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7/30/2019 Single Stage Air Compressor
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1.0 ABSTRACT
A vital part of many commercial, manufacturing, industrial, and automotive
applications is an air compressor. Air compressors are versatile mechanical tools that use
one or numerous pistons to pump compressed air into a defined space.
There are three basic types of air compressors: reciprocating, rotary, and centrifugal.
These general types of air compressors can be further categorized into single or multi
stage, packaged or non-packaged, air cooled or water cooled, and lubricated or non-
lubricated.
There are two types of piston-like air compressors: single-stage, and two-stage. These
piston-like air compressors will keep the storage tank at a predetermined PSI (Pounds per
Square Inch). The air compressors motor will turn off and turn on as needed to insure the proper PSI. Single-stage air compressors have one or more cylinders that pump air
directly into the storage tank. Two-stage air compressors use two or more cylinders to
pump air into another cylinder before pumping the air into the storage tank. Most single-
stage air compressors are sufficient for normal use. Two-stage air compressors are used
primarily by industries that have applications that require high-pressure.
Compact air compressors are popular for easy around-the-home projects. These small
air compressors do not have a storage tank; therefore they must always be running tosupply the air needed for a project. Many glue guns, caulking guns, and painting guns use
compact air compressors.
Air compressors require the proper size hoses for optimal performance. Purchasing
the right size and length of hose will keep PSI loss to a minimal. Check the hose for
cracks, sun damage, or cuts often. If any of these are found, replace your hose
immediately. Any leaks that may be caused by a faulty hose will add to an air
compressors operating cost. Air compressors should be approached with caution. Secure
the hose to guarantee minimal damage should your hose break free from the air
compressor.
Aftercoolers are heat exchangers that cool the heated compressed air. Once the
compressed air has been condensed, the removal of the excess moisture can follow.
Keeping the compressed air free from moisture is essential to most applications requiring
air compressors. Air compressors will last much longer, and be more efficient, if they
remain free from moisture.
http://www.thomasnet.com/products/air-compressors-17092800-1.htmlhttp://www.thomasnet.com/products/air-compressors-17092800-1.html7/30/2019 Single Stage Air Compressor
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Air compressors range in horse power, performance, price, operating cost, and ease of
use. Always check hoses, values, bearings, and the electrical outlet of all air compressors.
This will not only add to the longevity of the air compressor, but keep the operator safe.
2.0 OBJECTIVE
2.1 EXPERIMENT 1
To investigate the motor output power.
2.2 EXPERIMENT 2
To investigate the air flow rate and volume discharge of compressor cylinder.
2.3 EXPERIMENT 3
To investigate the compressor indicated power and mechanical efficiency of
compressor.
2.4 EXPERIMENT 4
To investigate the compressor isothermal power and isothermal efficiency.
2.5 EXPERIMENT 5
To investigate the time taken to fully occupied the compressor receiver tank.
3.0 PROCEDURE
3.1 EXPERIMENT 1
1. Connect plug to 1 phase 240V AC power supply
2. Switch on ELCB and main switch on the control panel.
3. Make sure all the meters is showing zero before experiment except
temperature meter. If the meter initial value is not zero set it by press the up
button.
4. Adjust the compressor to desirable speed by the speed controller on the
inverter.
5. Push the run button on the inverter operation panel and ensure that the run key
is light.
6. Record down motor speed (RPM), power (Watt),and torque (Nm) each 30s
time interval
7. The data continuous mark down until the pressure is automatically cut off.
8. Release air in receiver tank before next experiment.
9. Repeat step 3 to 7 by changing the speed of compressor to next desirablespeed.
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10. Plot graph of the pressure against temperature, indicated power against
compressor speed and efficiency of compressor against compressor speed.
3.2 EXPERIMENT 2
1. Connect plug to 1 phase 240V AC power supply
2. Switch on ELCB and main switch on the control panel.
3. Make sure all the meters is showing zero before experiment except temperature
meter. If the meter initial value is not zero set it by press the up button.
4. Adjust the compressor to desirable speed by the speed controller on the
inverter.
5. Push the run button on the inverter operation panel and ensure that the run key
is light.
6. Record down motor speed (RPM), power (Watt), and torque (Nm) each 30s
time interval
7. The data continuous mark down until the pressure is automatically cut off.
8. Release air in receiver tank before next experiment.
9. Repeat step 3 to 7 by changing the speed of compressor to next desirable speed.
10. Plot graph of the pressure against temperature, indicated power against
compressor speed and efficiency of compressor against compressor speed.
3.3 EXPERIMENT 3
1. Connect plug to 1 phase 240V AC power supply
2. Switch on ELCB and main switch on the control panel.
3. Make sure all the meters is showing zero before experiment except
temperature meter. If the meter initial value is not zero set it by press the up
button.
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4. Adjust the compressor to desirable speed by the speed controller on the
inverter.
5. Push the run button on the inverter operation panel and ensure that the run key
is light.
6. Record down the pressure (P 1, P2) motor speed (RPM), power (Watt),and
torque (Nm) each 30s time interval
7. The data continuous mark down until the pressure is automatically cut off.
8. Release air in receiver tank before next experiment.
9. Repeat step 3 to 7 by changing the speed of compressor to next desirable
speed.
10. Plot graph of the pressure against temperature, indicated power against
compressor speed and efficiency of compressor against compressor speed.
3.4 EXPERIMENT 4
1. Connect plug to 1 phase 240V AC power supply
2. Switch on ELCB and main switch on the control panel.
3. Make sure all the meters is showing zero before experiment except
temperature meter. If the meter initial value is not zero set it by press the up
button.
4. Adjust the compressor to desirable speed by the speed controller on the
inverter.
5. Push the run button on the inverter operation panel and ensure that the run key
is light.
6. Record down the pressure (P 1,P2)each 30s time interval
7. The data continuous mark down until the pressure is automatically cut off.
8. Release air in receiver tank before next experiment.9. Repeat step 3 to 7 by changing the speed of compressor to next desirable
speed.
10. Plot graph of the pressure against temperature, indicated power against
compressor speed and efficiency of compressor against compressor speed.
3.5 EXPERIMENT 5
1. Connect plug to 1 phase 240V AC power supply2. Switch on ELCB and main switch on the control panel.
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3. Make sure all the meters is showing zero before experiment except
temperature meter. If the meter initial value is not zero set it by press the up
button.
4. Adjust the compressor to desirable speed by the speed controller on the
inverter.
5. Push the run button on the inverter operation panel and ensure that the run key
is light.
6. Record down the tank pressure (P 1) each 30s time interval
7. The data continuous mark down until the pressure is automatically cut off.
8. Release air in receiver tank before next experiment.
9. Repeat step 3 to 7 by changing the speed of compressor to next desirable
speed.
10. Plot graph of the tank pressure against time (s).
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4.0 RESULTS AND DISCUSSION
Experiment 1
Motor Speed Controller = 10Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
RPM 0 464 442 418 366 218 139 80 40Torque (NM) 0 2.1 2.35 2.52 2.93 3.27 3.93 4.1 4.25Motor Input Power
(kW)0 0.588 0.735 0.818 0.969 1.389 1.322 1.457 1.437
Motor OutputPower (kW)
0 0.108 0.114 0.110 0.112 0.074 0.057 0.034 0.017
Motor Efficiency
(%)0 18.501 15.510 13.486 11.590 5.375 4.327 2.357 1.239
Motor Speed Controller = 20Hz
TimeData
0 30s 60s 90s 120s 150s 180s 210s 240s
RPM 0 987 916 872 898 763 752 749 743
Torque (NM) 0 3.06 3.49 3.97 4.2 4.43 4.7 4.81 4.95
Motor Input Power
(kW)0 0.815 0.941 1.021 1.101 1.183 1.295 1.434 1.394
Motor Output
Power (kW)0 0.33 0.11 0.36 0.40 0.35 0.37 0.38 0.39
Motor Efficiency
(%)0 41.08 12.11 35.51 35.88 29.92 28.58 26.31 27.63
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Motor Speed Controller = 30Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
RPM 0 1507 1450 1406 1361 1323 1277 1232 1200
Torque (NM) 0 3.92 4.47 4.81 5.11 5.34 5.59 5.73 4.95
Motor Input Power
(kW)0 0.999 1.145 1.244 1.332 1.404 1.466 1.589 1.593
Motor Output
Power (kW)0 0.68 0.11 0.71 0.73 0.74 0.75 0.74 0.62
Motor Efficiency
(%) 0 67.95 9.96 56.94 54.68 52.70 51.00 46.53 39.05
Motor Speed Controller = 40Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
RPM 0 1998 1935 1878 1819 1765 1718 - -
Torque (NM) 0 4.61 5.09 5.44 5.75 5.95 6.13 - -Motor Input Power
(kW)0 1.199 1.336 1.447 1.542 1.619 1.681 - -
Motor Output
Power (kW)0 1.03 0.11 1.07 1.10 1.10 1.10 - -
Motor Efficiency
(%)0 86.03 8.53 73.95 71.04 67.94 65.61 - -
Motor Speed Controller = 50Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
RPM 0 2636 2583 2514 2453 2395 2332 - -
Torque (NM) 0 4.22 4.7 5.21 5.59 5.9 6.07 - -
Motor Input Power 0 1.065 1.345 1.307 1.416 1.426 1.506 - -
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(kW)
Motor Output
Power (kW)0 1.27 0.11 1.37 1.44 1.48 1.48 - -
Motor Efficiency(%)
0 119.39 8.48 104.96 101.42 103.78 98.44 - -
As we can see from the graph, the output power increases over time. The output power for
50Hz is higher than the others because of the compressor need lot of energy for running at
speed.
Experiment 2
Motor Speed Controller = 10Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
RPM (motor) 0.00 464.00 442.00 418.00 366.00 218.00 139.00 80.00 40.00RPM (compressor) 0.00 176.78 168.40 159.26 139.45 83.06 52.96 30.48 15.24Air Flow Indicated 0.00 49.50 47.15 44.59 39.04 23.26 14.83 8.53 4.27
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 30 60 90 120 150 180 210
O u t p u t P o w e r
Time
Output Power vs Time
10Hz
20Hz
30Hz
40Hz
50Hz
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Motor Speed Controller = 20Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
RPM (motor) 0 987 916 872 898 763 752 749 743RPM (compressor) 0.00 376.05 349.00 332.23 342.14 290.70 286.51 285.37 283.08Air Flow Indicated 0.00 105.29 97.72 93.02 95.80 81.40 80.22 79.90 79.26
Motor Speed Controller = 30Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
RPM (motor) 0 1507 1450 1406 1361 1323 1277 1232 1200RPM (compressor) 0.00 574.17 552.45 535.69 518.54 504.06 486.54 469.39 457.20Air Flow Indicated 0.00 160.77 154.69 149.99 145.19 141.14 136.23 131.43 128.02
Motor Speed Controller = 40Hz
TimeData
0 30s 60s 90s 120s 150s 180s 210s 240s
RPM (motor) 0 1998 1935 1878 1819 1765 1718 0 1998RPM (compressor) 0.00 761.24 737.24 715.52 693.04 672.47 654.56 0.00 761.24Air Flow Indicated 0.00 213.15 206.43 200.35 194.05 188.29 183.28 0.00 213.15
Motor Speed Controller = 50Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
RPM (motor) 0 2636 2583 2514 2453 2395 2332 - -
RPM (compressor) 0.00 1004.32 984.12 957.83 934.59 912.50 888.49 - -
Air Flow Indicated 0.00 281.21 275.55 268.19 261.69 255.50 248.78 - -
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The pattern of air flow indicator for 10Hz, 20Hz, 30Hz, 40Hz and 50Hz are increasing at the
beginning and slowly decreasing at the end. This is because the compressor need a lot of air
at the beginning to full the tank and when tank are filled the air intake to the compressor
reduce.
Experiment 3
Motor Speed Controller = 10Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
P1 (bar) 0 -0.09 -0.08 -0.06 -0.01 -0.01 -0.01 -0.01 -0.01
P2 (bar) 0 0.4 0.6 0.8 0.8 0.9 1.0 0.8 0.6
RPM0 464 442 418 366 218 139 80 40Torque (Nm) 0 2.1 2.35 2.52 2.93 3.27 3.93 4.1 4.25
Power (kW) 0 0.108 0.114 0.110 0.112 0.074 0.057 0.034 0.017
Indicated Power 0 3.192 7.307 14.393 17.542 10.451 9.100 2.753 0.662
0
50
100
150
200
250
300
0 30 60 90 120 150 180 210
A i r F l o w
I n
d i c a t e
d
Time
Air Flow Indicated vs Time
10Hz
20Hz
30Hz
40Hz
50Hz
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Motor Speed Controller = 20Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
P1 (bar) 0 -0.4 -0.33 -0.31 -0.2 -0.21 -0.17 -0.16 -0.13
P2 (bar) 0 0.9 1.5 2.0 2.5 2.9 3.3 3.7 4.0
RPM 0 987 916 872 898 763 752 749 743
Torque (Nm) 0 3.06 3.49 3.97 4.2 4.43 4.7 4.81 4.95
Power (kW) 0 0.33 0.11 0.36 0.40 0.35 0.37 0.38 0.39
Indicated Power 0.00 47.31 229.73 651.47 1,687.092,738.
454,839.
938,208.
0811,791
.35
Motor Speed Controller = 30Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
P1 (bar) 0 -0.71 -0.64 -0.54 -0.52 -0.43 -0.46 0.41 0.37
P2 (bar) 0 1.5 2.3 3.0 3.7 4.4 5.0 5.6 6.1
RPM 0.00 574.17 552.45 535.69 518.54 504.06 486.54 469.39 457.20Torque (Nm) 0 1507 1450 1406 1361 1323 1277 1232 1200
Power (kW) 0 3.92 4.47 4.81 5.11 5.34 5.59 5.73 4.95
Indicated Power 0.00 247.53 1,210.353,641.
099,841.
4719,194
.9435,544
.5362,644
.8196,232
.12
Motor Speed Controller = 40Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
P1 (bar) 0 -0.104 -0.097 -0.086 -0.080 -0.068 -0.065 - -
P2 (bar) 0 2.5 3.4 4.3 5.2 6.0 6.7 - -
RPM 0 1998 1935 1878 1819 1765 1718 - -
Torque (Nm) 0 4.61 5.09 5.44 5.75 5.95 6.13 - -
Power (kW) 0 1.03 0.11 1.07 1.10 1.10 1.10 - -
Indicated Power0.00
1,854.21
6,765.13
19,613.14
51,655.70
90,781.27
158,333.64 - -
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Motor Speed Controller = 50Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
P1 (bar) 0 -0.154 -0.141 -0.130 -0.120 -0.112 -0.108 - -
P2 (bar) 0 1.6 2.4 3.6 4.6 5.6 6.6 - -
RPM 0 2636 2583 2514 2453 2395 2332 - -
Torque (Nm) 0 4.22 4.7 5.21 5.59 5.9 6.07 - -
Power (kW) 0 1.27 0.11 1.37 1.44 1.48 1.48 - -
Indicated Power 0.00 313.11 1,446.968,401.
9728,084
.9463,820
.87146,40
9.08 - -
For experiment 3 its show that power consumption increasing with time increase. Its because
single air compressor need high power to generate the compress air inside the tank. The
higher the Hz the higher power need.
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
0 50 100 150 200
I n d i c a t e
d P o w e r
Time
Indicated Power vs Time
10 Hz
20Hz
30Hz
40Hz
50Hz
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Experiment 4
Motor Speed Controller = 10Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
T1 (C) 0 38.0 38.7 39.2 39.4 38.7 37.6 37.3 37.2
P1 (bar) 0 -0.09 -0.08 -0.06 -0.01 -0.01 -0.01 -0.01 -0.01
P2 (bar) 0 0.4 0.6 0.8 0.8 0.9 1.0 0.8 0.6
RPM 0 464 442 418 366 218 139 80 40Torque (Nm) 0 2.1 2.35 2.52 2.93 3.27 3.93 4.1 4.25
Motor Speed Controller = 20Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
T1 (C) 0 44.2 47.2 49.6 51.7 53.7 55.6 57.2 58.7
P1 (bar) 0 -0.09 -0.08 -0.06 -0.01 -0.01 -0.01 -0.01 -0.01
P2 (bar) 0 0.4 0.6 0.8 0.8 0.9 1.0 0.8 0.6
RPM 0 448 428 378 244 54 164 170 25
Torque (Nm) 0 1.70 2.10 2.47 3.49 3.50 3.57 3.58 3.71
Motor Speed Controller = 30Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
T1 (C) 0 63.6 68.6 73.2 77.2 80.6 83.6 86.3 88.4
P1 (bar) 0 -0.76 -0.67 -0.61 -0.52 -0.52 -0.41 -0.44 -0.39
P2 (bar) 0 1.2 2.0 2.8 3.5 4.1 4.8 5.3 5.9
RPM 0 1538 1468 1420 1370 1326 1280 1235 1185
Torque (Nm) 0 3.51 4.11 4.50 4.85 5.06 5.30 5.52 5.66
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Motor Speed Controller = 40Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
T1 (C) 0 90.4 95.9 100.3 104.3 107.9 110.9 - -
P1 (bar) 0 -0.76 -0.67 -0.61 -0.52 -0.52 -0.41 - -
P2 (bar) 0 1.2 2.0 2.8 3.5 4.1 4.8 - -
RPM 0 1538 1468 1420 1370 1326 1280 - -
Torque (Nm) 0 3.51 4.11 4.50 4.85 5.06 5.30 - -
Motor Speed Controller = 50Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
T1 (C) 0 91.1 97.1 104.2 110.5 116.0 121.4 - -
P1 (bar) 0 -1.51 -1.37 -1.29 -1.19 -1.11 -1.00 - -
P2 (bar) 0 1.61 2.70 3.80 4.90 5.80 6.80 - -
RPM 0 2625 2552 2487 2430 2368 2306 - -
Torque (Nm) 0 4.17 4.83 5.26 5.62 5.86 6.05 - -
Experiment 5 show that torque increase when time increase. As rotational motion increases,
the amount of friction and constraints on the materials. If torque were to increases linearly,
0
1
2
3
4
5
6
7
0 50 100 150 200
T o r q u e
Time
Torque vs Time
10Hz
20Hz
30Hz
40Hz
50Hz
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the amount of the friction would also increase, and depending on the amount of friction/heat
the materials could take, would eventually cause a breakdown.
Experiment 5
Motor Speed Controller = 10Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
Pt (bar) 0 0.10 0.40 0.80 1.00 1.10 1.18 1.19 1.20
Motor Speed Controller = 20Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
Pt (bar) 0 0.85 1.55 1.90 2.70 3.40 4.00 4.60 5.25
Motor Speed Controller = 30Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
Pt (bar) 0 1.15 2.05 2.80 3.60 4.40 5.00 5.60 6.25
Motor Speed Controller = 40Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
Pt (bar) 0 1.30 2.55 3.50 4.60 5.30 6.30 - -
Motor Speed Controller = 50Hz
Time
Data0 30s 60s 90s 120s 150s 180s 210s 240s
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Pt (bar) 0 1.60 2.90 4.10 5.20 6.20 7.30 - -
For experiment 5 the pressure increase with increase of time. To compress air inside the tank
need pressure so to achieve desire amount of air compressor pressure will increase until its
full fill the quantity its need.
5.0 CONCLUSION
In this experiment we learn that the relationship between the RPM, motor output
power, air flow rate and volume discharge of compressor cylinder, mechanical efficiencyof compressor, compressor isothermal power and isothermal efficiency and time taken to
fully occupied the compressor receiver tank. We also learn how to operate the
compressor and its safety and precaution steps.
0
2
4
6
8
0 50 100 150 200
T a n
k P r e s s u r e
Time
Tank Pressure vs Time
10Hz
20Hz
30Hz
40Hz
50Hz