Reciprocating Air Compressors Research Articles

Prediction of air compressor faults with feature fusion and machine learning

Air compressors are critical for many industries, but early detection of faults is crucial for keeping them running smoothly and minimizing maintenance costs. This contribution investigates the use of predictive machine learning models and feature fusion to diagnose faults in single-acting, single-stage reciprocating air compressors. Vibration signals acquired under healthy and different faulty conditions (inlet valve fluttering, outlet valve fluttering, inlet-outlet valve fluttering, and check valve fault) serve as the study’s input data. Diverse features including statistical attributes, histogram data, and auto-regressive moving average (ARMA) coefficients are extracted from the vibration signals. To identify the most relevant features, the J48 decision tree algorithm is employed. Five lazy classifiers viz. k-nearest neighbor (kNN), K-star, local kNN, locally weighted learning (LWL), and random subspace ensemble K-nearest neighbors (RseslibKnn) are then used for fault classification, each applied to the individual feature sets. The classifiers achieve commendable accuracy, ranging from 85.33% (K-star and local kNN) to 96.00% (RseslibKnn) for individual features. However, the true innovation lies in feature fusion. Combining the three feature types, statistical, histogram, and ARMA, significantly improves accuracy. When local kNN is used with fused features, the model achieves a remarkable 100% classification accuracy, demonstrating the effectiveness of this approach for reliable fault diagnosis in air compressors.

Software Of Air Compressor Calculator

This paper proposes the development of software using HTML used in reciprocating air compressor studies in the undergraduate level of engineering students. This software helps the students understand the different types and different factors associated with reciprocating air compressors. A small study was conducted to merge coding with mechanical engineering problems. The data of different types of reciprocating air compressors are collected and layouts of these types are generated using HTML. The layout is then programmed with the expressions collected for reciprocating air compressors. This software enables the user to understand the overall aspects of the Air compressor and all its related parameters. Ultimately, this project seeks to empower the students to understand the different parameters of different types of reciprocating air compressors by providing a seamless and intuitive software experience. Key Words: software, reciprocating, compressor, layout, data, volumetric efficiency.

LSTM-AE based condition monitoring for reciprocating air compressors considering on/off characteristics

LSTM-AE based condition monitoring for reciprocating air compressors considering on/off characteristics

Detailed tribological analysis of compressor lubricants used in electrical technology

AbstractThis work presents a comprehensive tribological analysis comparing the performance of two types of lubricants—a synthetic and a natural ester—used in industrial reciprocating air compressors. A comprehensive tribological analysis comparing the performance of two types of lubricants—synthetic and natural esters—used in industrial reciprocating air compressors were carried out using surface characterisation methods and lubricant analyses. The formed and detected tribo‐films were not efficient to avoid the wear observed on the cylinders, although they may have been to avoid the wear on the rings. Regarding the lubricant analyses, particle analysis showed that none of the lubricants favoured solid particle leaching to a greater extent. A biolubricant such as the one employed in this study would be suitable for replacing a mineral lubricant in situations like the ones observed in this work.

The Survey on Reciprocating Gas Compressor: A Review

Abstract— This paper represent the survey on reciprocating gas compressor and there effects on different location whether it is onshore or offshore. Reciprocating air compressors are the foremost ordinarily used compressor for domestic and industrial functions. These papers also investigate the improving volumetric efficiency of two stage reciprocating gas compressor by providing IC Tube bundle and cooling system. These surveys perform the experiments of a two-stage with double-cylinder reciprocating gas compressor system with gas and different cooling systems were performed. This study develops a higher understanding on the impact of honing within the cylinder that reduces the surface roughness within the cylinder and ends up in bigger air output. In these review paper there are various things that are considered for designing the cylinder for the purpose of compressing the gas in differential uses. In these review the effecton reciprocating is seen whether it is steady state or in a thermal state conditions, so to get this results they have done assessments on various conditions and for various purpose. The aim of these survey papers is to define the proper way of research done on reciprocating compressor i.e. the research paper data, methodology, verification and validation, the way of results and discussion of various assessments test, etc. These paper mainly focus on the positive displacement compressor and that of the sub part is reciprocating gas compressor and their design, modelling, analysis and development i.e. from raw stage to the final stage of reciprocating gas compressor. From these survey we also find the whole process of reciprocating gas compressor and there future scope. Keywords— Reciprocating Gas Compressor, Honing, Two Stage Cylinder, Cooling, Volumetric efficiency

Development of an Optimized Rotary Screw Air Compressor for the Electrical Vehicle Air Brake Systems/Suspension Systems on Trucks and Buses

<div class="section abstract"><div class="htmlview paragraph">Air brake systems and their reciprocating air compressors are incumbent, legislated, and mature technologies integral to commercial trucks and especially the Class 8 Diesel Semi-Truck industry. The introduction of the Class 8 Electric-Semi Truck (electric-semi) will displace diesel driven trucks over time. The air brake systems and the requirement for an air compressor will not be displaced for the foreseeable future and the requirements will be inherited by the new electric-semi industry. The industry shall have to work hard to optimize the air compressor for this new electric platform that demands high energy density, high efficiency, low mass, excellent NVH management, small space claim, high levels of durability and reliability, low and easy maintenance over a life of 20 years. As with all systems on an electric-semi truck the benefits must be delivered with the best-in-class total cost of ownership to ensure fleet customers’ switching costs are low and their investment has a rapid payback.</div><div class="htmlview paragraph">Reciprocating compressors traditionally used in this market are not optimized for these new requirements. Alternative compressor technologies will be adopted, such as rotary screw, scroll, rotary vane, or possibly other technologies may replace piston compressor technology completely as part of the electrification of semi-trucks. Successful compressors in the electric-semi market can be expected to deliver solutions to the electric bus markets too if they have the capability of being highly reliable at very high duty cycles.</div><div class="htmlview paragraph">Each of the compressor technologies weak points must be addressed to the extent possible and must be designed specifically for the application by the technology specialists in order to compete in this market.</div><div class="htmlview paragraph">“The Company” has 35 years’ experience developing, manufacturing, and supporting their rotary screw technology on mobile platforms globally. “The Company” has taken on the challenge of developing an EV screw compressor solution for the electric-semi and bus application.</div><div class="htmlview paragraph">Based upon potential commercial electric-semi manufacturer demands the author analyzes the inherent advantages and disadvantages of different compressor technologies, their working boundary conditions and creates the basic technology specifications to meet the air deliver rate and discharge pressure requirements. Screw compressor technology has a reputation of high reliability, high energy efficiency and it is suited for extreme climatic conditions. It will be one potential candidate for electric-semi air brake systems. The primary design output requirements are considered to be 354 LPM (liter per minutes) or 12.5 CFM (cube feet per minutes) with discharge pressure range 1.02~1.36 MPa or 150~200 PSI. This broad air and pressure range is possible due to the characteristic of the screw compressor air deliver/RPM curve being flat.</div><div class="htmlview paragraph">This paper describes the unique approach “THE COMPANY” has taken to optimize rotary screw compressor technology to deliver the performance required by electric-semi’s and electric buses. This development introduces a single stage rotary screw technology into the mini-compressor world for a high air pressure application. The product is currently being prepared for low - medium volume production with high volume production potential in 2022. The performance and unique technology features as they pertain to the electric-semi market are described in this paper. “THE COMPANY” has verified that dramatically decreasing the size of the rotary screw technology addresses the high efficiency, size, mass, space claim, and reliability for this new application.</div></div>

A review on study of an air compressor

A device that converts mechanical energy into pneumatic energy is known as an air compressor. There are many distinct types of compressors, each with its own set of functioning principles and operating conditions. All have the same purpose: to extract air from the atmosphere and produce greater pressure air for various applications. The current paper provides a brief overview of an air compressor and its applications, as well as overhauling, condition monitoring, and maintenance programs for two-stage reciprocating air compressors, as well as a brief overview of recent developments in compressed-air vehicles, compressed-air engine and power source development, and the effect of temperature on moisture separation in air compressors. In the development of the industry, air separation is particularly significant. And there's the air compressor, which produces not only the necessary air but also the necessary pressure. Refrigeration and cooling equipment require high-pressure air. Plant, as well as the raw materials needed for separation a major device in an air separation plant is the plant. A case study was conducted on a locomotive compressor to improve performance and the development of a two-stage reciprocating air compressor.

Vibration Based Fault Monitoring of a Compressor using Tree-based Algorithms

Reciprocating air compressors are used as a part of manufacturing and engineering industries to offer pressurized air, which is utilized for different productive purposes. Compressors are trusted upon to be prepared and readily available as and when required and any interim stoppage or interruption will affect the manufacturing processes that are dependent on compressed air. From the reports of any maintenance engineer, one can find that in a reciprocating air compressor, components like bearings, valve blade, V-belt and piston rings add to a more noteworthy level of failure. Researchers do make attempts to find a suitable device that is profoundly welcome by the industry, for diagnosis of the fault that recommends a remedial action. Towards this direction, a study was attempted and vibration signals were collected from an experimental setup under supervised learning technique. Statistical features of the same were extracted for various combinations of fault conditions and analyzed using different tree-based algorithms with an intention to find the best one that will classify the fault with more accuracy and with the least computational time.

Experimental investigation on the extreme cold start-up of an air compressor for electric heavy vehicles

Engine-driven reciprocating air compressors are employed on fuel-powered heavy vehicles to actuate a number of auxiliary systems, like brakes and suspensions. Electrically-driven sliding-vane air compressors turn particularly suited for electric heavy vehicles. Unlike in fuel-powered vehicles, the compressor is not heated up in the case of electric mobility, a situation that may lead to potential issues in extreme cold weathers. This paper investigates experimentally the start-up of a sliding-vane air compressor designed specifically for electric heavy vehicles. The compressors, equipped with instruments, is positioned in a climatic chamber. During the tests, the chamber is set to a desired ambient temperature, 0, -10, -20, - 30 °C or 20 °C taken as reference following ISO 1217, and the compressor is started-up when a steady-state initial condition is achieved. The delivery pressure is controlled at 10 bar(g) and all measurements are recorded until a temperature of 80 °C is reached in the air-lube oil separator. No issues are encountered during the tests, such as sudden damage due to improper lubrication. Moreover, the curves of the measured temperature within the air-lube oil separator show similar trends but higher initial plateaus and lower slopes at lower ambient temperatures resulting into lower oil flow rates, higher energy spent for heating up the system as well as higher warm-up times, from 15 minutes at 20 °C up to 69 minutes at -30 °C.

Synthesis and tribological investigation of compressor’s linertribo pair material under the influence of biodegradable compressor oil

The present investigation is intended to synthesis biodegradable compressor oil for reciprocating air compressors and analyses the tribological behavior of liner-ring tribo pair material under the influence of new formulations. A pin-on-disc tribometer was used to perform the tribological investigations. EN 31 steel and EN-JL 1020 was selected as disc and pin material, respectively. An ultrasonication based transesterification process was used to formulate a biodegradable compressor oil. TGA and DSC analysis was performed to examine the thermos-oxidative stability of compressor oil. The newly formulated bio compressor oil showed better tribological parameters in terms of coefficient of friction, wear and specific wear rate as compared with SAE 30 grade compressor oil. SEM and EDAX analysis of testing pin surfaces proved that the worn surfaces were smooth with bio compressor oil.

Design, Modification and Analysis of Industrial Air Compressor (Type: Vt4): A Review

This paper presents a review on how important the intercooling of air compressor is necessary for an efficient process. Basically the meaning of air compression is to reduce a specified volume, resulting in an increase in pressure. For improving efficiency of the system compression is done in more than one stage and between each stage intercooler is provided. Intercooler improves the quality of air and reduces inlet air temperature. The function of the intercooler is to cool the air as it leaves the Low Pressure cylinder and before it enters the High Pressure cylinder. This improves the efficiency of the compressor and ensures that the temperature of the air receiver outlet valves is just right for optimum operation of the tools connected to the compressor. The cooler is composed of sheet metal plate elements or tabular core. Type VT4 compressor is a Two Stage Reciprocating Air Compressors which is most widely used for Industrial Purpose. This paper highlights the various efforts of the various researchers. On the basis of various researches it is proposed that the change in size of intercooler will avoid heating in High Pressure Cylinder during long run.

Intelligent Condition Based Monitoring Using Acoustic Signals for Air Compressors

Intelligent fault diagnosis of machines for early recognition of faults saves industry from heavy losses occurring due to machine breakdowns. This paper proposes a process with a generic data mining model that can be used for developing acoustic signal-based fault diagnosis systems for reciprocating air compressors. The process includes details of data acquisition, sensitive position analysis for deciding suitable sensor locations, signal pre-processing, feature extraction, feature selection, and a classification approach. This process was validated by developing a real time fault diagnosis system on a reciprocating type air compressor having 8 designated states, including one healthy state, and 7 faulty states. The system was able to accurately detect all the faults by analyzing acoustic recordings taken from just a single position. Additionally, thorough analysis has been presented where performance of the system is compared while varying feature selection techniques, the number of selected features, and multiclass decomposition algorithms meant for binary classifiers.

Measurement of reed valve kinematics

The measurement of key kinematic parameters of a reed valve movement is necessary for the further development of the reed valve system. These parameters are dependent on the geometry and material properties of the valve. As they directly affect the quantity of air flowing around the valve, a simple and easy to implement measurement of various valve configuration based on the air flow has been devised and is described in this paper, along with its technical parameters and drawbacks when evaluating reed valves used in reciprocating air compressors. Results are presented for a specimen of a compressor under examination. All kinematic parameters, and timing of the opening and closing of the valve, obtained from the measurement are presented and discussed.

Design considerations of Gudgeon pin in reciprocating air compressors by semi analytic approach

The deformation and stress experienced by the Gudgeon pin of a reciprocating compressor used in air brake system is scientifically predicted when the pin is fully floating with lubricating oil surrounding it and when starved of oil. Both semi analytical approach in finite element method and simple bending theory of beams are used. Inadequacy of the beam approach is highlighted. The results obtained by both the approaches are compared. Role of clearance in piston bore and small end of connecting rod and effectiveness of lubrication are examined. Factor of safety associated with the design of Gudgeon pin is also looked into. Key words: Gudgeon pin, semi and fully floating pin, semi analytic method, role of lubricant, factor of safety

Experimental validation of a mathematical model of a reed-valve reciprocating air compressor from an automotive-braking system

Mathematical simulation is the process of designing a model of a real system and then conducting experiments with the simulation to understand the system’s behavior. Mathematical simulation is widely used for investigating and designing compressors, and with a minimal number of simplifying assumptions, mathematical models can be used in conjunction with modern computing tools to solve complicated problems. A considerable amount of previous research has focused on the mathematical modeling of reciprocating air compressors used in automotive braking. The aim of the present work was to experimentally validate the mathematical model for such compressors. We present a simplified and effective mathematical model for estimating compressor performance, and this model can easily be executed using personal computers. Parameters such as compressor speed, discharge pressure and clearance volume were evaluated in terms of their effect on the thermodynamic behavior of compressors. The model can predict cylinder pressure, cylinder volume, cylinder temperature, valve lift and resultant torque at different crank angles; it can also predict the free air delivered and the indicated power of the compressor. Therefore, the model has been validated using experimental results.

이단 왕복동 공기압축기 구조에 따른 관성력 비교

For the purpose of high outlet pressure, compactness and low vibration and noise, 2 stage reciprocating air compressors can have various cylinder arrangement: opposed, in-line, and V type. This paper presents an effective method to calculate the inertia forces and to design counter weight. This method is based on the complex representation for the orbital behavior of the compressor shaft. This method helps to find the optimal balancing rate easily to reduce the inertial force or moment. This paper shows that the residual inertia forces of the single throw shafts and the residual inertia moments of the double throw shafts remain to be imbalanced.

Comprehensive evaluation of compressor oils by laboratory methods

The present work has been aimed at a comprehensive investigation of the carbon deposition, antioxidant, anticorrosion, and antiwear properties of a number of compressor oils, and at establishing a correlation between the results obtained in evaluations of high-temperature properties by different methods. The basic physicochemical properties and group compositions of the test oils are shown, which includes oils for reciprocating air compressors and other oils. Results are presented which were obtained in determinations of the carbon deposition tendency of compressor oils by two methods, the test-stand method and the laboratory method. Results are also shown from evaluations of the lubricity of the compressor oils and their anticorrosion properties at high temperature. The greatest viscosity increase is observed for the oil from medium-sulfur crudes with a high content of aromatic hydrocarbons, the smallest viscosity increase for oils with a naphthemic-paraffinic base.

Pressure Pulsations in pipe Systems with Multiple Reciprocating air Compressors and Receivers

A modified non-steady one-dimensional homentropic theory is used to predict the pressure pulsations in pipe systems with multiple reciprocating compressors and receivers. Allowance is made for heat losses in the pipes by correcting the pipe lengths. Receivers are simulated by neglecting the lengthwise wave action and using the generalized non-steady flow energy equation. An extensive test programme is described with one, two and three compressors in pipe systems with a single receiver. Different receiver sizes are used and tests are carried out with the compressors in phase and out of phase. The experiments show that the correction for heat losses may be obtained from a single test with a simple single pipe compressor system. This correction can be applied to all the subsequent complex systems. The experiments showed excellent agreement between the predicted and measured pressure wave amplitudes, frequency and phase relations but the mass flow predictions may be in error from 2 to 14 per cent high. The methods offer an accurate method of predicting pressure pulsations and valve movement in multicycle compressor pipe and receiver systems.

Paper 10: Lubrication of Air Compressors

There is an increasing use of pneumatic equipment in production and process industries and reliability of equipment in these industries is of paramount importance. The failure of an air compressor due to deficiencies in the lubricant can be very costly. In this paper important aspects of lubricant performance are discussed. The differences between the requirements of lubricants for rotary oil-cooled air compressors and for reciprocating air compressors are highlighted. Some of the requirements are conflicting and can cause problems if an oil is used in a type of compressor for which it is not designed. Mechanisms by which oil can cause failures are analysed. Some of the failures are common to certain types of compressor. Guidance is given which can reduce the risks of failures. This includes both design and operating instructions. Finally, full-scale methods of test for rotary oil-cooled and reciprocating air compressors are given, including a test method for very high-pressure reciprocating compressors; typical test results are supplied.