EP4112932A1 - Compresseur à piston et procédé de fonctionnement d'un compresseur à piston - Google Patents

Compresseur à piston et procédé de fonctionnement d'un compresseur à piston Download PDF

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Publication number
EP4112932A1
EP4112932A1 EP22180868.6A EP22180868A EP4112932A1 EP 4112932 A1 EP4112932 A1 EP 4112932A1 EP 22180868 A EP22180868 A EP 22180868A EP 4112932 A1 EP4112932 A1 EP 4112932A1
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EP
European Patent Office
Prior art keywords
lubricant
lubricating
piston
lubricating film
value
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP22180868.6A
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German (de)
English (en)
Other versions
EP4112932B1 (fr
EP4112932C0 (fr
Inventor
Matthias Kornfeld
Tino Lindner-Silwester
Bernhard Fritz
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Hoerbiger Wien GmbH
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Hoerbiger Wien GmbH
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Publication of EP4112932A1 publication Critical patent/EP4112932A1/fr
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Publication of EP4112932B1 publication Critical patent/EP4112932B1/fr
Publication of EP4112932C0 publication Critical patent/EP4112932C0/fr
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/02—Lubrication
    • F04B39/0207—Lubrication with lubrication control systems
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/02—Lubrication
    • F04B39/0223—Lubrication characterised by the compressor type
    • F04B39/0276—Lubrication characterised by the compressor type the pump being of the reciprocating piston type, e.g. oscillating, free-piston compressors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/02—Lubrication
    • F04B39/0284—Constructional details, e.g. reservoirs in the casing
    • F04B39/0292—Lubrication of pistons or cylinders
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
    • F04B39/04—Measures to avoid lubricant contaminating the pumped fluid
    • F04B39/041—Measures to avoid lubricant contaminating the pumped fluid sealing for a reciprocating rod
    • F04B39/042—Measures to avoid lubricant contaminating the pumped fluid sealing for a reciprocating rod sealing being provided on the piston
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06—Control using electricity
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B51/00—Testing machines, pumps, or pumping installations
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2201/00—Pump parameters
    • F04B2201/04—Carter parameters
    • F04B2201/0404—Lubricating oil condition
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2201/00—Pump parameters
    • F04B2201/08—Cylinder or housing parameters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B53/00—Component parts, details or accessories not provided for in, or of interest apart from, groups F04B1/00 - F04B23/00 or F04B39/00 - F04B47/00
    • F04B53/18—Lubricating

Definitions

  • the invention relates to a lubricating system for a reciprocating compressor for introducing a lubricant onto a cylinder running surface of a cylinder of the reciprocating compressor, in which a piston can be moved back and forth, with a lubricating system control unit being provided for controlling an amount of lubricant to be introduced.
  • the invention further relates to a piston compressor with a lubrication system and a method for operating a piston compressor with at least one cylinder, in which a piston is moved back and forth, with a lubricant being supplied to a cylinder running surface of the at least one cylinder by means of a lubrication system and with a quantity of lubricant of the supplied lubricant is controlled by a lubrication system control unit.
  • each cylinder has one or more lubrication points through which a lubricant can be introduced into the cylinder.
  • the lubrication points are usually supplied with lubricant from a central lubrication system. Dosing the lubricant into the cylinders as precisely as possible is crucial for reliable operation. Too little lubricant leads to increased wear on the moving components of the compressor, in particular on the piston rings or packing rings of sealing packings with which the piston rod is sealed. Increased wear leads to a reduced service life of these components and thus to reduced availability of the compressor.
  • lubricant usually leads to reduced life of components such as compressor valves due to an oil sticking effect, as well as reduced life of downstream equipment such as catalytic converters.
  • high amounts of lubricant naturally lead to increased operating costs due to lubricant consumption, as well as higher capital costs because additional equipment such as special separators is required to remove excess lubricant from the compressed process stream.
  • Known lubrication systems are usually based on a predetermined amount of lubricant for the respective piston engine. These specified amounts of lubricant are typically provided by the compressor manufacturers depending on the compressor type, size and process parameters and are based on empirical data or simplified calculation models. Due to uncertainties in these calculation models and to cover all designs and operating conditions of the compressors, safety factors are usually provided, which are chosen to be conservative, so that more lubricant is usually supplied than is necessary. Such "over-lubrication" of the cylinders during operation is of course disadvantageous for the operator of a piston compressor for the reasons mentioned above and is therefore undesirable.
  • the object is achieved with the lubrication system mentioned at the outset in that at least one lubricant sensor is provided for detecting a lubricating film measured variable that is representative of a lubricating film thickness of a lubricating film on the cylinder running surface of the cylinder, that the lubricating system control unit is designed to monitor the lubricating system during operation of the piston compressor to operate at least once in a predetermined calibration operating mode, to determine a lubricant film condition value based on the lubricant film measured variable recorded during the implementation of the calibration operating mode and to control the lubricant quantity to be introduced in the operation of the piston compressor after the end of the calibration operating mode depending on the lubricant film condition value determined.
  • the amount of lubricant required can be significantly reduced compared to conventional lubrication systems, so that the cylinders are not over-lubricated.
  • the lubricant sensor is preferably an ultrasonic sensor, with a temporal resolution of the lubricant sensor preferably being 0.01° to 5° crank angle. This makes it possible to easily record the measured variable of the lubricating film without having to have direct access to the cylinder running surface.
  • an ultrasonic sensor can easily be placed on the outside of an existing cylinder.
  • the lubrication system control unit is preferably designed to use a sensor value of the measured lubricant film variable to determine the lubricant film condition value, which is recorded during a piston stroke of the piston at a time when a piston ring of the piston is in the sensor area of the lubricant sensor, preferably one during of the piston stroke recorded minimum value of the lubricating film measured variable.
  • the lubrication system is designed for intermittent introduction of the lubricant into the cylinder, preferably as a pump-to-point system, as a divider block system or as a common rail system, and the lubrication system control unit is designed to the amount of lubricant by a Changing a frequency and / or an injection amount to control each injection of the intermittent introduction of the lubricant. This means that proven lubrication systems can be used and calibrated accordingly.
  • the lubrication system controller is advantageously configured to repeat the calibration mode of operation on a specified cycle to update the lube condition value and adjust the amount of lubricant to the updated lube condition value.
  • a duration of the calibration operating mode is preferably at least ten, preferably at least one hundred, particularly preferably at least one thousand crankshaft revolutions of the piston compressor or an equivalent time. This gives sufficient time to set and evaluate different states of the lubricating film.
  • the lubrication system control unit is designed to determine a maximum value and a minimum value in a time profile of the measured lubricant film variable recorded during the at least two time ranges, and from this to determine the lubricant film state value for controlling the amount of lubricant to determine.
  • a first time range with a specified duration and a subsequent second time range with a specified duration are defined and the quantity of lubricant introduced during the first time range is defined such that a completely wetted lubricating film is formed on the cylinder running surface and the amount of lubricant introduced during the second time range
  • the quantity of lubricant is determined in such a way that dry running occurs on the cylinder surface.
  • the duration of the first time range is preferably at least five crankshaft revolutions and the quantity of lubricant introduced during the first time range is preferably 90-200% of a quantity of lubricant specified by the compressor manufacturer.
  • the duration of the second time period is preferably at least five crankshaft revolutions and during the second
  • the amount of lubricant introduced over the period of time is preferably 0% of the amount of lubricant specified by the compressor manufacturer. This simulates various lubricating film conditions and uses them to determine a representative general lubricating film condition value.
  • the lubricating system control unit is designed to determine a differential value between the ascertained maximum value and the ascertained minimum value, to ascertain a lubricating film limit value from the maximum value and the ascertained differential value, and to use the lubricating film limit value as the lubricating film state value.
  • the lubrication system control unit is preferably also designed to control the lubrication system for introducing the lubricant during operation of the piston compressor after the end of the calibration operating mode if the measured lubricating film variable is in a lubricating system activation range between the minimum value and the lubricating film limit value.
  • this creates a differential evaluation method that is essentially independent of the recorded absolute values of the recorded lubricant film measurement variable and a simple indicator for activating the introduction of lubricant is provided.
  • a lubricant quantity detection unit is preferably also provided in the lubrication system for detecting a quantity of lubricant supplied to the lubrication point, and the lubrication system control unit is designed to compare the lubricant film measured variable obtained from the lubricant film sensor and the lubricant quantity obtained from the lubricant quantity detection unit in order to compare the two values to check for consistency and/or to detect a leak in the lubrication system.
  • This allows the function of the lubricant sensor to be checked and leaks in the lubricant lines to be detected. Based on this, certain actions, such as switching off the compressor or changing the lubrication to conventional over-lubrication, can be carried out, which can increase operational reliability.
  • the invention is also achieved with a method in that at least one lubricant sensor is used to detect a lubricating film measurement variable that is representative of a lubricating film thickness of a lubricating film on the cylinder running surface of the cylinder, that the lubricating system is monitored by the lubricating system control unit at least once in a predetermined Calibration mode is operated, based on the detected while performing the calibration mode lubricating film measured variable, a lubricating film condition value is determined and that the lubrication system control unit after the end of the calibration mode in operation of the piston compressor controls the quantity of lubricant to be introduced depending on the determined value of the condition of the lubricating film.
  • a simplified sectional view through a cylinder 2 of a piston compressor 1 is shown.
  • a piston 3 is arranged in a known manner in the cylinder 2 and can be moved back and forth in the cylinder between a top dead center OT and a bottom dead center UT.
  • the piston 3 can be driven in a known manner by a crankshaft (not shown) via a connecting rod (not shown), a crosshead (not shown) and a piston rod 4 .
  • a crankshaft not shown
  • a connecting rod not shown
  • a crosshead not shown
  • piston rod 4 a piston rod 4
  • other designs of the piston compressor 1 would also be possible, for example a direct drive of the piston 3 by a connecting rod without a crosshead and piston rod 4.
  • a cylinder liner 5 a so-called liner, is arranged in the cylinder 2, on the inner peripheral surface of which is a cylinder running surface for the piston 3 is formed.
  • a piston compressor 1 can, of course, have a plurality of cylinders 2, in each of which a piston 3 can be moved back and forth, it being possible for the plurality of pistons 3 to be driven by a common crankshaft.
  • One or more piston rings 6 can be provided on the piston 3 and are arranged in suitable circumferential grooves on the circumferential surface of the piston 3 .
  • a piston ring 6 is generally to be understood as meaning piston rings with different functions.
  • a piston ring 6 can be designed as a sealing ring, as a support ring or as a scraper ring.
  • a sealing ring is designed, for example, to seal against a differential pressure, while a Support ring usually develops no sealing effect and is designed to support the load of the piston 3 on the cylinder liner.
  • a scraper ring is designed to scrape the lubricating film from the cylinder running surface.
  • piston rings 6 could be provided, for example in the form of a sealing ring.
  • three piston rings 6a, 6b, 6c are provided, the first and third piston rings 6a, 6c being designed as sealing rings and the second piston ring 6b being designed as a support ring.
  • more or fewer piston rings 6 could also be provided, for example an oil scraper ring. It can be seen that the support ring 6b has a greater width (in the axial direction) than the sealing rings 6a, 6c, which is usually the case.
  • the groove in the piston 3, in which the support ring 6b is arranged is designed in such a way that the support ring 6b rests directly on the bottom of the groove.
  • the support ring 6b is thus essentially immovable in the radial direction in order to be able to support the load of the piston 3 better.
  • the sealing rings 6a, 6c can be moved radially in the respective grooves in order to be able to create a better seal.
  • a piston ring 6 can of course also have a certain overhang over the piston 3 in the radial direction, which for the sake of simplicity is shown in Fig.1 is not shown.
  • a compression space 7 delimited by the piston 3 is formed in the cylinder 2, on which a suction valve 8 and a pressure valve 9 are arranged.
  • the piston 3 is moved from top dead center OT to bottom dead center UT, and during a compression stroke, the piston 3 is moved from bottom dead center UT to top dead center OT.
  • a gaseous medium to be compressed for example air or a process gas, can be sucked into the compression chamber 7 via the suction valve 8 .
  • the medium in the compression chamber 7 is compressed and discharged from the compression chamber 7 via the pressure valve 9 .
  • the suction valve 8 and the pressure valve 9 are in Fig.1 only indicated as a schematic circuit symbol and can be designed differently.
  • suction valves 8 and pressure valves 9 can also be provided on the cylinder.
  • the suction valve 8 and the pressure valve 9 do not necessarily have to be arranged on the end face of the cylinder 2, but could also be provided on the peripheral surface of the cylinder 2 in the compression space 7, for example.
  • the suction valve 8 and the pressure valve 9 can be designed as known automatic ring valves, it also being possible for an unloader to be provided to keep the valves open.
  • the unloader can be controlled by a suitable compressor control unit 10 to regulate the capacity of the compressor 1 .
  • the piston compressor 1 also has a lubrication system for lubricating the at least one cylinder 2 .
  • the lubrication system has at least one lubrication point 12 for each cylinder 2 for introducing a lubricant into the cylinder 2 .
  • the lubricant forms a lubricating film 11 in the cylinder 2 in order to minimize the friction between the components that move relative to one another, in particular between the piston 3 or piston rings 6 and the cylinder running surface.
  • a plurality of lubrication points 12 can of course also be provided, which can be distributed on the cylinder 2, for example in the axial direction and/or in the circumferential direction, as shown in FIG Fig.1 is indicated by the lubrication points 12a, 12b.
  • the lubricant is introduced via the lubricating point 12 in the compression stroke and/or in the expansion stroke, for example before the respective piston ring 6 reaches the lubricating point 12, while the piston ring 6 is in the area of the lubricating point 12 or possibly also after the respective piston ring 6 has passed the lubricating point 12 .
  • the point in time at which it is introduced essentially depends on the lubrication system used.
  • a central delivery unit for delivering the lubricant and a so-called “divider block” for distributing the lubricant to the lubrication points 12 of the cylinders 2 are provided.
  • the quantity of lubricant conveyed by the central conveying unit is supplied to what is known as a “divider block”, divided up in this block and conveyed to the individual lubrication points 12 .
  • the lubricant is generally introduced into the cylinder 2 intermittently via individual injections. The amount of lubricant to be introduced is controlled by appropriate control of the central delivery unit.
  • the delivery quantity can be controlled via the speed and/or possibly via the piston stroke.
  • a change in the amount of lubricant during operation of the compressor 1 can be done, for example, by changing the frequency of the intermittent individual injections of the lubricant, for example by changing the pump speed. Due to the central delivery unit, however, the amount of lubricant can only be changed in a constant ratio for all available lubrication points 12 . Different quantities of lubricant for different lubrication points 12 or different cylinders 2 are not usually possible here.
  • each lubrication point 12 or each cylinder 2 is assigned its own delivery unit, for example a piston pump.
  • a corresponding quantity of lubricant is delivered to the associated lubrication point 12, again as a rule intermittently over individual injections.
  • the delivery units, in particular the piston pumps are driven via a common camshaft.
  • a change in the amount of lubricant during operation of the compressor 1 can be done, for example, by changing the frequency of the individual injections of the lubricant by adjusting the speed of the camshaft.
  • the amount of lubricant is usually only changed in a constant ratio for all lubrication points 12.
  • the delivery amounts can also be changed separately from one another, for example by an adjustable stroke of the piston pumps.
  • the amount of lubricant at each lubrication point 12 or for each cylinder 2 can be adjusted individually.
  • Suitable adjustment devices can be provided on the conveyor units, for example, to change the amount of lubricant.
  • the adjusting device can be designed for manual adjustment of the stroke of a piston pump, for example, or a suitable actuator can be provided for adjusting the stroke, so that the quantity of lubricant introduced can be changed for each injection.
  • the time of introduction at each lubrication point 12 or at each cylinder 2 can be adjusted individually and essentially independently of the operation of the high-pressure pump (as long as there is sufficient pressure in the pressure accumulator).
  • This makes it possible, for example, for a piston compressor 1 whose piston 3 has a plurality of piston rings 6 to carry out multiple injections within a piston stroke, so that each piston ring 6 can be supplied with a specific quantity of lubricant.
  • the control of the lubricant injection for example the time of an injection and/or the amount of lubricant per injection and/or the frequency of the injections, is usually carried out via a suitable lubrication system control unit 14.
  • the lubrication system control unit 14 can be used as separate hardware and/or software be trained or can, for example, in a parent Control unit such as the compressor control unit 10 can be integrated.
  • a "common rail" system is only shown as an example, with one electrically controllable injector 13 being provided for each lubrication point 12, which injector can be designed, for example, as an electromagnetic injector or as a piezo injector.
  • the injectors are connected to a central lubrication system control unit 14 by any suitable communication link, such as electrical wiring.
  • a central lubrication system control unit 14 can, for example, communicate with a compressor control unit 10 in order to obtain operating parameters BP of the piston compressor 1 that are relevant for the control of the lubrication system.
  • Such operating parameters BP can, for example, contain current data about the operating state of the compressor 1, for example a load signal L, a speed signal N, a crank angle signal °KW, lubricant temperature T, etc.
  • the lubrication system control unit 14 can take the operating parameters BP into account when controlling the lubrication system.
  • the amount of lubricant used to be controlled on the basis of manufacturer specifications which often led to over-lubrication, ie to the introduction of too much lubricant than necessary.
  • an automatic calibration of the lubrication system is provided according to the present invention, as a result of which the amount of lubricant can be adapted to the actual requirement.
  • at least one lubricant sensor 15 is provided in the lubricating system for detecting a lubricating film measured variable S representative of a lubricating film thickness of the lubricating film 11 on the cylinder running surface of the cylinder 2 .
  • the lubricating film measured variable S is essentially a measure of the lubricating film thickness of the lubricating film 11 on the cylinder running surface in a sensor area of the lubricant sensor 15.
  • the lubricant sensor 15 is connected to the lubricant control unit 14 via a suitable communication link in order to transmit the lubricating film measured variable S to the To transmit lubricant control unit 14, for example via suitable electrical measuring lines.
  • An acoustic sensor, in particular an ultrasonic sensor, is preferably provided as the lubricant sensor 15 .
  • the lubricant sensor 15 can be arranged at a suitable location on the outside of the cylinder 2, for example.
  • the lubricant sensor 15 is preferably arranged in the axial direction such that each piston ring 6 of the piston 3 is located once in the sensor area of the lubricant sensor 15 for each piston stroke, so that a lubricant film thickness in the area of each piston ring 6 can be detected.
  • Analogous to the multiple lubrication points 12 can a plurality of lubricant sensors 15 can also be arranged on the cylinder 2 at a distance from one another in the circumferential direction and/or in the axial direction. This can be particularly advantageous in the case of large compressors in order to cover a sufficiently large area of the cylinder running surface of cylinder 2 .
  • the temporal resolution of the lubricant sensor 15, in particular the ultrasonic sensor, for detecting the measured variable S of the lubricant film can be, for example, 0.01° to 5° crank angle.
  • the lubricating system control unit 14 is designed to operate the lubricating system at least once in a predetermined calibration operating mode during operation of the piston compressor 1 and to determine a lubricating film condition value SZ based on the measured lubricating film variable S recorded while the calibrating operating mode is being carried out. After the end of the calibration operating mode, ie during normal operation of the lubricating system when the piston compressor 1 is in operation, the lubricating system control unit 14 controls the quantity of lubricant to be introduced as a function of the determined lubricating film state value SZ.
  • the lubrication system is preferably designed for the intermittent introduction of the lubricant, preferably as a pump-to-point system, as a divider block system or as a common rail system.
  • the lubricating system control unit 14 can adjust the amount of lubricant as a function of the determined lubricating film condition value SZ, for example by changing the frequency of the intermittent introduction of the lubricant, and thereby reduce the amount of lubricant compared to the manufacturer's specification.
  • a corresponding design of the lubrication system e.g.
  • the (total) amount of lubricant introduced into the cylinder 2 can also be changed by changing the amount of lubricant per injection of the injector 13 in addition or as an alternative to the frequency change.
  • the frequency can be changed, as mentioned, e.g. by increasing the speed of the feed pump(s) of the respective lubrication system.
  • a sensor value Pi of the measured variable S of the lubricating film is preferably used to determine the lubricating film state value SZ, which is recorded during a piston stroke of the piston 3 at a time when a piston ring 6 of the piston 3 is in the sensor area of the lubricant sensor 15.
  • the minimum value of the lubricating film measurement variable S is used, as in Fig.2 is shown.
  • Fig.2 is an example of the detected lubricant film measured variable S of a lubricant sensor 15 over the crank angle °KW between top dead center OT and bottom dead center UT of the piston 3 in normal operation of the piston compressor 1 (and the lubrication system).
  • the piston 3 corresponds to the embodiment according to Fig.1 and correspondingly has three piston rings 6a, 6b, 6c. Of course, more or fewer piston rings 6 may be provided.
  • the curve shown corresponds to the measurement signal of the lubricant sensor 15 over the crank angle.
  • Fig.2 As can be seen, depending on the number i of piston rings 6i, there is a characteristic time profile of the lubricating film measured variable S, which can be used as a measure of the lubricating film thickness of the lubricating film 11 on the cylinder running surface of the cylinder 2.
  • the curve has a local minimum for each piston ring 6i, which is proportional to the lubricating film thickness of the lubricating film 11 on the cylinder running surface when the respective piston ring 6i is in the sensor area of the lubricant sensor 15.
  • these are the minimum values Pa, Pb, Pc, which are generally referred to below as PEAK values Pi within the scope of the invention.
  • the assignment of the PEAK values Pa, Pb, Pc to the respective piston ring 6a, 6b, 6c results from their arrangement on the piston 3.
  • PEAK values Pa, Pb, Pc (generally Pi) can now, according to the invention, be used in a calibration operating mode of the lubricating system can be used to determine the lubricating film condition value SZ, as follows based on Figure 3a +3b is explained.
  • each lubricant sensor 15 could of course also be provided in the lubrication system in order to enable redundant detection of the measured variable S of the lubricating film.
  • the lubricant sensors 15 can, for example, be arranged at a certain angular distance apart in the circumferential direction on the cylinder 2 and/or can be arranged on the cylinder 2 in a distanced manner in the axial direction.
  • each lubricant sensor 15 is preferably arranged in such a way that all available piston rings 6i of the piston 3 are once in the sensor area of the respective lubricant sensor 15 during a piston stroke.
  • Two lubricant sensors 15 with different positions in the circumferential direction and the same axial positions on the cylinder 2 would result, for example, in qualitatively the same curves of the lubricating film measured variable S, which, however, can differ quantitatively due to the locally different lubricating film thickness of the lubricating film 11 .
  • the PEAK values Pi would be at the same crank angle position.
  • two lubricant sensors 15 with different positions in the axial direction and the same positions in the circumferential direction would produce, for example, qualitatively and quantitatively different profiles of the lubricant film measured variable S.
  • the PEAK values Pi would lie at different crank angle positions.
  • the advantageous differential evaluation method of the PEAK value curves explained in more detail below, would again compensate for the different absolute values of the PEAK values Pi.
  • the PEAK values Pi may be sampled once every crankshaft revolution or once every piston stroke and stored in the lubrication system controller 14 .
  • the PEAK values Pi are not recorded continuously, i.e. not recorded for each crankshaft revolution or each piston stroke and stored for the evaluation of the time profile, but that the PEAK values Pi are recorded intermittently, for example, with a fixed interruption period of a few crankshaft revolutions or, for example, a time from 1 to 60 seconds.
  • FIG.3b An exemplary calibration mode of operation of the lubrication system is described below. while showing Fig.3b a time profile of the quantity of lubricant introduced into the cylinder 2 during the calibration operating mode over the crankshaft revolutions of the compressor 1.
  • FIG. 3a Using the example of the first piston ring 6a, a time profile of the stored PEAK values Pa over the crankshaft revolutions of the compressor 1 is shown, which changes due to the amount of lubricant introduced according to Fig.3b results.
  • a duration of the calibration operating mode can be, for example, at least ten, preferably at least one hundred, particularly preferably at least one thousand crankshaft revolutions of the piston compressor 1 . Since the crankshaft revolutions are proportional to the time, the time can in principle also be plotted on the abscissa.
  • the calibration operating mode is carried out at least once during operation of the piston compressor 1, for example after a run-in phase during initial commissioning or after service activity on the compressor 1.
  • the run-in phase typically corresponds to an operating time of 12 to 36 hours.
  • the calibration operating mode can also be repeated several times in a defined cycle in order to determine an updated lubricating film condition value SZ and to adapt the quantity of lubricant to the updated lubricating film limit value SZ.
  • different states of wear that occur during operation can be taken into account, which are usually associated with a change in the need for lubricant.
  • the lubrication system control unit 14 determines a maximum value Pi_max and a minimum value Pi_min over the course of time of the measured lubricant film variable S recorded during the at least two time ranges, in particular the PEAK values Pi and uses this to determine the lubricating film condition value SZ ( Fig.4 ) used to control the amount of lubricant.
  • the maximum value Pi_max and the minimum value Pi_min as well as the associated detection times are preferably determined and stored (at least temporarily).
  • the storage can generally take place, for example, in a suitable memory unit which can be integrated, for example, in the lubrication system control unit 14 or in a higher-level compressor control unit 10 .
  • the time ranges Zi and in the time ranges Zi The quantities of lubricant Mi introduced are determined in such a way that different friction and associated wear conditions occur on the cylinder running surface, from a fully wetted lubricating film to a partially wetted lubricating film to dry running.
  • the amount of lubricant M is in the diagram in Fig.3b given on the ordinate as a percentage of a quantity of lubricant specified by the compressor manufacturer.
  • a first time range Z1 with a specified duration and a subsequent second time range Z2 with a specified duration are defined only by way of example.
  • the amount of lubricant M1 introduced during the first time period Z1 is preferably defined in such a way that a completely wetted lubricating film is formed on the cylinder running surface.
  • the amount of lubricant M2 introduced during the second time period Z2, on the other hand, is preferably defined in such a way that dry running occurs on the cylinder running surface.
  • the duration of the first time range Z1 can be at least five crankshaft revolutions and the quantity of lubricant M1 introduced during the first time range Z1 can be 90-200% of a lubricant quantity specified by the compressor manufacturer.
  • the maximum value Pa_max is generally in the first time range Z1 and the minimum value Pa_min is generally in the second time range Z2.
  • the transition between the first time range Z1 and the second time range Z2 there is a characteristic drop in the course of the PEAK values Pa, as in Figure 3a is evident.
  • the duration of the second time range Z2 is preferably also at least five crankshaft revolutions, but can of course also be significantly longer, for example ten, hundred or thousand crankshaft revolutions.
  • the amount of lubricant M2 introduced during the second time period Z2 is preferably 0% of the amount of lubricant specified by the compressor manufacturer, so that no lubricant is introduced.
  • the quantity of lubricant M can be increased again, for example initially to the quantity of lubricant M3 specified by the compressor manufacturer, as indicated by the third time range Z3.
  • the calibration operating mode is completed after the second time period Z2 and from this point in time the lubrication system control unit 14 can use the lubricating film state value SZ ( Fig.4 ) to control the quantity of lubricant during operation of the piston compressor 1.
  • a differential value ⁇ Pa between the determined maximum value Pa_max and the determined minimum value Pa_min is advantageously first determined, as in FIG Figure 3a is drawn.
  • a lubricating film limit value Pa_limit can now be determined on the basis of the maximum value Pa_max and the determined difference value ⁇ Pa, which is advantageously used as the lubricating film state value SZ for controlling the quantity of lubricant can be, as follows using Fig.4 is described.
  • the evaluation and determination of the lubricant film state value SZ, in particular the limit value Pi_limit is of course preferably carried out for the lubricant film measured variable S of each lubricant sensor 15 .
  • mean values of the maximum values Pi_max and the minimum values Pi_min of a number of lubricant sensors 15 could also be used, for example, in order to calculate a mean limit value Pi_limit therefrom.
  • an average value could also be formed from a number of limit values Pi_limit and the quantity of lubricant could be controlled on this basis.
  • Fig.4 is analogous to in Fig.2 a course of the measured lubricating film variable S over the piston stroke between a top dead center OT and a bottom dead center UT during normal operation of the piston compressor 1 and in particular during normal operation of the lubrication system (after the end or outside of the calibration operating mode). Additionally are in Fig.4 the maximum value Pa_max and minimum value Pa_min determined beforehand in the calibration operating mode as well as the lubricating film limit value Pa_limit are drawn in. The hatched area between the minimum value Pa_min and the lubricating film limit value Pa_limit symbolizes a lubricating system activation area 17.
  • the lubricating system control unit 14 recognizes that the PEAK value Pa of the measured lubricating film measurement variable S is in the lubricating system activation area 17, the PEAK value Pa ie reaches or falls below the lubricating film limit value Pa_limit, then the lubricating system control unit 14 controls the lubricating system to introduce the lubricant.
  • the characteristic course of the lubricating film measured variable will change S change again over the crankshaft revolutions, so that the PEAK value Pa slowly approaches the lubrication system activation range 17 again.
  • the (total) amount of lubricant is thus essentially controlled by adjusting the frequency of the individual injections.
  • the amount of lubricant introduced per injection could also be varied.
  • the amount of lubricant introduced per injection essentially depends on the design of the delivery unit(s) (e.g. the displacement of a piston pump) and is usually unchangeable. An adjustment of the (total) quantity of lubricant can thus generally only be controlled by adjusting the frequency of the individual injections, for example by changing the speed of the piston pump(s).
  • the description based on the first piston ring 6a is of course only to be understood as an example and the calibration operating mode could of course also be carried out separately for a number of piston rings 6i.
  • the course of the measured lubricating film variable S of the lubricant sensor 15 can be evaluated for each piston ring 6i in order to determine a lubricating film state value SZi for each piston ring 6i for controlling the quantity of lubricant.
  • a limit value Pi_limit can be determined for each piston ring 6i, so that an associated lubrication system activation area 17i is determined for each piston ring 6i.
  • the lubricating system control unit 14 can then control the lubricating system to introduce lubricant during normal operation of the piston compressor 1 as soon as the respective PEAK value Pi is in the respectively assigned lubricating system activation range 17 .
  • the limit value Pi_limit can of course also differ.
  • a piston ring 6i has a higher lubricant requirement than another piston ring 6i, then it can basically also be sufficient if the calibration according to the invention is only carried out for the piston ring 6i with the higher lubricant requirement.
  • the limit value Pi_limit would thus only be determined for one piston ring 6i and the lubricating system control unit 14 would activate the lubricating system accordingly as soon as the assigned PEAK value Pi is in the determined lubricating system activation range 17i.
  • the introduction of the lubricant is preferably timed in such a way that the lubricant is supplied precisely to the piston ring 6i with the greatest need for lubricant.
  • the lubricant is introduced during the piston stroke, preferably in front of the piston ring 6i or directly onto the piston ring 6i.
  • the piston ring or rings 6i with the lower lubricant requirement consequently automatically receive a sufficiently large amount of lubricant.
  • the detection and evaluation of the quantity of lubricant according to the invention preferably takes place individually for each cylinder 2 by arranging at least one lubricant sensor 15 on each cylinder 2.
  • a lubricant quantity detection unit is provided in the lubricating system for detecting a quantity of lubricant supplied to the lubricating point 12 .
  • the lubricant quantity detection unit can be a suitable flow sensor 16, for example, which is integrated in a feed line to a lubrication point 12, as shown in FIG Fig.1 is indicated.
  • the flow sensor 16 is preferably connected to the lubrication system control unit 14 to transmit a measurement signal which is proportional to the amount of lubricant.
  • a calculation model could also be provided as the lubricant quantity detection unit, for example, which can be implemented in the lubrication system control unit 14, for example, and which calculates the quantity of lubricant supplied to the lubrication point 12 using available parameters of the lubrication system, for example based on the displacement of a piston pump and the pump speed, etc.
  • the lubrication system control unit 14 can thus compare the lubricant film measurement variable S obtained from the lubricant sensor 15 and the lubricant quantity obtained from the lubricant quantity detection unit in order to check the two values for consistency. As a result, a malfunction of the lubricant sensor 15 can be inferred, for example, if a certain discrepancy between the two values is determined. Likewise, the comparison can be used to detect a leak in the lubrication system. A leak can be present, for example, when the flow sensor 16 outputs a certain expected value and the lubricant film measured variable S detected by the lubricant sensor 15 assumes no value or a very low value.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Compressor (AREA)
  • Control Of Positive-Displacement Pumps (AREA)
EP22180868.6A 2021-06-28 2022-06-24 Compresseur à piston et procédé de fonctionnement d'un compresseur à piston Active EP4112932B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
ATA50536/2021A AT524547B1 (de) 2021-06-28 2021-06-28 Kolbenkompressor und Verfahren zum Betreiben eines Kolbenkompressors

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EP4112932A1 true EP4112932A1 (fr) 2023-01-04
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EP4112932C0 EP4112932C0 (fr) 2025-04-02

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EP (1) EP4112932B1 (fr)
JP (1) JP2023007494A (fr)
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Also Published As

Publication number Publication date
US20220412333A1 (en) 2022-12-29
EP4112932B1 (fr) 2025-04-02
EP4112932C0 (fr) 2025-04-02
AT524547B1 (de) 2022-07-15
JP2023007494A (ja) 2023-01-18
CN115596661A (zh) 2023-01-13
AT524547A4 (de) 2022-07-15

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