Many industries rely on screw air compressor to ensure production runs smoothly, but how does screw air compressor work? An opening valve draws atmospheric air into the compressor's core, where interlocking male and female rotors spin rapidly on high shaft speed. Oil is applied to the rotors to minimize mechanical and volumetric losses during compression, before moving through an additional filter before being discharged from the system.
Air end compressors are at the core of all rotary screw systems. Air enters, passes through an air filter to remove dirt and particles before entering the compression chamber, or "air end", where it meets oil. Oil is an essential element in rotary screw systems as it acts as a lubricant and coolant to reduce friction between mating screws, lower air temperatures in the compression chamber and prevent leakage by acting as a hydraulic seal.
When two rotors within an air end mesh together, their convex lobes push against one another to increase pressure and compress air within. When these rotors come close enough together, their concave ones push each other's convex ones outward, increasing air pressure within and increasing compression within.
Once compressed air has been sent through a compressor and dryer, it will go through a drain valve and an air dryer for further separation of oil from pure compressed air.
Air will then be transferred to an air receiver tank or storage facility for safe use, where it may pass through an oil-free air filter for added safety if the compressed air will be used in high-risk industries, where even minute contaminants could pose major risks.
The inlet valve draws atmospheric air into the compressor chamber, where screw rotors rotate at high shaft speeds to trap it in their cavities. Their length and pitch determine what pressure ratios can be expected from this compressor.
The rotors of screw air compressor is fitted with bearings to reduce friction between them as they mesh, thereby minimizing heat and wear while simultaneously increasing life span and performance. This feature helps minimize friction forces by minimizing heat generation as the meshing occurs, as well as heat dissipation during compression without unbalanced mechanical forces or volumetric losses; which enables high speed compression without creating unbalanced mechanical forces and volumetric losses, giving these compact space-saving designs such powerful performance capabilities.
Once the rotors reach the end of their rotation, once at rest the low-pressure end opens to the suction valve and starts discharging, maintaining a higher capacity than if both slide valves had opened simultaneously.
This valve never closes completely; rather it must leave an aperture open so oil can keep flowing in, which ensures that the rotors remain lubricated and cooled throughout operation. Once compressed air has been produced by the compressor, its oil separator removes excess oil before feeding it to an air filter before entering your receiver tank or other process for use.
A rotary screw air compressor requires a system of filters to separate oil from compressed air, beginning with intake filters which remove atmospheric contaminants before entering the compressor end, moving onto secondary separation filters for centrifugal force separation, then into an oil separator tank that also acts as an air cooler to help cool compressed air down further.
Oil-injected rotary air compressors require constant lubrication between their mating rotors to reduce friction and leakage, while compressor oil cools the rotors and helps maintain high compression pressure during compression. Air-injected screw air compressors may cost more than their oil-free counterparts but are capable of producing higher CFM and PSI thanks to less maintenance requirements for their rotors.
An air compressor can either be oil-free or oil-lubricated. Both models work effectively under harsh environments, pressurizing air even during periods of high or low temperature fluctuations. Industrial applications that require air purity typically utilize oil-free models while oil-lubricated compressors require regular maintenance such as changing and cleaning their filters regularly. Manufacturers recommend rebuilding air ends after approximately 60,000 or 70,000 hours of use in order to minimize damages and extend compressor longevity - accurately tracking running hours is key when managing maintenance schedules effectively.
Air that enters a screw air compressor chamber travels through various valves and chambers before passing between paired rotors to be compressed before passing back down toward its discharge valve. Because these insulated rotors feature interlocking twin rotors for minimal friction rotations to trap air for compression purposes, many rotary air compressors also boast high shaft speeds to achieve large compression rates in relatively limited spaces.
Once the rotors reach the discharge end of a chamber, they become nearly locked together with only a small opening left open for oil to flow in and ensure that their operation stays lubricated and cool.
Rotors are then released from their interlocking positions by air pressure moving across them, which reduces chamber temperature to an acceptable level for the compressor to work effectively. At this point, a discharge valve opens to release highly pressurized air into an outlet port.
Air from the rotors and system passes through filters, purifying it for use in the workplace before going into reserve tanks or being used by machines and tools. A timed electric valve then drains any extra condensed water regularly from its storage tank in order to prevent mineral deposits accumulating over time and cause damage.
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