What is a Piston Compressor?
A piston compressor is a type of compressor that uses the reciprocating motion of a piston to compress fluid. These compressors, also known as reciprocating compressors, fall under the category of positive displacement compressors. They are widely used in both air compressors and gas compressors for various gases, including nitrogen, carbon dioxide, hydrogen, oxygen, refrigerants, and more.
Piston compressors are known for their large torque fluctuations during rotation, which can lead to increased noise and vibration. However, this issue can be mitigated by employing multiple cylinders.
Applications of Piston Compressors
1. Air Compressors
Piston compressors for air compression are commonly used in small to medium-sized applications. These range from single to multi-cylinder models and are often integrated with an air tank, pressure gauge, regulating valve, and controller. Examples include bicycle inflators and large-scale installations in factories as compressed air sources. They are also used in train doors and brakes, bus and truck brakes, construction tools, spray painting, dental applications, and food production. For high-pressure applications, multi-stage compressors are used to avoid excessive temperature rise by sequentially compressing the air in different cylinders.
2. Gas Compressors
These compressors are designed for various gases other than air, such as carbon dioxide, nitrogen, hydrogen, oxygen, LPG, LNG, ammonia, ethylene, hydrocarbons, and refrigerants. Their design includes considerations for specific gas characteristics, and compression ratios, and may range from one to six cylinders. Special types include multi-stage, oil-free, and oil-lubricated compressors. For gases like LPG and LNG, which are extremely cold at suction, oil-free compressors with special materials and structures are used for sliding parts.
3. Refrigerant Compressors
Piston compressors are also utilized in air conditioners and refrigeration units. Hermetically sealed compressors are commonly found in electric refrigerators, small to medium air conditioners, and commercial refrigeration units, where the compressor and motor are enclosed in a welded container.
Principle of Piston Compressors
The key components of a piston compressor include the piston seal, crankshaft, cylinder, inlet and discharge valves, cylinder head, drive unit, valves in the gas passage, oil supply unit, and control unit. During the intake process, the descending piston creates negative pressure, drawing gas into the cylinder. After reaching the bottom dead center, the piston begins the compression process, and once the pressure exceeds the discharge pressure, the discharge valve opens. Compressors may be driven by electric motors (induction, DC brushless, commutator, or reluctance types), hydraulic motors, or engines. DC brushless motors, in particular, are energy-efficient and easily controlled when paired with an inverter.
Other Information on Piston Compressors
1. Precautions for Use
Generation of Heat: Compression of gas generates heat due to the increased velocity and reduced distance between gas molecules. The extent of heat generation depends on the specific heat ratio and the compression ratio. Cooling systems may be necessary for certain applications.
Generation of Water: In air compressors, the atmospheric water vapor condenses into water in the compressed air tank due to increased saturation. This water must be regularly drained to prevent negative impacts on the equipment.
2. Oil-less Compressors
Piston compressors come in oil-fed and oil-less varieties. Oil-fed compressors have an integrated oil supply system, while oil-less compressors contain no oil in the discharge gas, making them suitable for applications where oil contamination is a concern. However, oil-less compressors may have slightly less durability compared to their oil-fed counterparts.