The invention pertains to a multi-stage screw compressor system. Preferably, the screw compressor system is a “dry-running” system for high pressures, typically 40 bar and above. A preferred area of applicability is the production of compressed air for blow-molding of plastic bottles.
A two-stage screw compressor system is known from U.S. Pat. No. 3,407,996 (corresponding to DE-A-1628201). It has a gearbox with a perpendicular mounting wall, attached to which are two adjacent compressor stages that cantilever parallel with one another. Each compressor stage comprises a screw compressor with two mutually engaging screw rotors. Located in the gearbox is a transmission with a drive gear that meshes with two driven gears that rotate the rotors of the two screw compressors. Also disclosed in the document is that the invention described in it can also be used in multistage compressor systems with more than two stages. However, there is no indication of how further compressor stages can be arranged, and the design that is described in detail has no place for further compressor stages.
A similar two-stage screw compressor system is also known from DE 299 22 878.9 U1.
The object of the invention is to design a three-stage screw compressor system that can deliver a compressed gaseous fluid, in particular compressed air, at a very high pressure, typically about 40 bar and above, and that is characterized by its space-saving design, its simplicity and robustness. In another embodiment of the invention, the three-stage screw compressor system according to the invention allows the ratio of the RPM's of the three compressor stages to be changed in a simple manner.
The screw compressor system according to the invention can compress gaseous fluid, in particular air, to a very high pressure ratio, for example 40:1, using only three compressor stages; thus, compressed air can be supplied at a high pressure as is required for industrial manufacturing processes such as blow-molding of plastic bottles.
In the screw compressor system according to the invention, the screw compressors that constitute the first and second stages are located above the horizontal plane that runs through the rotating axis of the drive gear, whereas the screw compressor of the third stage is located below the screw compressors of the first and second stages and below the horizontal plane running through the rotating axis of the drive gear, and whereas its driven gear meshes with the drive gear near its lowest point. This results in an especially advantageous utilization of the existing space configurations and thus a space-saving, compact design of the compressor system. By using different exchangeable bearings and flange parts, the position of the drive shaft can be changed in the horizontal direction and the position of the third compressor stage can be changed in the vertical direction in order to adjust the gearing configuration to different diameters of gears and thus to different RPM ratios of the compressor stages.
In one construction, the invention provides a multi-staged screw compressor system with a gearbox (90), a drive gear (95) located in the gearbox, and a first, second and third screw compressor (60, 70, 80) that are fastened to the gearbox and coupled to the drive gear such that they are all driven in common by the drive gear. During operation, the first screw compressor (60) compresses a flow of gaseous fluid from an inlet pressure to a first intermediate pressure, the second screw compressor (70) compresses the flow of fluid from the first intermediate pressure to a second intermediate pressure, and the third screw compressor compresses the flow of fluid from the second intermediate pressure to a final pressure, wherein the final pressure is at least thirty times, preferably at least forty times the inlet pressure.
In another construction, a multistage screw compressor system consists of a gearbox (9)0, to which a first, second and third screw compressor (60, 70, 80) are attached in parallel and cantilevered, and which are driven in common by a drive gear in the gearbox. A gaseous fluid is compressed by the first screw compressor (60) to a first intermediate pressure of about 3.5 bar, by a second screw compressor (70) to a second intermediate pressure of about 12 bar and by the third screw compressor (80) to an internal pressure of about 40 bar. Driven gears (65, 75) of the first and second screw compressors mesh with the drive gear (95) above its axis, whereas the driven gear (85) of the third screw compressor (80) meshes with the drive gear (95) near its lowest point T. The position of the axis of the drive gear (95) is able to be changed in the horizontal direction and the position of the driven gear (85) of the third screw compressor (80) is able to be changed in the vertical direction for the capability of installing gear sets with different diameter ratios.
In another construction, the invention provides a multi-staged screw compressor system that includes a gearbox including a housing having a mounting wall. A drive gear is supported by the housing for rotation about a drive axis. The drive axis divides the drive gear into a first upper quadrant, a second upper quadrant, a first lower quadrant, and a second lower quadrant, each quadrant extending between a vertical plane and a horizontal plane that intersect on the drive axis. A first mating flange, a second mating flange, and a third mating flange are each formed as part of the mounting wall to define three substantially planar surfaces arranged normal to the drive axis. A low pressure screw compressor is coupled to the first mating flange and includes a first driven gear, the first driven gear disposed completely within the first upper quadrant. A middle pressure screw compressor is coupled to the second mating flange and includes a second driven gear, the second driven gear disposed completely within the second upper quadrant. A high pressure screw compressor is coupled to the third mating flange and includes a third driven gear, the third driven gear disposed within at least one of the first lower quadrant and the second lower quadrant. The low pressure screw compressor, the middle pressure screw compressor, and the high pressure screw compressor cooperate to compress a gas from a first pressure to a second pressure that is at least 30 times the first pressure.
One embodiment of the invention is explained in more detail with the help of the drawings. Shown are:
Not shown in
The screw compressors 60, 70 of the first and second stage are located next to one another horizontally, whereas screw compressor 80, the third stage, is located beneath the screw compressors of the first and second stage. The oil sump housing 76 has a recess 79 on its upper surface that creates additional space with which to hold the screw compressor of the third stage.
Each of the three screw compressors 60, 70, 80 of
The screw compressor shown in
The upper rotor 3 in
Rotor housing 1 is surrounding by a cooling jacket or cooling housing 21, which is for the most part designed as one-piece together with rotor housing 1, surrounding the same at a distance. Above and below, the cooling housing 21 has large openings that are closed off using a cover plate 23 and a base plate 25 fastened with bolts. Between the rotor housing 1 and the cooling housing 21, 23, 25 is an annular cooling space 27 surrounding the rotor housing 1 in which a liquid coolant circulates, such as water.
The screw compressor of the third stage shown in
At the left end of rotor housing 1 in
In operating the compressor system shown in
At the preferred operating pressures cited above, the pressure ratios in each of the three screw compressors 60, 70, 80 are nearly the same and decrease only minimally from the first to the third stage. At the pressures cited, the pressure ratio between the inlet ant outlet pressures in the first screw compressor 60 is approximately 3.5, in the second screw compressor 70 it is approximately 3.4 and in the third screw compressor 80 it is approximately 3.3.
In
A bearing seat 97 is set into the mounting wall 91 of the gearbox 90. The end of the drive shaft 94 (see
Furthermore, the flange plate 84 of screw compressor 80 that constitutes the third stage is removably bolted to the mating flange 89 of the gearbox, along with the rotor housing associated with it. This flange plate can be exchanged with a flange plate having a different hole pattern, which allows the position of the screw compressor 80 and thus its driven gear 85 to change in the vertical direction as indicated by the vertical double arrow 86 in
This ability to shift the drive gear 95 in the horizontal direction 98 and to shift the driven gear of the third stage in the vertical direction 86 enables the use of different gear sets for gears 95, 65, 7585 that make up the transmission, whereupon the gear ratios and thus the relative RPM's of the three compressor stages 60, 70, 80 can be changed by using different diameters matched with one another. In the process, all four gears 65, 75, 85, 95 that make up the transmission can be exchanged with such other diameters, wherein a shift of only two of these elements in two directions perpendicular to one another is sufficient, namely the drive gear 95 in the horizontal direction 98 and the gear 85 of the third stage in the vertical direction 86, to ensure proper meshing of the gears even when the diameter ratios are changed.
Number | Date | Country | Kind |
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10 2005 058 698 | Dec 2005 | DE | national |
This application is a continuation of U.S. patent application Ser. No. 12/094,390, filed May 12, 2009, now U.S. Pat. No. 8,342,829, which is a national stage filing under 35 U.S.C. 371 of International Application No. PCT/EP2006/005558, filed Jun. 9, 2006, which claims priority to German Patent Application No. 10 2005 058 698.8, filed Dec. 8, 2005, the entire contents of which are incorporated herein by reference.
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Number | Date | Country | |
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20130011285 A1 | Jan 2013 | US |
Number | Date | Country | |
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Parent | 12094390 | US | |
Child | 13618595 | US |