Linear Compressors for Clean and Specialty Gases
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1 Purdue University Purdue e-pubs International Compressor Engineering Conference School of Mechanical Engineering 1998 Linear Compressors for Clean and Specialty Gases R. L. Unger Sunpower Inc. Follow this and additional works at: Unger, R. L., "Linear Compressors for Clean and Specialty Gases" (1998). International Compressor Engineering Conference. Paper This document has been made available through Purdue e-pubs, a service of the Purdue University Libraries. Please contact epubs@purdue.edu 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 LINEAR COMPRESSORS FOR CLEAN AND SPECIALTY GASES Reuven Z. Unger Sunpower, Inc. PO Box 2625, Athens, OH USA Phone: Fax: ABSTRACT Advancements in linear compressor technology and reliability now allow potential applications to include compression of clean and specialty gases as well as refrigeration. Configurations that use a gas bearing system and require no oil in their operation are especially appropriate for specialty gases. Such configurations overcome the life limitation and maintenance issues of the contacting piston seal designs of existing compressors. Linear compressors that combine gas bearings and oil-less operation with the ability to modulate capacity or flow rate have special potential for applications in the medical and chemical industries. Recent work is demonstrating prototypes with reliable non-lubricated (oil-less) operation and the likelihood oflong life. This report presents examples of several different linear compressor designs and their widely divergent applications. These linear compressors include machines with a compression ratio up to 26:1 in a single stage, and up to several kw in input power. With this range of compression ratios and power, it appears likely that linear compressors can meet a wide range of industrial and commercial needs. INTRODUCTION A linear compressor is a piston-type compressor in which the piston is driven directly by a linear motor, rather than by a rotary motor coupled to a conversion mechanism as in a conventional reciprocating compressor. Linear motors are simple devices in which axial forces are generated by currents in a magnetic field. Because all the driving forces in a linear compressor act along the line of motion, there is no sideways thrust on the piston, substantially reducing bearing loads and allowing the use of gas bearings or low viscosity oil. Additional background on the origin and development oflinear compressors has been presented elsewhere (Refs. 1, 2, 3, 4). COMPONENTS Gas (Fluid) Bearings: The gas bearing system is an arrangement of pneumatic passages that allow a metered amount of gas to flow into the clearance seal area. This gas acts as a cushion to prevent contact between the piston and the cylinder. The gas bearing system is fed from the high-pressure side of the process. The typical power consumption of the gas bearing system is I to 2% of the input power. Linear Motor: The linear motor is a moving magnet type and characterized by an electromagnetic coupling constant Ci (units ofvolt*secondlm or Newton/amp), inductance and resistance. The value of Ci is constant as long as the magnet remains within the boundaries of the lamination poles. (Refs.5, 6, 7). Assembly of the linear motor magnets becomes cost effective with the aid of a magnet ring support system (Ref. 8). This is a structurally sound, low loss construction for the device holding the magnets in the air gap of a linear motor. Valves: Lack of lubricant effects valve dynamics and sealing properties. In oiled machines, oil satisfies the requirements for surface lubrication, damping between moving parts, and sealing. The disadvantage of oiled valves is in the need to overcome oil-induced stiction. In any reciprocating compressor, the typical valve configuration is a single flapper type for suction and discharge. The linear compressor has an inherent simplified mechanical arrangement with easy access to the backside of the piston, pennitting the use of axial flow. The suction valve can therefore use the piston face as the valve seat. The discharge valve is mounted on the valve plate. Advantages of the arrangement include: + Reduction in heat transfer between suction and discharge. The suction gas flows from the back of the compressor through the piston into the compression space and is discharged forward through the valve plate. + Increased flow area. The piston area can be used for ports, greatly increasing the flow area and reducing flow loss. 51
3 + The backside of the piston can be used as a muffler to reduce the sound generated by the suction process. We have not experienced degradation in performance due to valve-seat wear problems during performance and life testing. Extensive life tests will determine long-term stability and resistance to wear. Compliance: A compliant member is combined with fluid bearings and planar springs in a unique combination. The arrangement uses planar springs to resonate the piston at or near the operating frequency and to position the piston at the approximate center of the cylinder. The compliant member is located between the piston and an axially compliant spring. The anti-friction fluid bearings fme-tune the position of the piston by applying lateral centering forces such that the piston reciprocates linearly, virtually without friction. The combination of features permits easily achievable machining tolerances, simple assembly, and little or no wear on moving and adjacent components. (Ref. 9) OPERATION Dynamics: The free piston linear compressor provides the designer a great deal of flexibility for a wide range of working conditions. Because of the non-linear behavior of the gas spring, there is more than one dynamic mode of operation. This is particularly true for high compression ratio machines. In practice, to minimize the force required from the motor, the moving mass is resonated through a mass-spring combination, and designed such that the natural frequency will be close to the operating frequency. Part of that spring is the gas spring created by compression expansion processes. The gas spring is non-linear and subject to change as the cycle conditions vary; this in turn moves the natural frequency away from the initial conditions. To minimize those effects, mechanical springs are added along with an additional reciprocating mass. The result is a more stable but heavier machine, which produces stronger vibrations. The designer, of course, has to optimize these spring-mass trade-offs Controls: Varying both the stroke amplitude and mean position of the piston creates tight requirements for the controls. When the application calls for a low compression ratio, re-expansion volume (dead volume) has a small effect on flow rate and efficiency. In this case, the compressor can be designed and constructed with sufficient clearance at top dead center (TDC) for operation without collisions. With high compression ratios, clearances at TDC must be minimized, and the gas spring is highly non-linear over each operating cycle. This combination imposes severe requirements on the compressor control system. Different methods have been developed and implemented, using a dedicated position sensor (Ref. 10), or using the motor as sensor either for position or stroke control (Refs. II, I2). Some of these techniques are described in Ref. 7. Heat Management: Lack of oil introduces a difficulty in heat removal if the compressor is mounted through soft springs into the pressure vessel. Adequate heat removal is crucial when permanent magnets are part of the motor. One potential solution is a dedicated cooling loop. In this configuration, a secondary liquid is directed into the pressure vessel compressor assembly to absorb the heat from the compressor and transport and reject it outside. Another option is a "tight shell configuration," in which the compressor is hard-mounted to the pressure vessel. Heat flows from the compressor to the pressure vessel, and then to ambient air. The overall configmation can be smaller since there is no need for space between the compressor and the pressure vessel. The "tight shell configuration" does tend to increase noise and vibration levels. APPLICATIONS Below we present four separate linear compressors and their applications. The basic linear compressor technology as outlined above is used throughout all designs. Efficiencies, therefore, fall in similar ranges. The nature of the application, power level and system requirements influence the arrangement of the different components for any single compressor design. Differences in valve design and placement cause differences in flow management. Two of these compressors have been produced as hardware and used for extensive qualification and testing. Clean Air Compressor: in hardware The clean air compressor was designed to work at relatively low compression ratios and can be used in laboratory, medical, or chemical applications. Qualifications particularly relevant to these needs are the fact that it is oil-less, 52
4 ----'-, _,_IV-/A--, modulatable and highly efficient. Several variants of this application have been designed, constructed and tested. Some of these prototypes have demonstrated high reliability and life tests of over 24,000 hours with no degradation in performance. Figures 1 and 2 present the performance of the linear air compressor and a comparison between the linear and two production compressors A and B. The comparison is presented in a normalized flow ofliters per :Limn' Air Corq:ressor ~P-~--~--~--~--~--~~! I I I I 3~~--~~,--~~~~==~~--~~ --~~--~~~~ I 'i I ~~= f---1 2~ I : I I / 200 ~ I~ ,, - 1! L : I~~ I I /--,--"' ! ---+,--+--~---1 ~ ,...""-_..-/T----::!:---:±' :------':::-' ----±1----:::: ~ ~ ,:, :---+i i',1_-1 i I 1 0~ ~ Pressure (p;ig) Fig. 1. Input power of linear (free-piston) compressor over a range of pressure requirements I " 1.0,...---,...--~-~-~ ' ~...-' '-----~ -+--I..inear 0.7 t----'------'1± h... ~A! '----'---" ;_-~1 - '1\-. O:np' B = 0.5 t t:: ,-----f ~ " "i: 0.4 t-----i "'., ~ ::::i 0.3 t----'---..,.~..,-,< '----f : ~~--~ t ~ :..-..: IS Pressure (rsig) Fig. 2. Efficiency oflinear (free-piston) and two conventional, commercially available compressors minute per Watt of input power, vs. pressure. Flow rate can be maintained at a constant rate over a range of pressures (5 to 30 psig) (Figure 1). Efficiency exceeds that of conventional compressors throughout this range, and is notably higher in the lower pressure ranges (Figure 2). Fig. 3. Clean Air Compressor (back cover removed, two views). 53
5 Compressor Motor Motor Piston Seal Dnving Bearing Type Type efficiency Mechanism System Recip' Induction 70-80% Rings I Crank Shaft Oil/Grease Diaphragm Connecting Rod lubricated Linear Permanent Magnet 90% Clearance Direct Coupling Gas-Bearings Table 1. Characteristics of conventional (reciprocating, rotary) and linear compressor Specialty Gas Compressor: in hardware For some applications, compressed gas produced by lubricated refrigeration-type compressors can be adequately cleansed of oil residues. However, for systems with delicate gas passages or in cryogenic applications, the system can become blocked or contaminated by residues of oil, with performance degradation or system failure. The linear, oil-free specialty gas compressor should be able to provide the required compression and avoid the introduction of contaminants entirely. To meet this need, an oil-less compressor with a 26:1 compression ratio was constructed and tested. This compressor delivers a special mixture of gases from a low side of above atmospheric pressure and discharges it at higher then 28 bar. The single piston configuration required special attention to seal properties, thermal expansion, and material compatibility. Also, special consideration was needed in dealing with the highly non-linear gas spring and sophisticated piston control. The system has performed successfully in reliability tests, is currently in beta testing, and is being prepared for production. The machine (Figure 3) operates at We input level and is mounted inside the pressure vessel on soft springs. This mounting arrangement is very similar to those in conventional refrigeration compressors, and provides sufficient vibration isolation, but complicates heat removal from the compressor to the outside. Fig. 4. Special Gas Compressor (without pressure vessel), 26:1 Compression Natural Gas Compressor: in design stage With the deregulation of utilities, there will be a significant market for distributed power generation ( kw) that can supply electricity and heat directly to end-users. One such distributed power generation system is a micro- 54
6 turbine using natural gas as fuel. Full development and market use of micro-turbines has been limited by past regulatory practice. An essential element of a natural gas-flred micro-turbine system is a gas compressor, which needs to be clean, efficient, and exhibit very low vibration. Figure 5 shows a two piston opposed unit, one means of obtaining the required level of vibration control This machine would be appropriate for use with micro-turbines in the 50 to 75 kw 0 range. 1-S t Suction Dis:cho.rge Suction Fig kw Natural Gas Compressor Valveless compressor (pressure wave generator): in design sta2:e A different use of the oil-less free piston compressor is in the form of pressure generator. In these applications the valves are removed from the compressor. This allows the unit to be coupled into an arrangement such as a pulse tube cooler, a Stirling machine, or any other system requiring a pressure wave generator. These machines typically operate at very low compression ratios (less then 2:1). With the absence of suction and discharge processes, the dynamics approach the ideal of sinusoidal behavior. CONCLUSIONS There is a wide range of possible non-refrigeration applications for the linear compressor. Two applications have been proven in hardware and are moving towards commercialization. Other applications are demonstrated at the design stage. Any of these machines may find applications beyond those suggested here, and numerous other specific designs are feasible. The linear compressor is now proven in a variety of hardware. Its efficiency, modulation, oil-free option, and precise control are features that should make it compete successfully with conventional compressors over a wide range of applications. 55
7 ACKNOWLEDGMENTS The author wishes to express his sincere appreciation for the valuable contributions of Nicholas R. Vander Walt in the development ofsunpower's linear compressors. REFERENCES I. Vander Walt, N.R. and Unger, R. "The Simulation and Design of a High Efficiency, Lubricant Free, Linear Compressor for a Domestic Refrigerator." International Compressor Engineering Conference, July 14-17, Purdue University, West Lafayette, Indiana, USA. 2. Berchowitz, D.M. "Free-Piston Rankine Compression and Stirling Cycle Machines for Domestic Refrigeration." Greenpeace Ozone Safe Conference, October 18-19, Washington, DC. 3. Vander Walt, N.R. and Unger, R. "Linear Compressors- A Maturing Technology." International Appliance Technical Conference, May 9-11, University of Wisconsin. Madison, Wisconsin. 4. Unger, R.Z. and van der Walt, N.R. "Linear Compressors for Non-CFC Refrigeration." International Appliance Technical Conference, May 13-15, Purdue University, West Lafayette, Indiana, USA. Available at 5. U.S. Patent 4,602,174. Issued Electromechanical Transducer Particularly Suitable for a Linear Alternator Driven by a Free-Piston Stirling Engine.. Also patented in Germany, UK, Japan. 6. Redlich, R. "A Summary of Twenty Years Experience with Linear Motors and Alternators." Distributed at Linear Drives for Industry Applications, May 31 - June 2, 1995, Nagasaki, Japan. Available at 7. Redlich, R., Unger, R., and van der Walt, N. "Linear Compressors: Motor Configuration, Modulation and Systems." International Compressor Engineering Conference, July 23-26, Purdue University, West Lafayette, Indiana, USA.. Available at 8. U.S. Patent 5,642,088. Issued Magnet Ring Support. Patents pending in Australia, Brazil, EPO, Japan, South Korea, Mexico, New Zealand, Singapore. 9. U.S. Patent 5,525,845. Issued Fluid Bearing with Compliant Linkage for Centering Reciprocating Bodies. Also patented in Taiwan, Australia. Patents pending in India, Canada, EPO, Japan, South Korea, Mexico, New Zealand. 10. U.S. Patent 5,592,073. Issued Triac control circuit. Patents pending in Australia, Brazil, EPO, Japan, South Korea, Mexico, New Zealand, Singapore. 11. U.S. Patent 5,342, 176. Issued Method and Apparatus for Measuring Piston Position in a Free Piston Compressor. Also patented in New Zealand, Australia, EPO. Patents pending in Japan, Korea. 12. U.S. Patent 5,496,153. Issued Method and Apparatus for Measuring Piston Position in a Free Piston Compressor. 56
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