The present invention is directed to sound attenuation for compressors, and specifically is directed to an attenuating apparatus for a positive displacement compressor.
Noise generation due to pressure pulsations is a natural phenomenon in undamped positive displacement compressors used in HVAC systems as well as other applications such as pipeline applications, as discrete volumes of gaseous fluid enter a chamber at a low, suction pressure, are compressed to a high pressure and are then discharged from the chamber at a high discharge pressure. The periodic suction and discharge of the gaseous fluids is a pulsation event that produces a vibration. At certain frequencies, about 20 to 20,000 Hz, these vibrations fall within the audible range for humans and are perceived as noise. Of course, vibrations are readily propagated along the metal surfaces that comprise the pipes, conduits and other equipment through which the gaseous fluid is circulated.
When the periodicity of the vibrations changes, as a result of change in, for example, the speed of operation of the variable speed compressor, the frequency of vibration also changes. Some noise at certain frequencies resulting from the operation of positive displacement compressors may be less annoying than other frequencies. While it is desirable to completely attenuate the noise generated by operation of a positive displacement compressor, sometimes this is not possible. Mufflers are added to either or both the suction side (low pressure side) of the compressor or the discharge side (high pressure side) of the compressor. While mufflers ideally attenuate sound to eliminate noise, in practice mufflers are designed to tune the sound that is propagated so that sound in certain undesirable frequencies, typically the most annoying frequencies, is attenuated. Thus, these mufflers or resonators are designed to target a fixed frequency and cannot be adjusted readily. To change the target frequency, the muffler physically must be removed from the system and physically modified or replaced with a muffler or resonator designed for a different fixed frequency. Physical modifications to a resonator can require removal of the resonator from site and returning it to the manufacturer. The periodicity of vibrations produced by a positive placement compressor is variable and may change with load, which can vary not only from season to season, but also from day to day, depending upon the application. The frequency range attenuated is generally limited. However, mufflers are designed to attenuate predetermined frequencies. Thus, mufflers can become ineffective as the periodicity of vibrations changes with the speed of operation of the compressor. What is desired is an attenuating apparatus that can dampen noise across a range of frequencies and that readily can be adjusted to attenuate noise at preselected frequencies within the range of frequencies, as conditions warrant.
A manual selective attenuator for use with a positive displacement compressor is set forth herein. The manual selective attenuator is integral with the discharge side of the positive displacement compressor and acts as an adjustable resonator. The adjustable resonator permits an HVAC technician to tune the resonance resulting from operation of the positive displacement compressor at different speeds or under different load conditions. The manual selective attenuator allows the HVAC technician to adjust the volume in a discharge chamber of the compressor so that pulsations produced by the compressor occur at a resonant wavelength of the most undesirable noise frequencies, producing a cancellation effect. In effect, the manual selective attenuator is an active attenuator that enables the HVAC technician to mechanically vary the volume of the discharge cavity, thereby “tuning” the sound produced by the positive displacement compressor.
A manual selective attenuator includes a bore formed in a compressor housing, the bore being positioned at an angle to and in fluid communication with, the compressor discharge chamber. The manual selective attenuator also includes a plug positioned within the bore and movable within the bore to a preselected position. The plug is either capable of being locked or otherwise prevented from inadvertent movement once moved into the preselected position. The manual selective attenuator also is provided with a sealing means to prevent leakage of high pressure gas discharged by the compressor from migrating along the interface between the plug and the bore and escaping into the atmosphere. At least one end of the plug is accessible from the exterior of the housing, the end including means for moving the plug to a preselected position within the bore. The plug positioned within the bore forms a tuning chamber or cavity. As the plug is moved from a first position within the bore at which the tuning chamber has a first volume, to a second position within the bore at which the tuning chamber has a second volume, the resonance characteristics of the sound of the pulsations of the compressed gas discharged into the discharge chamber are modified. When the plug is adjusted within the bore to a preselected position wherein the tuning chamber achieves a volume that resonates the most undesirable sound produced by the compressor discharged at a ¼ wavelength increment (and whole number multiples thereof e.g. ½ wavelength increment), the attenuator will attenuate at least some of the most undesirable sound produced by the compressor discharge, the sound being propagated in the direction of the compressed fluid discharged from the compressor. The tuning chamber acts to cancel, at least partially, the sound produced by the compressor. The manual attenuator may achieve this result in any manner; however, in its simplest form, a technician can achieve this cancellation manually by adjusting the tuning chamber to a position in which sound attenuation is deemed to be at the most acceptable level. The technician may achieve this result using his own auditory faculties, or the technician may employ a sound spectrum analyzer.
An advantage of the present invention is that undesirable noise produced by a positive displacement compressor can be reduced by a trained technician by varying the volume of the discharge cavity without the necessity of deactivating the system in order to access the system interior. The manual selective attenuator permits adjustments from the exterior of the system.
Another advantage of the present invention is that noise in different frequency ranges can be tuned by the manual selective attenuator without having to otherwise replace or alter the installed attenuator. When the frequency ranges of the noise produced by the compressor changes, the manual selective attenuator can be adjusted so that the discharge volume is changed, thereby altering the sound characteristics of the compressor without the need to cease operation of the compressor or replace parts.
Still another advantage of the present invention is that the manual selective attenuator can be utilized while the positive displacement compressor is operating, so there is no need to shut down the system for the modifications produced by the manual selective attenuator.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
A manually adjustable resonator for modifying the vibration characteristics of a positive displacement compressor is set forth herein. Positive displacement compressors include screw compressors, reciprocating compressors and screw compressors. These compressors compress a gas, preferably a refrigerant gas, by introducing a gas from the suction side of the system into a space, mechanically reducing the volume thereby compressing the gas in the working region of the compressor, and then releasing the compressed gas into a discharge chamber on the high pressure side of the system. The flow of gas from the low pressure, suction side, of the system and discharge of compressed gas into the high-pressure side of the system produces gas pulsations. The compressed gas travels downstream along the high pressure side in a direction away from the compressor. The gas pulsations are the primary source of noise in a positive displacement compressor, and the noise is propagated along the piping and other components, which, being metal, are excellent conductors of sound waves. Sound also is propagated by the pulsating gas moving through the system. The frequencies of the sound waves that are produced by the gas pulsations are dependent upon the discharge opening. Unlike previous solutions to the problem of the noise due to gas pulsations, which involve the use of passive sound attenuators, such as mufflers, designed to attenuate a specific frequency or limited range of frequencies by using sound absorption techniques, the manual selective attenuator dampens sound by modifying the volume in the discharge chamber, on the discharge side of the compressor, thereby modifying the characteristics (frequency) of the sound produced by sound cancellation techniques. When properly tuned, the chamber can act as a ¼ wavelength or ½ wavelength resonator of the most unpleasant or obnoxious frequencies, which are usually the high frequency sounds within the audible frequency range for humans. When acting as such a resonator, the tuned chamber acts to cancel, or at least reduce the amplitude of these undesirable frequencies.
The opposite end 28 of the threaded device 24 extends outside of the pressure boundary of the system, providing plug or threaded device 24 with an exterior surface 12 readily accessible to a technician, so that system operation may continue. Also evident in
In operation, a technician may utilize manual selective attenuator 14 of the present invention to modify the acoustic characteristics of the compressor. As previously noted, a positive displacement compressor generates multiple frequencies. For example, a single screw compressor generally generates low noise. However, oil injection free technology, which has been implemented to eliminate the need for an oil separator in screw compressors, has been the source of increased noise that desirably is eliminated. Variable speed drives may be another source of noise. Here the speed at which the compressor may be driven can vary by the load on the compressor. This load will change based on the circumstances in the space that is being conditioned. As the compressor load changes, the speed at which the compressor is driven changes and the noise that is generated also changes. This usually occurs with changes of season, and it would be desirable to tune out the most disagreeable frequencies. The most disagreeable frequencies are usually the frequencies at the higher end of the sound range, above 5000 Hz to about 22,000 Hz. It should be noted that depending on the individual, the sound range capability of many individuals particularly with increasing age, may be limited to well below 22,000 Hz. It may be that some individuals may not be able to perceive sound above 10,000-12,000 Hz. Nevertheless, it may be necessary for the technician to use the manual selective attenuator to adjust the sound produced by the compressor in the range of, for example, 15,000-22,000 Hz because some portion of the general population that may occupy the space may be capable of hearing sounds in these frequencies generated by the compressor system. In some circumstances, particularly if the hearing capability of the technician is limited, it may be necessary for the technician to use sound spectrum analyzers to properly adjust the unpleasant sounds, particularly at higher frequencies.
Since the frequency of the sound wave is dependent on the volume of discharge chamber 20 plus the volume of tuning cavity 26, this volume can be adjusted, within limits, by adjusting the volume of tuning cavity 26, since the volume of discharge chamber 20 is fixed. The opposite end 28 of threaded device 24 permits the adjustment of the threaded device 24 in bore 22 and hence the volume of tuning cavity 26. This can be done by a technician from the exterior of positive displacement compressor 10 using a means for adjustment that permits the manual selective attenuator 14 to be moved in relation to discharge cavity 20. In the embodiment shown in
The active manual selective attenuator of the present invention may be provided with additional sound absorption capabilities to further allow for additional controls of frequency response by combining it with passive sound absorptive materials. Passive sound absorptive material can be added to tuning cavity 26 to assist in controlling frequencies above about 400 Hz. The characteristics of passive sound absorptive material include inertness both with respect to the refrigerant used in the compressor as well as any oil that may be utilized for compressor lubrication. Acceptable passive absorptive materials include melamine foam and glass fiber, although passive absorbers are not limited to these two materials. The passive sound absorptive material may be inserted into the tuning cavity of threaded device 24. In this manner, the passive sound absorptive material moves with threaded device 24 as it is moves within bore 22 during tuning operations. Alternatively, the passive sound absorptive material may be placed within bore 22 beyond the travel of threaded device 24 in bore 26. The placement at this location assures that the passive absorptive material cannot inadvertently be moved by threaded device 24 into the discharge cavity. Other combinations of the active absorber of the present invention coupled with passive sound absorptive material to reduce the overall sound generated by the compressor are envisioned.
As shown in the figures above, the active sound attenuator of the present invention is added to the housing of the screw compressor in proximity to the compressor discharge chamber. This may also be accomplished with a reciprocating compressor and with a scroll compressor, when possible. However, in some circumstances, housing for a manual selective attenuator may not be available. In such circumstances, a housing that can accommodate the manual selective attenuator may be attached to the system piping as close to the compressor discharge chamber as possible. Sound propagates along the piping and the frequency of the sound that is propagated can be modified, and thus attenuated, by applying a manual selective attenuator downstream of the discharge chamber of the compressor, although it is preferable to provide the manual selective attenuator adjacent to the discharge cavity and perpendicular to the flow direction of the refrigerant.
In still another arrangement, threaded device 24 may not include a tuning cavity machined into threaded device 24. Instead, threaded device is inserted into bore 22, and tuning cavity 26 is formed by bore 22, as previously discussed. An o-ring seal is provided to seal the gap in the bore between the housing of the positive displacement compressor and the threaded device, the length of tuning cavity being determined by the distance that threaded device is inserted into bore 22.
The figures depict threaded device 24 and bore 22 being partially threaded and engaged with one another along their respective threads. However, the invention is not so limited. Indeed, the entire length of the housing along bore 22 in the housing and some or the entire exterior surface of the threaded device may be threaded, as long as appropriate stops are included to preclude over-travel either out of the housing or inward in the direction of discharge chamber 20 so as to block the flow of refrigerant.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
This application claims priority to U.S. Provisional Application 61/384,791 filed Sep. 21, 2010, incorporated herein by reference.
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