achieved compression.
Non-positive-displacement compressors use air velocity
to increase pressure.
28
Basic Compressor Classifications
A reciprocating compressor
has a positive displacement.
29
DeVilbiss Air Power Company
Compressor Design and Operation
Reciprocating compressors use a cylinder and a
reciprocating piston to achieve compression.
Rotary compressors use continuously rotating vanes,
screws, or lobed impellers to move and compress the air.
30
Compressor Design and Operation
Reciprocating compressors are commonly used in
pneumatic systems:
Very small, single-cylinder, portable compressors for
consumer use
Large, industrial, stationary units may produce
thousands of cubic feet of compressed air per
minute
31
Compressor Design and Operation
Large, industrial, reciprocating compressor:
32
Atlas Copco
Compressor Design and Operation
33
Reciprocating compressors use a single-acting or
double-acting compression arrangement
Single-acting compressors compress air during one
direction of piston travel
Double-acting compressors have two compression
chambers, allowing compression on both extension
and retraction of the piston
Compressor Design and Operation
Double-acting compressor
34
Compressor Design and Operation
Multiple cylinders may be arranged as:
Inline
Opposed
V type
W type
Other cylinder configuration
35
Compressor Design and Operation
Inline reciprocating
compressor:
36
Compressor Design and Operation
V-type reciprocating compressor:
37
Compressor Design and Operation
Rotary, sliding-vane compressors use a slotted rotor
containing movable vanes to compress air:
Rotor is placed off center in a circular compression
chamber, allowing the chamber volume to change
during rotation
These volume changes allow the intake, compression,
and discharge of air during compressor rotation
38
Compressor Design and Operation
Centrifugal force keeps the vanes in contact with the walls
39
Compressor Design and Operation
Rotary screw compressors use intermeshing, helical
screws to form chambers that move air from the
atmosphere into the system on a continuous basis.
This produces a nonpulsating flow of air at the desired
pressure level.
40
Compressor Design and Operation
Rotary screw compressors have intermeshing, helical screws:
41
Compressor Design and Operation
Rotary screw compressors have become popular for larger
industrial installations:
Lower initial cost
Lower maintenance cost
Adaptable to sophisticated electronic control
systems
42
Compressor Design and Operation
Sliding vane and screw compressor designs often inject
oil into the airstream moving through the compressors:
Reduces wear on vane and screw contact surfaces
Improves the seal between the surfaces
Oil is removed by a separator to provide near-oilless
compressed air for the pneumatic system.43
Compressor Design and Operation
Lobe-type compressors consist of two impellers with two or
three lobes that operate in an elongated chamber in the
compressor body:
Spinning impellers trap air in chambers that form
between the lobes
As the impellers turn, this trapped air is swept from the
inlet port to the outlet port to increase system pressure
44
Compressor Design and Operation
Impellers from a lobe-type compressor.
45
Compressor Design and Operation
Lobe-type compressors are often called blowers.
They are typically used in applications requiring air
pressure of only 10 to 20 psi.
46
Compressor Design and Operation
The basic operating theory of dynamic compressors is
converting the kinetic energy of high-speed air into pressure.
Dynamic compressor designs are either:
Centrifugal
Axial
47
Compressor Design and Operation
Centrifugal dynamic compressor:
An impeller increases airspeed
Prime mover energy is converted into kinetic energy
as air speed rapidly increases through the impeller
Kinetic energy is converted to air pressure as air
movement slows in the volute collector
48
Compressor Design and Operation
Centrifugal dynamic
compressor:
49
Compressor Design and Operation
Axial-flow dynamic compressor:
Rotating rotor blades increase airspeed
Fixed stator blades decrease airspeed
Kinetic energy is converted to air pressure
Series of rotor and stator sections are staged
to form the axial-flow compressor
50
Compressor Design and Operation
Axial-flow dynamic compressor:
51
Compressor Design and Operation
Axial-flow dynamic compressor:
52
Compressor Design and Operation
Pressure is created when
high-speed air is slowed
by the fixed stator blades.
53
Compressor Design and Operation
Dynamic compressor designs are used to compress air
and other gases for large, industrial applications:
Oil refineries
Chemical plants
Steel mills
54
Compressor Design and Operation
Compressor staging involves connecting a number of basic
compressor units in series to raise air pressure in small
increments.
This method permits easier control of air temperature, which
results in more-efficient compressor package operation.
55
Compressor Design and Operation
Inline, staged, reciprocating compressor:
56
Compressor-Capacity Control
Compressor-capacity control refers to the system that
matches the compressed-air output to the system-air
demand.
The better the air output of the compressor matches
system consumption, the more cost effective the
operation of the system.
57
Compressor-Capacity Control
Compressor-capacity control systems include:
Bypass
Start-stop
Inlet valve unloading
Speed variation
Inlet size variation
58
Compressor-Capacity Control
Bypass control uses a relief-type valve to exhaust excess air.
Air is continuously delivered to the system at the
compressor’s maximum flow rate.
This type of control is not considered desirable as it is
inefficient.
59
Compressor-Capacity Control
Start-stop capacity control is commonly used with small,
electric motor-driven compressor packages that operate
pneumatic systems consuming air on an intermittent basis.
60
Compressor-Capacity Control
Start-stop control uses a
pressure-sensitive switch
to start and stop the
compressor to maintain a
preselected pressure
range.
61
Compressor-Capacity Control
Start-stop control: compressor start
62
Compressor-Capacity Control
Start-stop control: compressor stop
63
Compressor-Capacity Control
Inlet valve unloading controls compressor output by
holding the inlet valve open whenever maximum
system pressure is achieved:
Allows the prime mover to operate continuously
Can be used in systems having internal combustion
engines or electric motors as the prime mover
64
Compressor-Capacity Control
Varying compressor speed can control compressor capacity:
Can be used with reciprocating and rotary compressor
designs
Primarily used on large, industrial installations
Sensors monitor pressure and send a signal to control
compressor speed
65
Compressor-Capacity Control
Varying the size of the compressor inlet can control
compressor capacity:
Compressor operates at a constant speed
The volume of air that can enter the compressor is
restricted
Output varies with the size of the inlet
Primarily used on dynamic compressors
66
Selecting a Compressor Package
Establishing the level of system air consumption is a key
factor when selecting a compressor
This can be accomplished by identifying:
Actuators used in the system
Compressed-air needs of each item
Percentage of time each functions
67
Selecting a Compressor Package
Other factors must be considered during system
compressor selection:
Compressor and prime mover type
Method of compressor-capacity control
Auxiliary controls such as coolers, separators, and
driers
System instrumentation
68
The end.
69