| 螺杆空压机节能与可靠性矛盾分析 |
| 添加时间：2017/8/28 16:00:01 浏览次数： |
| 1、螺杆机转速越高越节能，但是可靠性随转速升高而降低 1, screw speed is higher, energy saving, but the reliability decreases with the increase of speed 机头的内泄漏是影响螺杆机耗能的最关键因素，一台特定的螺杆机泵头在一定排气压力下泄漏量是常数，提高转速可以改善相对泄漏量，提高效率。 The head of internal leakage is the key factor affecting the energy consumption of the machine screw, a screw pump head in particular must exhaust pressure discharge leakage is constant, the increase of rotational speed can improve the relative amount of leakage, improve efficiency. 例如，泄漏常量0.5m³/min的机头，在3000转每分钟下打3m³/min，相对泄漏量是0.5/3=0.17，即17%；在6000转每分钟下打6m³/min，相对泄漏量是0.5/6=0.083，即8.3%；也就是说在较高转速下相对泄漏量显著减小，所以能效明显提高。 For example, the leakage constant 0.5m /min fand, at 3000 rpm under 3M /min fand leakage is relative, 0.5/3=0.17, 17%; at 6000 RPM under 6m /min fand leakage is relative, 0.5/6=0.083, 8.3%; that is to say in high speed relative leakage decreases significantly, so improve energy efficiency. 高转速下，轴承和轴封磨损加剧；润滑油的冷却效果降低，机头内温远高于排气温度，润滑油加速老化，润滑性能降低。 At high speed, the wear of bearings and seals increased; the cooling effect of lubricating oil decreased; the internal temperature of the engine was much higher than the exhaust temperature; the lubricant accelerated aging and the lubrication performance decreased. 用户对空压机的核心诉求是安全性和可靠性，牺牲可靠性换取节能是本末倒置，得不偿失。 The core demand of the air compressor is safety and reliability, and sacrificing the reliability to save energy is putting the cart before the horse, which is not worth the candle. 2、机头间隙越小越节能，但是过小的间隙对污物敏感转子和轴承容易拉伤和卡死 2, the gap between the smaller the head, the more energy-efficient, but too small clearance for dirt sensitive, rotor and bearing easily strain and stuck 机头间隙小自然内泄漏就少，减小间隙是提高机头能效的有效措施，但是螺杆机的润滑油非常脏。有进气带进系统的尘埃，有冷凝水造成的润滑油乳化物，有金属零件锈蚀在系统内生产的氧化物。由于螺杆机油过滤器精度一般大于15微米，所以大量污物伴随润滑油循环，当泵头内部间隙过小时，污物极易聚集，拉伤和卡死轴承及转子。 Small clearance of the head, less leakage in nature, reducing clearance is an effective measure to improve the energy efficiency of the head, but the lubricating oil of the screw machine is very dirty. There are air intake system dust, condensate caused by lubricating oil emulsion, metal parts corrosion, the production of oxides in the system. As the screw oil filter accuracy is generally greater than 15 microns, so a lot of dirt accompanied by lubricating oil circulation, when the pump head clearance is too small, dirt easily gathered, pull and stuck bearings and rotors. 3、螺杆机排气温度越低越节能，但是温度低造成零部件生锈加剧磨损、堵塞节流孔和阀门 3, screw machine exhaust temperature lower, more energy saving, but low temperature, cause parts rust, aggravate wear, plug, throttle and valve 当螺杆机排气温度80度，环境温度30度，油分罐内壁温度会低于60度，压缩空气中的水分会在油分罐内壁和油分罐盖板内壁形成露水，水分伴随润滑油循环。停机后，水分从油中析出，沉在润滑油下方，造成存油的各部位被水浸泡，加剧零部件生锈。 When the screw machine exhaust temperature of 80 degrees, the ambient temperature of 30 degrees, the oil tank wall temperature will be lower than 60 degrees, the compressed air in the water branch in the oil tank wall and oil tank cover to form dew wall, water with oil circulation. After stopping, the water is separated from the oil, and it is buried under the lubricating oil. The parts of the oil storage are soaked in water, and the parts become rusty. 4、节流孔越小越节能，但是节流孔缩小更容易被堵塞导致机器耗油量增大，排气含油量增大 4, the smaller the orifice, the more energy saving, but the narrowing of the throttle hole is more likely to be blocked, resulting in increased engine oil consumption, exhaust oil content increases 油分芯滤除的润滑油必须返回系统，这部分润滑油被油分罐盖板的生锈形成的氧化物、油分芯的纤维和胶结剂脱落物污染，当回油节流孔过小时，极易被堵塞，必需停机疏通。如果不及时疏通，机器耗油量和排气含油量加大，甚至造成机头缺油，引起高温、过度磨损甚至抱死。加大节流孔机器的可靠性显著提高，但是流量减少，比功率恶化。 The lubricating oil filter core must be returned to the system, this part of the oil by the oil tank cover the formation of rust oxide, oil core fiber and cement off contamination, when the oil return throttling hole is too small, easy to be blocked, must stop dredging. If not clear, machine oil consumption and exhaust oil content increase, even cause the nose out of oil, caused by high temperature and excessive wear or lock. To increase the reliability of flow hole machine significantly improved, but the flow is reduced, deterioration of specific power. 5、两级压缩节能，但是关键零部件数量翻倍导致可靠性大幅下降 5, two compressed energy saving, but the number of key components doubled, leading to a significant decline in reliability 两级压缩螺杆机节能主要取决于级间冷却，但在冷却过程中水分从空气中析出，含液态水的压缩空气和润滑油进入二级泵头，导致二级泵头的润滑较差，锈蚀倾向加大，磨损加剧。两级压缩的螺杆机二级泵头是薄弱环节，是故障高发点。 Two stage compression energy-saving screw machine mainly depends on the inter stage cooling, but in the process of cooling water release from the air, liquid water containing compressed air and lubricating oil into the two stage pump head, resulting in two poor lubrication pump head, the corrosion tendency increases, wear. Two stage compression screw machine, two stage pump head is the weak link, is the breakdown high frequency spot. 此外，两级压缩的螺杆机泵头运转零部件数量是单级压缩的2.3倍，零部件越多故障率越高。 In addition, two screw compressor pump head running parts and components are 2.3 times the number of single-stage compression, the more parts, the higher the failure rate. 6、变频压缩机其实不节能，但是降低了螺杆空压机的可靠性 6, inverter compressor is not energy efficient, but it reduces the reliability of screw air compressor 变频器自身消耗输入功率的5%，机头和电机偏离设计转速，效率降低5%左右，电机反复加速和减速（制动）耗电显著大于恒速运转，折算到每一立方压缩空气的耗电量和生产成本，明显大于工频螺杆机。 The inverter input power consumption 5%, machine head and motor speed deviation from the design, reduce the efficiency of about 5%, repeated motor acceleration and deceleration (braking) power consumption is significantly greater than the constant speed operation, converted to every cubic compressed air consumption and production costs, significantly greater than the frequency of screw machine. 反复加减速导致转子和轴承遭受交变冲击性负荷，如果转子是铸铁材料制造，易造成材料的疲劳破坏。 Repeated acceleration and deceleration results in alternating impact loads on the rotor and bearing. If the rotor is made of cast iron, it is liable to cause fatigue damage to the material. 此外，轴电流提高了电机轴承温度，易造成润滑脂流失，导致电机轴承磨损。 In addition, the shaft current improves the bearing temperature of the motor, and it is easy to cause the loss of grease, which leads to the wear of the motor bearings. 变频器是个复杂的电器组件，还易受到供电品质和外界电磁干扰，所以变频器自身就存在严重的可靠性问题。 Frequency converter is a complicated electrical component, and it is also vulnerable to the power supply quality and the external electromagnetic interference, so the inverter itself has serious reliability problems. 7、高能效螺杆机的节能效果很短暂 7, the energy-saving effect of high efficiency screw machine is very short 高能效螺杆机往往是通过减小泵头间隙和提高泵头转速来实现的。任何螺杆机的能效评价都是在实验室或新机状态下做出的。一般200～3000小时运转后，轴承磨损，间隙增大和三滤阻力增大都造成螺杆机节能水平下降。 High energy efficiency screw machine is usually achieved by reducing the clearance of the pump head and increasing the speed of the pump head. The energy efficiency evaluation of any screw machine is done under laboratory or new machine condition. 200 to 3000 hours after the operation, bearing wear, the gap increases and filter resistance increases have caused the level of energy saving screw machine down. 越是能效等级高的螺杆机，节能水平下降越快。螺杆机在常态下，能保持三级能效就很不错了。做合同能源管理项目时一定要充分考虑能效下降的情况，通过大大缩短三滤和润滑油更换周期，定期调整泵头间隙来延缓能效水平的衰退。 The higher the energy efficiency of the screw machine, the faster the decline in energy efficiency. Screw machine in the normal, can maintain three level energy efficiency is very good. Do the contract energy management project must take full account of the decline in energy efficiency, through the filter and greatly shorten the replacement cycle of lubricating oil, pump head to periodically adjust the recession gap delay efficiency level. 8、警惕提升螺杆机能效等级的不正当手段 8, be vigilant to improve the screw rod energy efficiency level of improper means 检测过程中刻意缩小节流孔通径； During the test, the orifice diameter was deliberately reduced; 检测过程中不装空滤芯； No empty cartridge in the test process; 检测过程中刻意降低排气温度； The exhaust temperature was deliberately lowered during the test; 检测过程中用蓄电池为风扇和控制系统供电； During testing, the battery is used to supply power to the fan and control system; 检测过程中用蓄冷材料降低泵头进气温度； During the test, the inlet temperature of the pump head is reduced by using the cold storage material; 特意为应对检测减小泵头间隙； Specially designed to reduce the clearance of the pump head; 特意为应对检测采用高效电动机或工频永磁电机； In order to detect the use of high efficiency motor or power frequency permanent magnet motor; 特意为应对检测采用特种润滑油； Specially designed to meet the need for special lubricants; 特意为应对检测采用特制油分芯； Specially designed to deal with the detection, the use of special oil core; 特意为应对检测采用液压马达驱动风扇。 Specially designed to use the hydraulic motor to drive the fan. |
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