Japan air compressor is a machine which uses a drive motor or an electric gas to power the device, which sucks in successive volumes of air from the atmosphere, compresses (squeezes) each volume of air in the limited space to increase the pressure, resulting in a smaller amount, and then transfers the air high pressure in the receiver tank according to the study site Energy TechPro. High pressure air is removed from the receiving tank for the electrical equipment. Or in simple words we can say that the job of an air compressor is to compress air and to deliver it for end use.
What is the working principle of Air compressor?
The basic working principle of an air compressor is to compress atmospheric air, which is then used as per the requirements. In the process, atmospheric air is drawn in through an intake valve more and more air is pulled inside a limited space mechanically by means of piston, impeller, or vane. Since the amount of pulled atmospheric air is increased in the
receiver or storage tank, volume is reduced and pressure is raised automatically. In simpler terms, free or atmospheric air is compressed after reducing its volume and at the same time, increasing its pressure.
How does Air compressor work?
Air compressors are relatively simple machines that have three main components:
Drive which can be a gas engine or electric motor, provides the power to propel the compressor pump.
Pump which uses the energy from the drive to draw in atmospheric air and compress it to elevated pressure. This compressed air is then sent through a discharge tube into a storage tank for use later.
Storage tank which is equipped with a one-way valve called a check valve that keeps compressed air from applying back pressure on the pump. The air storage tank acts as an air flow buffer, eliminating the need to run the compressor continuously, resulting in less pump wear and motor damage from overheating. The air inside the tank is stored at a higher pressure than the air in the room (or atmosphere), and it wants to return to the outside pressure. When the regulator is opened, air escapes. This compressed air can be harnessed to perform work such as powering tools, spraying paint or operating a pneumatic device.
The atmospheric air that is drawn into the tank contains water molecules, which do not stay suspended in the air when under increased pressure at room temperature. As a result, these water molecules condense in the storage tank. To deal with this moisture, each tank is outfitted with a drain valve located at the bottom of the tank. This allows users to drain trapped moisture, maintain tank volume and prevent tank corrosion. In addition, every air compressor has a pressure switch that automatically starts the unit when the air pressure in the tank is below the rated cut-in, or “on” pressure, and stops the compressor when the tank pressure reaches the cut-out or “off” pressure.
The tank pressure gauge measures the air pressure inside the tank. When the compressor turns off, an unloader valve releases the pressurized air in the discharge tube. This allows the pump to start without having to overcome the resistance the trapped air would cause. In the unlikely event, the pressure switch should fail to shut off the compressor, a built-in safety valve is there to release the excess pressure. The safety valve and pressure switch on an air compressor are factory set for safe operation and should not be readjusted.
On portable air compressors, a regulator is provided and allows the user to control the outlet pressure of the air flowing into the tool. Most air tools require delivered air pressure of either 40 psi or 90 psi for proper operation. The regulated air pressure is displayed on the outlet pressure gauge that is attached to the regulator and should be set dynamically while operating the tool.
Classification of Air Compressor:
Compressors can be classified according to the pressure delivered:
Low-pressure air compressors (LPACs), which have a discharge pressure of 150 psi or less
Medium-pressure compressors which have a discharge pressure of 151 psi to 1,000 psi
High-pressure air compressors (HPACs), which have a discharge pressure above 1,000 psi
They can also be classified according to the design and principle of operation:
- Single-Stage Reciprocating Compressor.
- Two-Stage Reciprocating Compressor.
- Compound Compressor.
- Rotary-screw compressor.
- Rotary Vane Compressor.
- Scroll Compressor.
- Turbo Compressor.
- Axial Compressore.
The three basics types of Air Compressor are:
The first, called a reciprocating compressor, uses a piston in a cylinder to squeeze the air.
The second, called a rotary screw compressor, uses a rotating spiral screw of gradually diminishing volume to compress the air.
The third, called a centrifugal compressor, uses a rotating impeller to transfer momentum to the air, thereby compressing it.
There are numerous methods of air compression, divided into either positive-displacement or roto-dynamic types.
Positive-displacement compressors work by forcing air into a chamber whose volume is decreased to compress the air,Once the maximum pressure is reached, a port or valve opens and air is discharged into the outlet system from the compression chamber.
Common types of positive displacement compressors are:
This principle is used in air compressor by pumping air into an air chamber through the use of the constant motion of pistons.They use one -way valves to guide air into and out of a chamber whose base consists of a moving piston. When the piston is on its down stroke, it draws air into the chamber , when it is on its down stroke, it draws air into the chamber.
When it is on the charge of air is forced out and into a storage tank. Piston compressors generally fall into two basic categories, single-stage and two-stage. Single stage compressors usually fall into the fractional through 5 horsepower range Two-stage compressors normally fall into the 5 through 30 horsepower range. wo-stage compressors provide greater efficiency than their single-stage counterparts. For this reason, these compressors are the most common units within the small business community.
Rotary Screw Compressors: Use positive – displacements compression by matching two helical screws that, when turned, guide air into a chamber, whose volume is decreased as the screws turn.
Vane Compressors: Use a slotted rotor with varied blade placements to guide air into a chamber and compress the volume. This type of compressor delivers a fixed of air at high pressures.
Dynamic displacement air compressors include centrifugal compressors and axial compressors. In these types, a rotating component imparts its kinetic energy to the air which is eventually converted into pressure energy. These use centrifugal force generated by a spinning impeller to accelerate and then decelerate captured air, which pressurizes it.
Air compressors have many uses, including:
1. Supplying high-pressure clean air to fill gas cylinders.
2. Supplying moderate-pressure clean air to a submerged surface supplied diver, supplying moderate-pressure clean air for driving some office and school building pneumatic HVAC control system valves.
3. Supplying a large amount of moderate-pressure air to power pneumatic tools, such as jackhammers, filling high pressure air tanks (HPA), for filling tires, and to produce large volumes of moderate-pressure air for large-scale industrial processes (such as oxidation for petroleum coking or cement plant bag house purge systems). Most air compressors either are reciprocating piston type, rotary vane or rotary screw.
Centrifugal compressors are common in very large applications.
There are two main types of air-compressor pumps: oil-lubed and oil-less. The oil-less system has more technical development, but is more expensive, louder and lasts for less time than oil-lubed pumps. The oil-less system also delivers air of better quality.
The most common types of air compressors are:
electric or gas/diesel powered compressors. The power of a compressor is measured in HP (horsepower) and CFM (cubic feet per minute of intake air). The gallon size of the tank specifies the volume of compressed air (in reserve) available.
Gas/diesel powered compressors are widely used in remote areas with problematic access to electricity. They are noisy and require ventilation for exhaust gases.
Electric powered compressors are widely used in production, workshops and garages with permanent access to electricity.
Common workshop/garage compressors are 110-120 Volt or 230-240 Volt. Compressor tank shapes are: “pancake”, “twin tank”, “horizontal”, and “vertical”. Depending on a size and purpose compressors can be stationary or portable.
To ensure all compressor types run efficiently with no leaks, it is imperative to perform routine maintenance, such as monitoring and replacing air compressor fittings. It is suggested that air compressor owners perform daily inspections of their equipment, such as:
- Checking for oil and air leaks.
- Checking the differential pressure in the compressed air filter.
- Determining whether or not the oil in the compressor should be changed.
- Verify safe operating temperature to avoid overheating the unit and it is used in sucking the air.
- Draining condensed moisture from the tank.
Top selling companies of air compressor:
- Firstly, Chicago Pneumatic
- Secondly, Ingersoll Rand Compressors
- Thirdly, Quincy Compressors
- Then, Champion air compressor
- Further, KORE Compressor
- Finally, Atlas Copco Compressors