Improved design of air compressor air volume adjustment mechanism

The air compressor station of Bengang Cold Rolling Plant is responsible for the compressed air supply task of the whole plant. The main equipment is 5L40/8I (3) two-pole two-cylinder double-acting water-cooled oil-free lubricating air compressor produced by 8 Shenyang Gas Compressor Factory. The theoretical displacement of this model is (40 ± 2) m nominal pressure (outlet final pressure) is 0.8 M Pa. The displacement adjustment uses the top open suction valve adjustment method. The composition and working principle of the adjustment method are as follows: the suction valve top open frame and the pressure regulator together constitute a gas volume adjustment mechanism. The adjustment of the displacement by the gas volume adjustment mechanism is achieved by the change of the gas pressure in the gas storage tank (see Figure 1).

Connected. When the gas pressure in the gas tank exceeds the use pressure of 0.8 MPa, the cone valve of the pressure regulator 5 is pushed open, and the gas enters the suction valve (8, 11) on the cylinder (7, 10), and the gas pushes the column. Plug 2, make the opening and closing frame 3 move forward, open the suction valve (Fig. 1), the compressor will reduce or stop the air supply, enter the half load or no load dynamic state, reduce the power consumption when the pressure in the gas storage tank When descending, the cone valve on the pressure regulator closes under the action of the spring force, shutting off the gas so that it cannot enter the cylinder. Thus, the switch frame is retracted under the action of the spring (see Figure 1) and the compressor resumes normal operation.

1—Valve cover 2—Plunger 3—Opening and closing frame 4—Spring 5—Intake valve 6—o-ring 7—Cylinder head 1—Safety valve 2—Gas storage tank 3, 4—Filter 5—Pressure regulator 6—Host 7—Class 1 cylinder 8—Class 1 suction valve 9—Line 10—Secondary cylinder 11—Secondary suction valve 1 The problem often occurs in production practice, that is, the system does not use air volume. When the pressure is high, the pressure of the air compressor (see Figure 2) is often released. After analysis, it is found that the root cause is that the gas volume adjustment mechanism is not flexible and can not play the role of regulating gas volume. The Journal of Shenyang University of Technology has played a role in safety generation and equipment function. The reason why the air volume adjusting mechanism is inflexible is mainly the mechanical failure of the bonnet plunger (Fig. 1) in the exhaust gas volume adjusting system. The suction valve cover is cast iron material, and the plunger 2 is sealed by an O-ring. The compressed air flowing through the air hole in the cylinder acts on the cross section of the plunger. When the pressure is sufficiently large, the plunger is opened, and the column is opened. The plug is connected with the opening and closing frame 3 (threaded connection), and the annular valve piece on the suction valve 5 is opened to connect the inner and outer gases into one body, so as to be circulated, thereby realizing automatic adjustment.

Since the pipeline from the gas storage tank to the cylinder is long and the pipeline is rusted by the action of water vapor, the rust is returned to the plunger chamber of the cylinder head (Fig. 1) under the pressure flow stamping to form a blockage. In addition, since the valve cover is made of cast iron, the processing surface is rough, about or lower, and the action of water vapor and ash scale, so that the plunger action is not flexible, and the gas regulation system is often in a fault state.

2 The countermeasures adopted are directed to the disadvantages of poor machining accuracy and rusting of the inner surface of the original plunger cavity of the cast iron bonnet. The corresponding countermeasures are as follows: the original surface roughness is low, and the blockage phenomenon is easy to occur, so that the plunger cannot move back and forth flexibly. , affecting the adjustment effect, it is decided to finish the finishing surface. In view of the fact that the wall thickness δ of the original casting is only about 5 mm, there is not enough machining allowance, so the method of inserting is used to process the copper material of H62 material with high strength, good friction reduction and corrosion resistance. The rod body with a surface of 40n6 is cut into a length of about 50 mm, and then embedded in the original plunger cavity of the bonnet by the loading method under the interference pressure, and then the bonnet copper material which has been embedded in the H62 bar is placed on the bonnet of the bonnet. Pre-drilled hole with diameter = 20 mm, put it on the four-claw lathe, use the outer surface of the bonnet as the reference surface, ream the inner car, and finish the car to 36 H7 1.6, and finally the flat B side, make the sleeve and The bonnet is integrated. Correspondingly, the plunger is also reworked, and the original 40 section is machined into a plunger of 36 g6 on the outer surface according to the nominal size of the bonnet, so that it forms a clearance fit with the bonnet, and then processes the nozzle on the plunger. Sealing ring groove for sealing. Since the roughness of the contact surface is improved and the copper material which is not easily rusted is used, the flexibility and reliability of the opening and closing frame are greatly improved, and the incidence of failure is reduced.

The pipeline leading to the cylinder of the gas storage tank is made of ordinary carbon steel, and the pipeline is long (more than ten meters). It is economically uneconomical to change to other materials, and it is impossible to overcome the problem of water vapor and dust in the gas passage to the plunger chamber of the bonnet. influences. In order to avoid the above situation, a new air filter device (model 398) has been added to the pipeline near the bonnet. The device has the function of filtering water vapor, decompression and oiling. Was completely eliminated.

3 Improvement effect After the above modification of the first and second intake valves of the 5L40/8 air compressor, the defects of the air volume adjustment device being inflexible and unreliable have been basically overcome, and the expected purpose has been fully achieved. In the actual application of the month, there was no previous work failure, and the safe and reliable production of the equipment was realized.

Xu Fuling. Hydraulic and pneumatic transmission [M]. Beijing: Mechanical Industry Publishing Guangzhou Machine Tool Research Institute. Machine Tool Hydraulic System Design Instruction Manual [ M] .

Guangzhou: Guangdong Higher Education Press, 1993.

Zuo Jianmin. Hydraulic and pneumatic transmission [M]. Beijing: Mechanical Industry Publishing Zheng Hongsheng. Pneumatic Transmission and Control [M]. Beijing: Mechanical Industry Publishing [6] Meng Fanhua, Li Tiangui. Application of pneumatic technology in automation [M]. Beijing: National Defense Industry Press, 1989.

Tian Guofu et al.: Improved Design of Air Compressor Air Volume Regulating Mechanism Journal of Shenyang University of Technology

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