Patent Grant
8231363
The present application claims priority from Japanese application JP2005-169661 filed on Jun. 9, 2005, the content of which is hereby incorporated by reference into this application.
The present invention relates to a screw compressor, and more particular, to a large capacity screw compressor that generates a compressed air.
Screw compressors comprise a male rotor and a female rotor, of which rotating shafts are in parallel to each other and which rotate so that spiral teeth thereof mesh with each other, and a casing that accommodates therein the male rotor and the female rotor. A plurality of compressive working chambers are defined by tooth grooves of the male rotor and the female rotor, and an inner wall of the casing. The compressive working chambers are decreased in volume to compress an air while moving in an axial direction as the male rotor and the female rotor rotate.
Conventionally, the construction for a two stage type screw compressor is exemplarily disclosed, which comprises: a low pressure stage compressor body; an intercooler that cools a compressed air from the low pressure stage compressor body; a high pressure stage compressor body that further compresses the compressed air cooled by the intercooler; and an aftercooler that cools the compressed air from the high pressure stage compressor body (for example, see JP-A-2002-155879). According to the related art, pinion gears, respectively, are mounted on rotor shafts (either of a male rotor and a female rotor) of the low pressure stage compressor body and the high pressure stage compressor body. The pinion gears, respectively, mesh with a bull gear, which is mounted on a rotating shaft of a motor (electric motor). As the motor is driven, a rotational power of the motor is transmitted and increased in speed through the bull gear and the pinion gears, whereby the low pressure stage compressor body and the high pressure stage compressor body, respectively, are driven.
However, the related art leaves the following room for improvement.
That is, according to the related art, a speed increasing ratio is determined by a ratio of a working pitch diameter of the bull gear on a side of the motor to a working pitch diameter of the pinion gear on a side of the compressor body, and a rotational power of the motor is increased in speed in one stage according to the speed increasing ratio to drive the low pressure stage compressor body and the high pressure stage compressor body, respectively. Therefore, in order to obtain a predetermined speed increasing ratio in a compressor unit of a large capacity with, for example, an output of several hundreds of kilowatts (kw), it is necessary to increase a diameter of the bull gear on the side of the motor corresponding to the pinion gear on the side of the compressor body, or to decrease a speed increasing ratio to heighten the rotational speed of the motor. In the case where the gear is to be made large in diameter, manufacture becomes sometimes difficult in terms of a manufacturing facility (for example, limitation in a range of working performed by a machine tool). Consequently, the gears or the motor is increased in cost.
It is an object of the invention to provide a screw compressor, a motor of which can be made relatively low in rotating speed while inhibiting gears from being increased in diameter, thereby enabling achieving reduction in cost.
a compressor body;
a rotor side gear provided on a rotor shaft of the compressor body;
a motor;
a motor side gear provided on a rotating shaft of the motor; and
an intermediate shaft supported rotatably and provided with a first speed-increasing gear, which meshes with the motor side gear, and a second speed-increasing gear, which meshes with the rotor side gear.
According to the invention, there is provided an intermediate shaft provided with a first speed-increasing gear, which meshes with the motor side gear, and a second speed-increasing gear, which meshes with the rotor side gear. A speed increasing ratio of the motor side gear to the first speed-increasing gear, and a speed increasing ratio of the second speed-increasing gear to the rotor side gear cause a rotational power of the rotating shaft of the motor to be increased in speed in two stages and transmitted, thus rotationally driving the rotor shaft of the compressor body. Thereby, as compared with, for example, the case where the motor side gear and the rotor side gear meshes with each other to attain an increase in speed in one stage, it is possible to make the motor relatively low in rotating speed while inhibiting the gears from being increased in diameter, thus enabling achieving reduction in cost.
a low pressure stage compressor body;
a high pressure stage compressor body that further compresses a compressed air compressed by the low pressure stage compressor body;
a plurality of rotor side gears, respectively, provided on rotor shafts of the low pressure stage compressor body and the high pressure stage compressor body;
a motor;
a motor side gear provided on a rotating shaft of the motor; and
an intermediate shaft supported rotatably and provided with a first speed-increasing gear, which meshes with the motor side gear, and a second speed-increasing gear, which meshes with the plurality of rotor side gears.
Thereby, as compared with, for example, the case where a motor is arranged on one side in an axial direction and a compressor body is arranged on the other side in the axial direction, the whole axial dimension composed of the motor, the compressor body, etc. can be shortened. Consequently, an arrangement of the compressor unit can be heightened in freedom of layout.
a low pressure stage compressor body;
a high pressure stage compressor body that further compresses a compressed air compressed by the low pressure stage compressor body;
a plurality of rotor side gears, respectively, provided on rotor shafts of the low pressure stage compressor body and the high pressure stage compressor body;
a motor;
a motor side gear provided on a rotating shaft of the motor; an intermediate shaft supported rotatably and provided with a first speed-increasing gear, which meshes with the motor side gear, and a second speed-increasing gear, which meshes with the plurality of rotor side gears;
a gear casing that accommodates therein the motor side gear, the first speed-increasing gear, the intermediate shaft, the second speed-increasing gear, and the rotor side gears;
a first cooling apparatus that cools a compressed air from the low pressure stage compressor body; and
a second cooling apparatus that cools a compressed air from the high pressure stage compressor body,
wherein the motor, the gear casing, the low pressure stage compressor body, and the high pressure stage compressor body are arranged centrally of the compressor unit, the first cooling apparatus is arranged on one side in a long width direction of the compressor unit, and the second cooling apparatus is arranged on the other side in the long width direction of the compressor unit.
As described in (3), for example, when the rotating shaft of the motor and the rotor shaft of the high pressure stage compressor body are arranged in parallel to each other, and the motor, the low pressure stage compressor body, and the high pressure stage compressor body are arranged upward and downward on one side in axial directions thereof, the whole axial dimension composed of the motor, the low pressure stage compressor body, the high pressure stage compressor body, etc. can be shortened. Thereby, axial directions of the rotating shaft of the motor and the rotor shafts of the low pressure stage compressor body and the high pressure stage compressor body can be arranged in the short width direction of the compressor unit. The motor, the gear casing, the low pressure stage compressor body, the high pressure stage compressor body, etc. are arranged centrally of the compressor unit, and interposing them, the first and second cooling apparatuses, respectively, are arranged on one side and on the other side in the long width direction of the compressor unit. Consequently, it is possible to arrange elements in the compressor unit in an efficient and well-balanced manner, thus enabling making the whole unit small in size.
Thereby, it is possible to shorten a connection pipe between the low pressure stage compressor body and the first cooling apparatus, and a connection pipe between the high pressure stage compressor body and the second cooling apparatus.
Thereby, as compared with, for example, the case where any intake space is not formed between the air intake port and the heat exchanger for compressed air, and the case where any exhaust space is not formed between the cooling fan and the exhaust port, it is possible to reduce leakage of noise generated in the heat exchanger for compressed air, etc.
In, for example, a compressor unit of a large capacity, a heat exchanger for compressed air becomes large in size, so that it becomes sometimes difficult to manufacture it in existent manufacturing facilities (for example, due to a problem of a size of a furnace or the like). According to the invention, a plurality of the heat exchangers for compressed air are provided, and they are arranged in juxtaposition with flow of a cooling wind in the duct. Thereby, the single heat exchanger for compressed air becomes small in size, so that it is possible to facilitate manufacture thereof even in the case where the size thereof is limited by an existent manufacturing facility or the like. Furthermore, pressure loss is decreased as compared with the case where, for example, a plurality of heat exchangers for compressed air are arranged in series, so that it is possible to reduce power required for a cooling fan.
In this manner, by inclining the heat exchanger for compressed air, it is possible to shorten a dimension in the short width direction of the compressor unit.
According to the invention, it is possible to make a motor relatively low in rotating speed while inhibiting gears from being increased in diameter, thus enabling achieving reduction in cost.
Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
Embodiments of the invention will be described below with reference to the drawings.
A first embodiment of the invention will be described with reference to
In
The motor 4 is fixed to a motor frame 6. The motor frame 6 is mounted on a base 7 with a plurality of vibration-proof rubber pieces 8 therebetween. A rotating shaft 4a of the motor 4 is supported rotatably through, for example, a radial bearing 4b provided on a loaded side (on the right in
The low pressure stage compressor body 2 is a screw compressor of, for example, an oil free type (operated with an interior of a compressive working chamber in an oilless state) comprising a male rotor 2a and a female rotor 2b, of which rotating shafts are in parallel to each other and which rotate so that spiral teeth thereof mesh with each other. One ends (on the lower side in
Likewise, the high pressure stage compressor body 3 is a screw compressor of, for example, an oil free type comprising a male rotor 3a and a female rotor 3b, of which rotating shafts are in parallel to each other and which rotate so that spiral teeth thereof mesh with each other. One ends (on the lower side in
An intermediate shaft 16 is provided in the gear casing 5 to be supported rotatably through, for example, a thrust bearing 15A and a radial bearing 15B, the intermediate shaft 16 being made in parallel to the rotating shaft 4a of the motor 4, the male rotor 2a of the low pressure stage compressor body 2, the male rotor 3a of the high pressure stage compressor body 3, and the like. The radial bearing 15B is provided, for example, on the one side of the gear casing, and the thrust bearing 15A is provided, for example, on a bearing support 17 mounted to an opposite side (on the upper side in
Fitted onto the intermediate shaft 16 are a pinion gear 19 (first speed-increasing gear), which meshes with the bull gear 10 on the rotating shaft 4a of the motor 4, and a bull gear 20 (second speed-increasing gear), which meshes with the pinion gear 12 on the male rotor 2a of the low pressure stage compressor body 2 and the pinion gear 14 on the male rotor 3a of the high pressure stage compressor body 3. A working pitch diameter of the pinion gear 19 on the intermediate shaft 16 is smaller than that of the bull gear 10 on the rotating shaft 4a of the motor 4, so that a rotational power of the rotating shaft 4a of the motor 4 is increased in speed and transmitted to the intermediate shaft 16 through the bull gear 10 and the pinion gear 19. A working pitch diameter of the bull gear 20 on the intermediate shaft 16 is larger than that of the pinion gear 12 on the male rotor 2a of the low pressure stage compressor body 2 and that of the pinion gear 14 on the male rotor 3a of the high pressure stage compressor body 3, so that a rotational power of the intermediate shaft 16 is increased in speed and transmitted to the male rotor 2a of the low pressure stage compressor body 2 and the male rotor 3a of the high pressure stage compressor body 3, respectively, through the bull gear 20 and the pinion gears 12, 14.
Thus, according to the embodiment, the intermediate shaft 16 is provided to comprise the pinion gear 19, which meshes with the bull gear 10 on the rotating shaft 4a of the motor 4, and the bull gear 20, which meshes with the pinion gear 12 provided on the male rotor 2a of the low pressure stage compressor body 2 and the pinion gear 14 provided on the male rotor 3a of the high pressure stage compressor body 3. A speed increasing ratio of the bull gear 10 and the pinion gear 19, and a speed increasing ratio of the bull gear 20 and the pinion gear 12 (or the bull gear 20 and the pinion gear 14) cause a rotational power of the rotating shaft 4a of the motor 4 to be increased in speed in two stages and transmitted, thus rotationally driving the male rotor 2a of the low pressure stage compressor body 2 (or the male rotor 3a of the high pressure stage compressor body 3).
Thereby, as compared with the case where, for example, the bull gear provided on the rotating shaft 4a of the motor 4 meshes with the pinion gears, respectively, provided on the male rotors 2a, 3a to provide for an increase of speed in one stage, the motor 4 can be relatively low in rotating speed while the gears are inhibited from being increased in diameter. That is, it is possible to meet with even the case where, for example, gears in a compressor unit of a large capacity with an output of several hundreds kilowatts are restricted in size in terms of a manufacturing facility, and to facilitate manufacture thereof. Furthermore, for example, a four-pole motor can be used for the motor 4, which is relatively low in rotating speed. Accordingly, it is possible to achieve reduction in cost.
In addition, by inhibiting gears from being increased in diameter, it is possible to inhibit the gear casing 5 from being made large in size. Also, by decreasing the motor 4 in rotating speed, a load is reduced, so that it is possible to improve reliability of parts such as bearings, etc.
Furthermore, by providing the motor 4, the low pressure stage compressor body 2, and the high pressure stage compressor body 3 on the one side (in other words, one side of the rotating shaft 4a and the male rotors 2a, 3a in an axial direction) of the gear casing 5, the whole axial dimension composed of the motor 4, the low pressure stage compressor body 2, the high pressure stage compressor body 3, etc. can be shortened as compared with the case where, for example, the motor 4 is arranged on the one side of the gear casing 5, and the low pressure stage compressor body 2 and the high pressure stage compressor body 3 are arranged on the other side. Accordingly, an arrangement of a compressor unit (see a second embodiment) described later can be heightened in freedom of layout.
In the embodiment, for example, a compressor unit 21 of a large capacity (an output in the order of several hundreds kilowatts) is a package type compressor unit covered by a sound-proof cover 22 or the like. The motor 4, the gear casing 5, the low pressure stage compressor body 2, and the high pressure stage compressor body 3 are mounted centrally of the base 7. As described in the first embodiment, since the whole axial dimension composed of the motor 4, the low pressure stage compressor body 2, the high pressure stage compressor body 3, etc. is relatively short, axial directions of the rotating shaft 4a of the motor 4, the male rotor 2a and the female rotor 2b of the low pressure stage compressor body 2, and the male rotor 3a and the female rotor 3b of the high pressure stage compressor body 3 are oriented in a short width direction (a vertical direction in
A first cooling apparatus 23 that cools a compressed air from the low pressure stage compressor body 2 is mounted on the base 7 on one side (on the right in
The low pressure stage compressor body 2 is arranged in the gear casing 5 on one side of the compressor unit 21 in the long width direction. Thereby, it is possible to shorten a connection pipe (a discharge pipe 25, etc. described later) between the low pressure stage compressor body 2 and the first cooling apparatus 23. The high pressure stage compressor body 3 is arranged in the gear casing 5 on the other side of the compressor unit 21 in the long width direction. Thereby, it is possible to shorten a connection pipe (a discharge pipe 26, etc. described later) between the high pressure stage compressor body 3 and the second cooling apparatus 24.
The first cooling apparatus 23 comprises: a duct 27 arranged in a substantially vertical direction (a vertical direction in
When the cooling fans 28A, 28B are rotated as the fan motors 29A, 29B are driven, an outside air from the first air intake port 22b is introduced as a cooling wind into the air intake duct 31 and a cooling wind in the duct 27 flows upward to be discharged from the first exhaust port 22a via the intercoolers 30A, 30B and the cooling fans 28A, 28B. At this time, the air intake duct 31 defines an intake flow passage 32 (intake space) between the first air intake port 22b and the intercoolers 30A, 30B, and an exhaust flow passage 33 (exhaust space) is also defined between the cooling fans 28A, 28B in the duct 27 and the first exhaust port 22a. Thereby, as compared with, for example, the case where the intake flow passage 32 and the exhaust flow passage 33 are not defined (more specifically, the case where intercoolers are provided to abut against the first air intake port 22b and the case where cooling fans are provided to abut against the first exhaust port 22a), it is possible to reduce leakage of noise generated by the intercoolers 30A, 30B, etc.
The cooling fans 28A, 28B are arranged in juxtaposition with each other in the short width direction (a left and right direction in
The intercoolers 30A, 30B are provided to be inclined relative to a flow of a cooling wind in a vertical direction within the duct 27 (more specifically, provided to be inclined outward upwardly in the short width direction of the compressor unit 21 and arranged in a V-shaped configuration). Thereby, it is possible to decrease a widthwise dimension of the first cooling apparatus, that is, a dimension W of the compressor unit in the short width direction. The intercoolers 30A, 30B may be provided to be inclined upward in the short width direction of the compressor unit 21 and made in parallel to each other.
For the sake of an efficient arrangement, a jacket system oil cooler 35 is provided between the intercoolers 30A, 30B. An oil supplied through an oil pipe 37a from the oil reservoir in the gear casing 5 by an oil pump 36 is caused by the jacket system oil cooler 35 to exchange heat with a cooling wind to be cooled, and the cooled oil is supplied through an oil pipe 37b to a liquid-cooled jacket 1d of the low pressure stage compressor body 2. The oil having cooled the liquid-cooled jacket 1d of the low pressure stage compressor body 2 is introduced through an oil pipe 37c into a liquid-cooled jacket 3d of the high pressure stage compressor body 3 to be cooled, and thereafter returned through an oil pipe 37d to the oil reservoir in the gear casing 5.
The second cooling apparatus 24 is constructed in the same manner as the first cooling apparatus 23, and comprises: a duct 38 provided in a substantially vertical direction (a vertical direction in
When the cooling fans 39A, 39B are rotated as the fan motors 40A, 40B are driven, an outside air from the second air intake port 22d is introduced as a cooling wind into the air intake duct 42 and a cooling wind in the duct 38 flows upward to be discharged from the second exhaust port 22c via the aftercoolers 41A, 41B and the cooling fans 39A, 39B. At this time, the air intake duct 42 defines an intake flow passage 43 (intake space) between the second air intake port 22d and the aftercoolers 41A, 41B, and an exhaust flow passage 44 (exhaust space) is also defined between the cooling fans 39A, 39B in the duct 38 and the second exhaust port 22c. Thereby, as compared with the case where, for example, the intake flow passage 43 and the exhaust flow passage 44 are not defined (more specifically, the case where aftercoolers are provided to abut against the second air intake port 22d and the case where cooling fans are provided to abut against the second exhaust port 22c), it is possible to reduce leakage of noise generated by the aftercoolers 41A, 41B, etc.
The cooling fans 39A, 39B are arranged in juxtaposition with each other in the short width direction (a left and right direction in
The aftercoolers 41A, 41B are provided to be inclined relative to a flow of a cooling wind in a vertical direction within the duct 38 (more specifically, provided to be inclined outwardly upwardly in the short width direction of the compressor unit 21 and arranged in a V-shaped configuration). Thereby, it is possible to decrease a widthwise dimension of the second cooling apparatus 24, that is, a dimension W of the compressor unit 21 in the short width direction. In addition, the aftercoolers 41A, 41B may be provided to be inclined upward, for example, in the short width direction of the compressor unit 21 and made in parallel to each other.
For the sake of an efficient arrangement, a lubrication system oil cooler 47 is provided between the aftercoolers 41A, 41B. An oil supplied through an oil pipe 48a from the oil reservoir in the gear casing 5 by the oil pump 36 is caused by the lubrication system oil cooler 47 to exchange heat with a cooling wind to-be cooled, and the cooled oil is supplied through oil pipes 48b, 48c to bearing-timing gear portions of the low pressure stage compressor body 2 and the high pressure stage compressor body 3. The oil having cooled the bearing-timing gear portions of the low pressure stage compressor body 2 and the high pressure stage compressor body 3 is returned through an oil pipe 48d to the oil reservoir in the gear casing 5.
As described above, according to the embodiment, it is possible to make the whole unit small in size, and it is possible to greatly produce the effect, in particular, in the compressor unit 21 of a large capacity type. Furthermore, the compressor unit 21 is made small in size whereby it is possible to make conveyance means therefor small in size.
It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.
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