Development of capacity modulation compressor based on a two stage rotary compressor – part I: Modeling and simulation of compressor performance

Two-stage rotary compressors are gaining popularity because of their ability to reduce operating and energy costs over the entire compressor life cycle. In this work, a capacity modulation compressor based on a two-stage rotary compressor (CMCTR) is developed to improve the performance of the rotary compressor system. The working principle of the CMCTR is presented and the cycle efficiency of the compressor through two-stage compression is numerically investigated. The CMCTR model considers mass and energy balance for a control volume, the internal leakage condition for all leakage paths, the discharge valve motion, and the force and moment balance. For simulation results, the motor efficiency is estimated with respect to shaft power and the pressure during an entire cycle is obtained with respect to the compression volume for saving mode and power mode. The optimum efficiency of the CMCTR is obtained for the modulation for these modes.     

Experimental study on stepless capacity regulation for reciprocating compressor based on novel rotary control valve

A capacity-regulation system based on a novel rotary control valve for reciprocating refrigeration compressor is proposed and designed for the first time. The regulation system is mainly composed of a rotary control valve and an adaptive regulation system. The structure and working principle of the rotary control valve is described in detail, and the control process of the adaptive regulation system for the valve is studied together with the program design. In addition, the parameters for the design and control of the rotary control valve are theoretically determined. To verify the feasibility and effectiveness of the proposed system, a three-cylinder reciprocating compressor was adopted as a test device. Experimental results showed that the technology was able to realize continuous stepless capacity regulation for the compressor within the range of (0)10–100%, and power consumption decreased correspondingly with the load reduction.     

液氦温区脉管制冷机的优化实验

研制了一台用作德国国家标准局 (PTB)约瑟夫森效应 (JosephsonEf fect) 1V电压标准冷却系统的二级脉管制冷机。其设计要求在 4 2K提供 1 0 0mW左右制冷量 ,并同时冷却 70K左右的冷屏。采用额定功率为 1 8kW的氦压缩机驱动脉管制冷机 ,在不同制冷量负荷条件下分别对其进行了优化。初步实验结果表明 ,在输入功率 1 8kW的情况下 ,该制冷机最低制冷温度达 2 8K ,4 2K制冷量最大达 1 90mW ,制冷系数达 1 0 6× 1 0 4,火用效率最高达 1 1 3% ,可以充分满足冷却电压标准芯片的需要。此外 ,还与用 6kW压缩机驱动同一制冷机的实验结果进行了比较。     

膜式燃气表内部流动数值模拟研究

采用CFD数值模拟方法对有柔性膜片的膜式燃气表内部流动进行数值模拟研究,解决了皮膜和旋转阀之间的联动关系以及旋转阀转动与皮膜运动的仿真实现等技术问题;运用滑移网格、动网格及用户自定义函数(UDF)技术实现了膜式燃气表内部流动的动态数值模拟,获得了旋转阀与阀座存在1mm间隙的情况下膜式燃气表内部流场和仪表压损数据.结果表明,数值模拟技术用于膜式燃气表这种复杂结构的内部流动研究是可行的.     

A mathematical model of variable displacement swash plate compressor for automotive air conditioning system

A mathematical model of control mechanism used in the variable displacement swash plate compressor (VDSC) is developed firstly based on the force balance equation, mass and energy conservation equation. The model of moving components dynamics is developed then by analyzing the forces and force moments acting on the pistons and the swash plate. The compression process model is obtained by fitting the data from our experiments. And finally, the steady-state mathematical model of VDSC is developed by combining the three sub-models above. In order to verify the mathematical model, a test bench for control mechanism and the test system for VDSC have been established, and the simulated results agree well with the experimental data. The simulation results show that, like the variable displacement wobble plate compressor, there are four operation modes for the VDSC, i.e. constant rotary speed and constant piston stroke length (PSL), variable rotary speed and constant PSL, constant rotary speed and variable PSL, variable rotary speed and variable PSL, which have included almost all operation modes of the refrigeration compressor in common use. And there is a hysteresis zone and multiple-valued relationship between the compressor parameters when PSL changes.     

Two-stage pulse tube refrigerator in an entire coaxial configuration

In this paper, we introduce a new kind of two-stage pulse tube refrigerators. The chosen entire coaxial configuration combines the advantages of the coaxial design with the two-stage pulse tube concept. Lead coated screens build the inhomogeneous regenerator matrix of the second stage. Without any rare earth compounds the refrigerator reaches a no load temperature of 6.6 K at the second stage cold tip. The active type of phase shifting is generated by a rotary valve combined with two needle valves at the hot end of each pulse tube (compressor Leybold RW 6000, 6 kW input power). This paper focuses on the design parameters and first performance measurements.     

簧片阀流量系数的实验研究与数值模拟

在压缩机簧片阀的数值模拟中,簧片阀的流量系数和相应的有效流通面积是须预先知道的关键参数。一般来说,流量系数和有效流通面积是通过实验测得的。但是,当制冷剂在封闭的系统中流动时,很难测得簧片阀的流量系数。本论文提出了一种思路,建立以空气为工质来测量簧片阀流量系数的模型,同时用静态吹风实验来测量空气的流量系数,得到了空气在不同流量和阀片升程下的流量系数。改变工质为R600a后,模拟计算了簧片阀的流量系数,并通过压缩机整机性能实验对流量系数的正确性进行了间接的验证。结果表明:以空气为工质模拟计算的流量系数与实验结果符合较好,这一模型能够用于计算工质为R600a时的流量系数。     

Efficiency analysis of power consumption in small hermetic refrigerant rotary compressorsAnalyse,du point de vue du rendement,de la consommation d'énergie dans les petits compresseurs frigorifiques rotatifs hermétiques

Theoretical and experimental studies of small hermetic rotary compressors for room air conditioners are reported. Comparing rotary and reciprocating compressors from the viewpoint of efficiency, the rotary compressor has a disadvantage of higher friction loss because the sliding surfaces in the compression chamber increase in number, however it has the following three significant features: volumetric efficiency is high; valve loss is low; since suction, compression and discharge are performed simultaneously, suction velocity and discharge velocity become approximately one half. Therefore the efficiency of the rotary compressor is higher than that of the reciprocating compressor.     

Efficiency analysis of power consumption in small hermetic refrigerant rotary compressors

Theoretical and experimental studies of small hermetic rotary compressors for room air conditioners are reported. Comparing rotary and reciprocating compressors from the viewpoint of efficiency, the rotary compressor has a disadvantage of higher friction loss because the sliding surfaces in the compression chamber increase in number, however it has the following three significant features: volumetric efficiency is high; valve loss is low; since suction, compression and discharge are performed simultaneously, suction velocity and discharge velocity become approximately one half. Therefore the efficiency of the rotary compressor is higher than that of the reciprocating compressor.     

Numerical simulation and its verification for an active magnetic regenerator

In this study, a one-dimensional model for the active magnetic regenerator (AMR) is established and verified by comparison with the experimental results. Besides four basic governing equations concerning mass and momentum conservation of heat transfer fluid and energy conservation of fluid and magnetic refrigerant, energy conservation of the regenerator wall is considered to achieve high accuracy and generalization. For the verification, a room temperature AMR has been fabricated with Gd and Halbach array. The AMR is operated by helium compressor with a rotary valve so that the effect of gas-compression/expansion also exists. Instantaneous mass flow rate and temperature distributions are measured during the experiment. Measured values are utilized as the boundary conditions and compared with the simulation results. Instead of cooling capacity or COP, simulation results are directly compared with the experimental results by temperature distribution in the AMR. The model and simulation results predict temperature distribution of the AMR properly at cyclic steady-state.     

分离型二级脉管制冷机的实验研究--Ⅱ:液氦温区二级脉管制冷机

研制1台新型液氦温区分离型二级脉管制冷机,该制冷机由2台独立的脉管制冷机组成,一级回热器冷端和二级回热器中部通过热桥相连,从根本上弥补了传统直接耦合型多级脉管制冷机级间干扰的不足.采用双压缩机双旋转阀驱动该二级脉管制冷机,第二级最低温度达到了2.5 K,在4.2 K下有508 mW制冷量,同时一级在37.5 K有15 W制冷量.第二级充气压力由1.7 MPa增大到1.85 MPa,制冷机在4.2 K下的制冷量可以达到590 mW.为了能简化结构、扩大应用,提出采用单压缩机单旋转阀驱动该分离型脉管制冷机,达到了相同的制冷性能.     

A comprehensive model of a novel rotating spool compressor

A comprehensive simulation model of a novel rotating spool compressor is presented. The spool compressor provides a new rotary compression mechanism with easily manufactured components. A detailed analytical geometry model of the spool compressor is presented, which includes the geometry of the vane. This geometry model is included in an overall comprehensive compressor model that includes sub-models for friction, leakage, and heat transfer. The results of the comprehensive model were validated using experimental data from a prototype compressor. The prototype compressor has an overall displacement of 23.9 cm³, and was operated using R410A as the working fluid. The model predicts the volumetric efficiency, discharge temperature, and shaft power of the prototype compressor to within 3.13% MAE, 16.5 K and ?13.2 W average deviation, respectively. The trends and spread in the data indicate that additional effort should be focused on the operation of the active sealing elements within the compressor.     

Valve timing effect on the cooling performance of a 4 K pulse tube cooler

Generally, a compressor together with a rotary valve system generates the pressure oscillation in GM-type cryocoolers. The timing of the rotary valve, which is one of the key operating parameters for cryocoolers, determines the relationship between intake and exhaust processes. A systematic investigation of valve timing effects on cooling performance of a two-stage 4 K pulse tube cooler (PTC) is reported. The experiments show that the optimization of valve timing can considerably improve the cooling performance for both stages. For the same PTC, a performance comparison for operation on different compressors with various input powers ranging from 0.5 to 6.0 kW is also presented.     

小型冷库制冷系统稳态仿真

对小型冷库制冷系统进行了稳态仿真.建立了压缩机稳态仿真模型,重点考虑了压缩机输运环节的计算.建立了热力膨胀阀模型,重点建立了流量与阀前后压差及制冷剂进出口干度的关系.实验表明,模型精度达到工程实用要求;结合实验和仿真分析,对小型冷库的运行和设计提出了建设性意见.     

A Simulation Study on the Transient Motion of a Reciprocating Compressor Suction Valve Under Complicated Conditions

Stepless capacity control technology for reciprocating compressors is a key contributor to energy saving for the petroleum and petrochemical industries. Devices called “unloaders” are utilized to control the capacity of the compressor by forcibly holding the suction valves open during a variable portion of the compression stroke to control the compressor output. This approach can also lead to various faults of the suction valve. This paper describes the simulation and experimental studies of the transient motion of suction valves under stepless capacity control. Beginning with mathematical models for the normal cycle, improved models of a reciprocating compressor under stepless capacity control have been built. A simulation study of the working process of a double-acting reciprocating compressor has been completed. Theoretical formulas for the transient motion of the valve plate under complicated conditions and the dynamic pressure in the cylinder are compared with the experimental results. Based on the above simulations, a finite element analysis of the valve plate and valve seat has been completed. The experiment results showed that the vibration of the compressor cylinder under complicated conditions was consistent with numerical simulation results. Research presented in this paper is significant in providing tools for diagnosing faults in order to optimize the design of reciprocating compressors that utilize a stepless capacity control system.     

Investigation on a three-cold-finger pulse tube cryocooler

This paper introduces a new type of pulse tube cryocooler, three-cold-finger pulse tube cryocooler (TCFPTC), which consists of one linear compressor and three cold fingers, i.e., CFA, CFB and CFC. Those three cold fingers are driven by the linear compressor simultaneously. This paper investigates two aspects. First, it studies the mass flow distribution among the three cold fingers by varying the input electrical power. The cooling powers of the three cold fingers at constant cooling temperatures and the cooling temperatures of the three cold fingers at constant cooling powers with various input electrical powers are investigated. Secondly, the interaction among the three cold fingers is investigated by varying the heating power of any one cold finger. Generally, if the heating power applied on one cold finger increases, with its cold head temperature rising up, the cold head temperatures of the others will decrease. But, when the cooling power of CFC has been 4 W, the cold head temperature of whichever cold finger increases, the cold head temperature of CFA or CFB will seldom change if its heating power keeps constant.     

CFD在滚动转子压缩机设计中的应用

通过CFD工具对滚动转子压缩机在消音腔优化、壳体内部流动、供油分析和润滑油加注量等方面进行了三维数值模拟,并通过实验验证了CFD的模拟结果。结果表明:在滚动转子压缩机设计中使用CFD工具,可以更加深刻的了解压缩机的物理规律,指导压缩机开发设计,节约开发成本和时间。     

Friction losses in rolling piston type rotary compressors. III

The present Paper is concerned with a rolling piston type rotary compressor for air conditioning use. The leakage through clearances between rolling piston faces and cylinder head walls is analysed theoretically and experimentally. The leakage decreases volumetric efficiency and increases power consumption of the compressor.     

Leakage losses with a rolling piston type rotary compressor. II. Leakage losses through clearances on rolling piston facesPertes dues à des fuites d'un compresseur à piston rotatif. II. Pertes dues à des fuites par les espaces morts sur les faces d'un piston rotatif

The present Paper is concerned with a rolling piston type rotary compressor for air conditioning use. The leakage through clearances between rolling piston faces and cylinder head walls is analysed theoretically and experimentally. The leakage decreases volumetric efficiency and increases power consumption of the compressor.     

滚动转子式压缩机吸气压力脉动研究

滚动转子式压缩机吸气压力脉动对其制冷剂吸入量有着重要的影响。本文以某种型号的滚动转子式压缩机为研究对象,借助流体仿真软件Star-CD,模拟压缩机旋转压缩过程,得到汽缸吸气口的压力脉动规律,并同NI试验测试的压力脉动进行对比,发现两者结果较为吻合;并通过仿真对比吸气管路对压缩机吸气压力和吸气量的影响。