Verification of Flapper Suction-Va1ve Simulation Program

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1 Purdue University Purdue e-pubs International Compressor Engineering Conference School of Mechanical Engineering 1980 Verification of Flapper Suction-Va1ve Simulation Program H. Richardson G. W. Gatecliff G. C. Griner Follow this and additional works at: Richardson, H.; Gatecliff, G. W.; and Griner, G. C., "Verification of Flapper Suction-Va1ve Simulation Program" (1980). International Compressor Engineering Conference. Paper This document has been made available through Purdue e-pubs, a service of the Purdue University Libraries. Please contact for additional information. Complete proceedings may be acquired in print and on CD-ROM directly from the Ray W. Herrick Laboratories at Herrick/Events/orderlit.html

2 VERIFICATION OF FLAPPER SUCTION VALVE SI~lliLATION PROGRAM Hubert Richardson, Jr., Project Engineer Geox ge IV. Gatecliff, Ph.D., Chief Research Engineer Glenn C. Griner, Research Mechanical Engineer Tecumseh Products Company ABSTRACT This paper describes the process and instrurnentation used to verify a computer program simulating flapper-type suction valve mo t;ion and gas flow in a hermetic compressor. IIITRODUC'J:'lON The air conditioning and refrigeration industry's req_u.irements for higher efficiencies and lower sollild l<::lvels at minimal cos-c, has resulted in the compressox designer'll need for more detailed in:fonnation on the interne.l operation of compx essox s. The valve. action is pax tic Lllar~r important :i.n regard to compressor performance and sound levels. To 1'acili tate the improvement of valve designs, a tool is needed for quick analysis of different valve configurations. The digital computer is the perfect tool, if a computer program can be formulated w:1ich is rigorous enough to accurately model valve motion and gas flow through the valves of a hermetic compressor. However, before such a program can be relied on, actual experimental data must be obtained from a compressor to compare with computer predicted data. ESTABLISII~lEN'r OF A DATUM BASE COMPRESSOR 'the first step in the verification process is the assembly of ~ compressor which has been dimension ~lly analyzed. This analysis should include: 1 Connec-cing rod length Crankshaft throw Piston diameter Suction valve length Suction valve thickness Suction valve base width Suction vs,lve tip width Suction port rel:tef" depth SuctiG!l port relief G.iamec:er Sctcticn port throat diameter Crar1kcase suction valve stop deptb.. r:1e corr~pressor is 1"r1;.en L.ested on a ca.lorimeter at the cor;:,para.c;i ve cesc; condition--in this case, the 2.J..:; ~oul:. c;;' C~':!.ng ru.tillg poirrc (ASRET). This test d.ata is compared w h~.storical rating data to determine if the co!npressor has acceptable performance. The test data is also used for later comparison of the compressor's performance after the modifications necessary to install the instrumentation have been made. INSTRUivJBN'TATION USED The followiil6 is a list of the instrumentation used: I. Suction valve motion - Bently Nevada Proximity Probe (Model # ) II. Displacement, TDC ('.Cop Dead Center), and BDC (Bottom Dead Center) markers -Bently Nevada Proximity Probe (Model # ) III. Cylinder pressure - Kistler Piezoelectric Pressure Transducer (Model #60lA) MODIFICATIONS NECESSA.~Y TO INSTALL INSTRUMENTATION The installation of the instrumentation requires the following modifications to the test compressor: I. Suction Valve Motion Probe- (See Figure #1.) II. A. Two holes are drilled and tapped into cylinder head to hold probe mounting fixture which centers probe in suction port throat. B. Manufacture of a mounting fixture to hold the probe. Displacement, TDC, and BDC Pro"be - (See Figure #2.) A. Drill and tap a hole through the side of the cylinder wall with a large counter bore. B. Machine a tapered flat surface on the side of the piston. III. C;,rlinder Pressure Transducer - (See Figure #].) A. Drill a small diameter hole from a flat surface on the crankcase to the top edge 180

3 IV. of the cylinder bore. B. Machine a flat surface on the sj. de of the crankcnse. C. Manufacture a fixture to hold the pressure transducer, which has an "O" ring seal around the tip of the transducer which seals against the flat surface machined on the crankcase. D. Drill and tap two holes to hold the mounting fixture to the flat surface on the crankcase. E. Cut a notch through the edge of the piston which lines up with hole drilled through crankcase. Suction and Discharge Plenum - (See Figure #4.) A. Drill a hole through the center of two - l/8" pipe plugs and solder a capillary tube in each plug. INSTALLATION OF INSTRlillENTATION The displacement probe is cs.librated after installation into the crankcase. The caljbration process consists of heating the partial compressor assembly and the probe to the compressor operating temperature in an oven, and recording voltage readings vs. the measured piston displacement from Top Dead Center. The suction valve displacement probe is also calibrated at the elevated temperature in the suction probe location. The cylinder pressure transducer is calibrated on a bench test rig. The transducer is then mounted on the bottom of the crankcase. The compressor is tested at the base de ';urn tc;>st point conditions with the transducer and probes installed. A typical suction valve motion vs. time and displacement vs. time oscilloscope trace is shown in Figure #6. A typical cylinder pressure vs. time and displacement vs. time oscilloscope trace is shown in Figure #7- B. Drill and tap a hole in the suction plenum cover to install a modified 1/8" pipe plug to measure suction plenum static pressure. C. Drill a hole through the suction plenum cover for the suction valve motion probe and suction plenum thermocouple leads. D. Drill and tap a hole in the discharge plenum to install a conax fitting for measurement of discharge plenum temperature. E. Drill and tap a hole in the discharge plenum to install a modified l/8" pipe plug to measure discharge plenum static pressure. V. Housing Modifications- (See Figure #5.) A. Install sight glass flange. R. Manufacture a metal sight glass which has holes drilled and counterbored for installation of Hermetic Microdot Feedthrus. C. Mount pipe couplings to the housing for the conax fittings required for the plenum temperature and pressure data signals. After making these modifications, the appropriate holes are plugged and dummy probes are installed. The compressor is reassembled and tested at the base datum test point conditions. This performance data is compared to the base data to insure minimal alteration to the performance characteristics of the compressor. COMPUTER MODEL A data set is generated for the test compressor using the physical dimensions and test conditions. The computer program is run using this data set. COMPARISON OF COMPUTED VS. MEASURED DATA Suction valve opening MEAS. COMP. % DATA DATA DIFF. (D.A.T.D.C.*) Suction valve closing (D.A.T.D.C.) Suction valve open interval (Degree) Maximum suction underpressure (PSI) Mass flow rate (LB/HR) *(D.A.T.D.C. - Degree After Top Dead Center) CONCLUSION The results of this analysis indicates excellent correlation between the measurements made in the compressor and the computer model predictions. The accuracy of this correlation indicates that the suction valve simulation program is a valuable tool for the analysis of flapper-type valve designs. The described process has been used to verify a flapper discharge valve simulation program and will be used to verify circular suction and discharge valve programs, in the future. The use of these simulation codes enables the analysis of many aspects of valve design with minimal testing. Therefore, the design engineer can optimize a valve design using the computer and thf'n build that optimized design for testing. 181

4 ACKNOWLEDGMENT The authors wish to acknowledge Russell D. Cowen, Tecumseh Products Company, for the preparation of the excellent graphics contained in this paper. REFERENCES 1. Griner, G. C., Gatecliff, G. W., and Richardson, H., "Static and Dynamic Analysi:J of Reed Valves Using a Mini Computer Based Finite Element System", Proc Purdue Compressor Technology Conference, July, Gatecliff, G. W., Griner, G. C., and Richardson, H., "A Compressor Valve Model for Use in Daily Design Work", Proc Purdue Compressor Technology Conference, July, FIGURE#I SUCTION VALVE MOTION PROBE CONFRIGURATION PROBE MOUNTING GASKET FIXTURE SUCTION PORT BENTLY NEVADA PROXIMITY PROBE (# ) FIGURE #2 DISPLACEMENT, TDC, AND BDC PROBE CQ'\JFRIGURATION BENTLY NEVADA PROXIMITY PROBE (* ) 182

5 FIGURE#3 CYLINDER PRESSURE TRANSDUCER CONFRIGURATION SMALL DIAMETER HOLE FLAT SURFACE PRESSURE TRANSDUCER ---lb..,, ~ MOUNTING FIXTURE KISTLER PRESSURE TRAN~ iicf'f~-~~ (MODEL 601A,IN MTG. ADAPTER TYPE 6504) ~..._ CRANKCASE CYLINDER BORE "o" RING SEAL PISTON NOTCH IN PISTON FIGURE#4 SUCTION AND DISCHARGE PLENUM PRESSURES AND TEMPERATURES EPOXY HOLE AFTER ASSEMBLY SUCTION COVER CYLINDER HEA SUCTION VALVE MOTION PROBE CABLE SUCTION PLENUM THERMOCOUPLE -----TEFLON BUSHING CAPILLARY TUBE FOR ---t~-::...jtll!!:.~ ';..<.,;ini"'ct SUCTION PLENUM PRESSURE MODIFIED 118" PIPE PLUG MODIFIED 1/8" PIPE PLUG CAPILLARY TUBE DISCHARGE PLENUM PRESSURE ~DISCHARGE PLENUM X FITTING FOR DISCHARGE PLENUM THERMOCOUPLE 183

6 FIGURE # 5. HOUSING MODIFICATION "RING SEAL STEEL "SIGHT GL~SS" SIGHT GLASS FLANGE.1.SSEMBLY PE COUPLING CONAX FITTING HERMETIC MICRODOT FEEOTHRU (PC 8 ~ 070AI4) FIGURE#6 SUCTION VALVE MOTION VS. TIME CYLINDER DISPLACEMENT VS. TIME FIGURE#? CYLINDER PRESSURE VS. TIME CYLINDER DISPLACEMENT VS. TIME 184

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