How to increase the output of the compressor
The main thing to keep in mind when choosing a compressor. there is no “one size fits all. Choose the equipment you need for the job and the amount of work to be done.
We have already touched on the choice of compressors in the context of the choice of spray guns. In this article we want to tell you how to choose a compressor that will best meet the conditions of operation and at the same time have a reasonable price. We do not try to sell you “whatever” but at a higher price. Our goal is to provide you with quality equipment that will fully meet your requirements and expectations.
We will choose the compressor by the example of equipment with one oil-cooled cylinder. This approach can also be applied to the choice of a professional belt drive compressor.
In the vast majority of cases a compressor with a capacity of 1.1-1.8 kW, compressor tank capacity of 24-25 liters, 8 bar pressure and capacity of 206 l / min is quite enough. If you want, you can buy a compressor in a store of the same type only with a receiver for 50 liters, and the other parameters will remain the same.The cost of such a compressor will range from 140 to 220 U.S. dollars.
Basic selection criteria
Air receiver volume. Low-priced compressors have an index in the range of 24-50 liters. The equipment with a large air receiver (100, 200, 500 liters) is used where there are frequent power failures or there is a risk of prolonged idle time of the equipment. The compressor principle is as follows: The air receiver ensures the accumulation of air and thus the creation of the required outlet pressure. For example, during operation, the electricity supply is cut off and the air supply in the large air reservoir is quite enough for a longer period of operation than in models with a small air reservoir. In addition, to buy a compressor in an online store with a large air reservoir makes sense when the equipment is turned on several times a day for a short time and delivers small portions of air. In this case, the available air supply is sufficient not to have to run the engine every time. Most models have a threaded connector for a larger capacity tank or cylinder.
Engine output. Average compressor motor power is 1.1-1.3 kW. But there are also some models where fantastic power is claimed. This is not true and is done solely to increase sales. There were cases when with a declared capacity of 600 liters per minute in practice the compressor could barely cope with 250 liters.
Pressure. A vast majority of compressors have a maximum working pressure of 8 bars. When this level is reached, the automatic system switches the compressor off and when the pressure drops to 6 bar, it switches it on again and pumps up the missing volume. The more expensive models may have the maximum threshold at 10 bars and higher.
Efficiency (liters per minute) is the main criterion for choosing a compressor. To determine the optimum efficiency you need to determine the level of air consumption of your compressed air tool. This data can be taken from the instructions of the equipment. Please note, however, that the manufacturer usually indicates flow rate at the inlet, which is approximately 1/3 higher than at the outlet of the receiver. Losses at the outlet are about 35%. So for an input capacity of 206 l/min we get 206 l/min 0,65 = 133,9 l/min. The real capacity will differ dramatically from the declared one and will be 133,9 l/min.
So, when choosing a compressor for performance, you should determine the air consumption of pneumatic tools and buy the equipment with a margin of performance of 30-30% for domestic pneumatic tools and 35-40%. for imported.
The internal utilization factor CVI. The higher the value of this parameter, the longer the device is able to work without stopping. The TCC is 0.15 for intermittent duty, 0.75 for continuous duty and 0.5 for intermittent duty.
With one or more cylinders. they can be oil- or oil-free. Oil-less units can work less continuously compared to oil-less units but are often used in places where you need clean air without oil particles in compressed air, such as dentistry, but clean air can be achieved with the help of modern air treatment means. filters, dehumidifiers, air treatment units. The choice of oil-free compressor is left to the discretion of the customer.
With belt drive or regular transmission. belt drive relieves the motor significantly during compressor operation and allows greater output, but this design is more bulky and heavy. Selected already for professional use with considerable loads.
Screw-type compressors are an industrial type of compressor with impressive capacity. Based on a completely different air compression principle which gives significant output results. Screw-type compressors are capable of supplying compressed air to entire production halls. Many of them have a capacity measured in tens of thousands of liters per minute.
If the need for a fragmented compressed air supply arises, consider a reciprocating air compressor. For long-term operation, it is better to choose a device with a continuous cycle of compressed air supply. a screw unit. Such a unit is already industrial and costs a fortune, but with it you will forget about the lack of productivity. However, it is better not to use it for fragmented supply, because the screw unit needs to provide a certain temperature condition of the compressor unit.
Particular attention should be paid to what will feed your compressor. As a rule, you have to choose between one- and three-phase versions. For work in conditions where there is no possibility to connect to the electricity grid, use a compressor running on an internal combustion engine. There is also mobile equipment consisting of a compressor, an electric generator, a welder. For domestic use (garage, small workshop) equipment with capacity up to 350 l/min is quite enough.
Compressor choice for paint sprayer
The average consumption of a paint sprayer is 185-220 l/min. If you take a compressor with a claimed capacity of 206 l/min (the real 133.9 l/min), the air shortage will be 50 l/min or more. This will provoke a drop in pressure in the receiver, especially if the engine will run nonstop. As the result it will be possible to work with the sprayer for 1-2 minutes and then it will be necessary to wait until the compressor pumps the required volume and the air pressure is restored. Operating pressure requirements are different for different spraygun models (LVLP from 2 bar, HVLP up to 3-4 bar, HP up to 5-6 bar). Operating equipment under these conditions will not only make the spray gun inadequate, but will also cause the compressor motor to overheat or seize. And such a breakdown under the category of warranty does not fall into the category of the, so the service is unlikely to repair the compressor at no charge.
Here is a simple calculation to help you choose a compressor. The difference between the input capacity listed in the manual and the actual output capacity of the equipment:
400 l/min at 0,65 inlet = 260 l/min at outlet
600 l/min at the inlet 0,65 = 390 l/min at the outlet
900 l/min at 0,65 inlet = 585 l min at outlet
1400 l/min at 0,65 inlet = 910 l/min outflow
And considering the fact that not only the paint sprayer can be connected to the compressor, but also other equipment (hydraulics, blow-offs, swaps, tire changers, etc.), the compressor can also be connected to the evaporator.When selecting the unit, the possible total air consumption of the units to be connected at the same time (e.g. several persons in a workshop) must be taken into account.).
Conclusion: It is necessary to choose the compressor with care and not to forget that dishonest sellers at times are ready to “push” anything they like and often are not able to determine how this or that model meets the requirements of the buyer.
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Capillary tube installed between condenser and evaporator. Liquid refrigerant enters the tube under condensing pressure. As the refrigerant flows through the tube, its pressure gradually decreases and at the outlet of the tube corresponds to the pressure of boiling refrigerant in the evaporator. If the capillary tube sizes for a given compressor are accurately sized, then all of the liquid refrigerant entering the evaporator will be sucked out by the compressor and the refrigeration unit will operate with the greatest efficiency. But this will only be the case at certain condensing and boiling pressures of the refrigerant, i.e.е. at certain operating temperature conditions of the refrigeration unit. As the condensing and boiling pressures change, t.е. as the temperature conditions change, the efficiency of the unit will decrease. This is because the pattern of changes in compressor capacity and capillary tube capacity will not be the same with changes in condensing and boiling pressures. Let’s consider what will happen if these conditions change. The temperature of the ambient air will increase the condensing pressure, from. with change of condensing and boiling pressures and thus compressor efficiency would decrease (high discharge backpressure) and capillary capacity would increase. If the compressor capacity is reduced, it will suck less refrigerant from the evaporator, which will lead to overfilling of the evaporator. At the same time, of. Because of worsened condensing conditions, vapor bubbles will enter the capillary tube and evaporator along with the liquid refrigerant. An excess of liquid refrigerant in the evaporator and the vapor bubbles will cause an increase of pressure in the evaporator which will increase the capacity of the compressor. The presence of vapor bubbles in the condenser will cause inhibition of liquid refrigerant flow when it enters and reduction of capillary capacity. Thus, after some time of operation of the unit at a higher ambient temperature, the compressor capacity and the capillary tube capacity will be matched again, but the unit will become less efficient. LIFTING THE TEMPERATURE of the ambient air will reduce the condensing pressure and consequently reduce the capillary capacity and increase the compressor capacity. The compressor will draw more refrigerant from the evaporator and into the condenser than the capillary can take in. The condenser will begin to fill with excess liquid refrigerant, thus reducing its heat transfer surface and increasing the condensing pressure. The lack of refrigerant in the evaporator, however, will cause a drop in evaporating pressure from. Thus, the compressor capacity will decrease and the capillary capacity will increase. Consequently, also under conditions of reduced ambient air temperature, the compressor capacity and capillary capacity will also be matched after some time of operation of the unit and the efficiency of this refrigeration unit will deteriorate. It follows that the optimum cooling capacity of the capillary unit can only be obtained under certain calculated conditions. In all other cases, the adjustment of the evaporator coil will be accompanied by a corresponding loss of refrigerating capacity. BENEFITS OF CAPILLARY TUBES. Capillary tubes have the following advantages over other chokes (such as thermostatic expansion valves). simplicity of design;. No moving parts;. reliability in operation. There is also a capillary tube. Connecting the discharge and suction sides, it equalizes the pressure in the system when the unit is stopped (Fig. 3.17).
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Moisture in the Hermetic Refrigerator The main source of formation of the majority of impurities and contaminants in the working environment is moisture. In this connection, according to the requirements of modern technology for assembling sealed units in the process of manufacturing or repair, the moisture concentration in the internal system should not be exceeded
Failures of domestic refrigerators caused by clogged capillary tubes (CCs) were almost never observed until recently. These were isolated cases, having in their basis “mechanical” nature (small metal chips, etc.).). Entrained by the flow of refrigerant, these particles
This value describes the power of the compressed air produced and maintained by the compressor in the receiver. Working pressure with capacity affects the compatibility of the compressor with the air tool. Unit of measure. bar. Too little pressure will make the connected equipment impossible to operate, too much pressure will result in equipment breakdown.
The working pressure determines the class of the compressor:
The optimal choice for home use is a compressor with a pressure of 8-10 bar. This pressure is sufficient for household pneumatic tools, including airbrush guns and impact wrenches.
Important: In practice, the actual compressed air pressure, which gives the compressor, less than the stated parameter by 2 bars. So choose a model with this difference in mind.
When buying a compressor, start with the specifics of the tools you are going to work with. Some machines need high pressure and relatively low air consumption, and other machines use a lot of air but make do with low pressure.
How to set up the compressor for automatic switching on?
This feature works on air compressors by default. Piston compressors have intermittent operation. The motor turns on automatically and actuates the discharge pistons when you need to pump air into the receiver. Once the set pressure in the pneumatic system has been reached, the unit turns off.
Controls the mode of the compression relay (pressostat). This device gives control command to the motor when pressure in the pneumatic system reaches a predetermined value. When the maximum is reached, the relay actuates to disconnect the motor. the pumping stops. When the compression ratio drops to a preset minimum, the pressostat switches on the electric motor to pump air into the system.
The question of setting it to automatic is if there is a problem with the pressure switch. Usually it’s not a question of getting the motor to turn on at all. It is often necessary to set the automatic activation at the desired degree of compression of the medium.
How to increase the power of an aquarium compressor?
There is an aquarium compressor ViaAqua VA-A2500, 220V, 3W.Converted to vacuum pincer by rearranging the valves on the opposite side.It works. And it even holds what it wants. Circuits, processors and computer bridges.Enough power to lift a regular 220V, 75W bulb.
In general, everything seems to be fine, but when you try to take off the motherboard solder IR bridge, it does not have enough power.The forces of surface attraction of solder hold the chip so that it has to be undermined with a toothpick, only then the vacuum tweezers are able to grasp, hold and lift it.
It turns out that the hot chip compressor can not lift. Maybe because of the decrease in hot air density?Is it possible to somehow increase the power of this compressor or look for/buy another, more powerful?
It is not possible to apply resonance because of too high resistance of the winding. 15Kohm.By the way, the inductance of the compressor winding is 33Gn.
Maybe rewind the winding with a thicker wire. As much as you can fit and pick up the voltage?Or just power it with higher voltage, for example,
I have a HANDI-VAC kit, t. н. Vacuum tweezers with a set of suction cups from 3 to 12 mm in diameter. The breakout force depends on the suction cup, and there is only one vacuum source. A small spongy conductive rubber bulb. IMHO, increasing the power of the compressor (within reasonable limits), the problem can not solve.
First, pay attention to the tightness of the suction cup edges. For the experiment, it is possible to smear the edges of the suction cup with silicone sealant and press it against a smooth surface (plexiglass wiped with silicone oil, or Teflon. Don’t use glass), let the sealant harden. Silicone is elastic and heat resistant Better, use Vixint (silicone and hardener).
Second, use as much suction cup as possible.
Third, in any compressor, the valves are designed for a certain pressure difference. Maybe when the chip comes off, the valve is leaking. Try replacing the valve diaphragm with a stiffer one
DWD: Converted to vacuum tweezers by rearranging the valvesThe thing is, the compressor is designed for discharge. and you need a vacuum. A simple rearrangement of suction and discharge solves 50-70% of the problems.You have to disassemble the pump heads themselves and unscrew them backwards.
I see. Then you need to look for another compressor, a more powerful one.
So far I’ve decided to reduce the number of turns on the coil. And while stripping the insulation managed to tear the winding wire. Law of fate. Internal.Had to rewind completely.
The original winding was wound with 0.04mm wire.Wound a new one with 0.12mm wire until it fills the frame. I got 3,000 turns.The winding resistance is 330 Ohm.
Armature stroke used to be about 5mm. Now. about 10mm. And even then, it’s limited purely mechanically. And the “roar” became louder, because the anchor began to hit the rubber stop.
The power has increased. If before I could not tear my cell phone off the table, now it is completely lifted by one side. True, you can only grab the side of the screen (where the surface is smooth), that is, with a skew and the suction cup slides to the edge of the mobile. And reaching it. comes off. I think if I could grasp the center of gravity, I would lift it fully.
One bad thing. It heats up a lot. You can’t hold it for more than a minute, or the tape on the winding will start to float.You have to limit the tension somehow.And this will reduce the force.
Boris Paramonov: The thing is, the compressor is designed to pressurize. And you need a vacuum1 For the pump to pump (and even to pump) well, you have to minimize the “stray” volumes inside the head. When I did a similar compressor redesign, I filled the gut under the diaphragm with epoxy in the form of plasticine and pressed the diaphragm to it. Holes for valves, of course, provided. The result is. 0.5 atm discharge,
Experiments. it’s good, but you need to work and you can’t plug the compressor directly into the mains.
That’s why I tried to limit the voltage of the compressor somehow.The condenser did not work, because too much capacitance is needed.
Decided to use a choke.I took an ordinary power adapter from the switch (7.5V, 1A) and switched the primary of its transformer in series with the compressor, and the secondary switched. It turned out something like a magnetic amplifier. At first I wanted to put a variable resistor on the secondary winding. I was fine tuning the 10 ohm wire, but then I changed my mind and just shorted the secondary. The main thing is. Works for now, and in the meantime will look for something initially more powerful.
With the “limiter”, the compressor voltage is 98V and it is less warm. It takes a few minutes before the smell of burnt insulation appears, and usually one minute is enough. And it doesn’t turn on very often. So while it will fit.
Interestingly, the armature travel is almost the same (about 1cm) and the power is almost the same. The same cell phone lifts over the edge as it does without the stopper. It’s less noisy.
HDAN: Try replacing the valve diaphragm with a stiffer
How To Make Air Compressors Efficient
What kind of material would you recommend??Originally there are two rubber (silicone type) plates of thickness. Hmm, I don’t remember, but less than 1mm.Maybe 0.6-0.7mm.
NPI: When I did a similar remodel on the compressor, I filled the gut under the diaphragm with epoxy in the form of plasticine.
There are two chambers. One large, the other a little smaller.Are you suggesting to just fill them with something to reduce the void?Thermal glue will work? Fill almost completely, leaving only room for the valve?
DWD: Fill them with something to reduce the void?Yes. Imagine a reciprocating compressor. The piston went up, the air is compressed, but how much? If the “combustion chamber” above the piston has a large volume, we never get more pressure at the compressor output than in the “combustion chamber”. It’s the same with the vacuum. Recall Komovsky’s school pump, it has a parasitic volume of zero at all, t.к. the piston rests against the cylinder cap and pushes it into the oil. But it also creates a decent vacuum, enough for demonstrations of Kruks tubes, etc.DWD: Thermoclay is fine? Fill almost completely, leaving only room for the valve?Thermal glue. I don’t know, maybe the membrane will stick to it during molding?
I made a homemade vacuum tweezers out of a pear. At the pharmacy I asked them to give me the hardest one to choose. Pressing with the foot like a pedal. Very handy, two hands free. Somewhere on youtube was a video of how to make. Made it, all is well but it is not convenient to deflate the SMD-shka when you put it in, added 2 ball valves. great. No yuck-yuck-yuck and the “pedal” can be pressed sharply.
They can not tear off the solder from large ICs. the nozzle is too small. There is no point in doing it on purpose, I rarely get such work. Why can’t you use ordinary tweezers to do it??
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How to increase compressor capacity
AC motors powered by 50 Hz industrial network do not allow to get the speed above 3000 rpm. Therefore, to obtain high frequencies a collector motor is used, which is also lighter and smaller than AC motor of the same power, or special transfer mechanisms are used that change the kinematic parameters of the mechanism to the required one (multipliers). When using frequency converters or having a higher frequency network (100, 200, 400 Hz), AC motors are lighter and smaller than collector motors (the collector assembly sometimes takes up half the space). The life of AC induction motors is much longer than that of collector motors and is determined by the condition of the bearings and winding insulation.
A synchronous motor with rotor position sensor and inverter is the electronic counterpart of a DC collector motor.
could this be considered the right direction of my idea? if yes, there is another question piston compressor, will the air injection system itself be able to withstand a twofold increase in rate?
Increased flow mode: safely boosting the capacity of an air compressor
Sometimes the capacity of the production and the compressed air system being used is at its limits. Thanks to Atlas Copco’s Flow Boost mode, the new VSD s air compressor no longer experiences pressure loss, which reduces efficiency and risks production stoppages, when it reaches its maximum capacity limit. Learn how to safely get the extra power when you need it.