Presentation

on
Compressors and
Pneumatic Components

Presented
By
Mr.Patil Gopal Bhaskar
Department of Mechanical Engineering
K.E.Society’s Rajarambapu Institute of
Technology(Polytechnic),Pune
Compressor:
It is a mechanical device which converts mechanical
energy into fluid energy. The compressor increases the air
pressure by reducing its volume which also increases the
temperature of the compressed air. The compressor is selected
based on the pressure it needs to operate and the delivery
volume.
Applications of Compressor:
1. For filling the air in tube of vehicles
2. In automobile service station to clean vehicles.
3. For spray painting in paint industries.
4. In vehicle to operate air brakes.
5. For cleaning workshop machines.
6. For supercharging of an IC engines.
7. For operation of pneumatic tools i.e. rock drills,
vibrators etc.
Definitions of Compressor
Compression ratio:-
It is defined as the ratio of volume of air before
compression to the volume of air after compression.
Compressor capacity:-
It is the quantity of air actually delivered by a
compressor in m3/minute or m3/sec.
Free air Delivered(FAD):-
It is the volume of air delivered by compressor under the
compressor intake conditions ( i.e. temperature and pressure ).
Swept Volume:-
The volume displaced or swept by piston when it moves
between top dead center and bottom dead center.
Clearance volume:-
It is the difference between the total volume and the
swept volume, basically the gap that remains between the piston
head and the cylinder head when at top dead center
Efficiencies:
Volumetric efficiency:- It is the ratio of actual volume of
the FAD at standard atmospheric condition in one delivery
stroke (Actual air intake) to the swept volume (theoretical
air intake) by the piston during the stroke.

Isothermal efficiency:- It is defined as the ratio of

isothermal power (Piso) (i.e. required input power at
isothermal process) done to the indicated power (IP) or
actual work done.

Mechanical efficiency:- It is the ratio of indicated power

(IP) to the shaft(Brake) Power (Pshaft).

Overall efficiency:- It is the ratio of isothermal power

(Piso) to the shaft(Brake) Power (Pshaft).
 Classification of Compressors:-

Compressor

Positive Non positive

Displacement Displacement

Reciprocating Rotary Centrifugal Axial

Single Double
Vane Screw Lobe
Acting Acting
Reciprocating Compressor:
In a reciprocating compressor, a volume of air
is drawn into a cylinder, it is trapped, and
compressed by piston and then discharged into the
discharge line. The cylinder valves control the flow
of air through the cylinder; these valves act as check
valves.
There are two types of reciprocating compressor.
1. Single Acting compressor:
It is a compressor that has one discharge per
revolution of crankshaft.
2. Double Acting Compressor:
It is a compressor that completes two discharge
strokes per revolutions of crankshaft. Most heavy-
duty compressors are double acting..
1.Single Acting compressor:
It is a positive-displacement compressor that
Uses pistons driven by a crankshaft to deliver gases at high
pressure. The intake gas enters the suction manifold, then flows
into the compression cylinder .It gets compressed by a piston
driven in a reciprocating motion via a crankshaft, Discharged
at higher pressure
Double acting compressor
The pulsation of air can be reduced by using double acting compressor as
shown in Figure 6.1.4. It has two sets of valves and a crosshead. As the
piston moves, the air is compressed on one side whilst on the other side of
the piston, the air is sucked in. Due to the reciprocating action of the piston,
the air is compressed and delivered twice in one piston stroke. Pressure
higher than 30bar can be produced.
Multistage compressor
As the pressure of the air increases, its temperature rises. It is essential to
reduce the air temperature to avoid damage of compressor and other mechanical
elements. The multistage compressor with intercooler in-between is shown in Figure
6.1.5. It is used to reduce the temperature of compressed air during the compression
stages. The intercooling reduces the volume of air which used to increase due to
heat. The compressed air from the first stage enters the intercooler where it is cooled.
This air is given as input to the second stage where it is compressed again. The
multistage compressor can develop a pressure of around 50bar.
Screw compressor:
Screw compress or Piston compressors are used when high pressures and
relatively low volume of air is needed. The system is complex as it has many moving
parts. For medium flow and pressure applications, screw compressor can be used. It
is simple in construction with less number of moving parts. The air delivered is
steady with no pressure pulsation. It has two meshing screws. The air from the inlet
is trapped between the meshing screws and is compressed. The contact between the
two meshing surface is minimum, hence no cooling is required. These systems are
quite in operation compared to piston type. The screws are synchronized by using
external timing gears.
Rotary vane compressors:
The unbalanced vane compressor consists of spring loaded vanes seating in
the slots of the rotor. The pumping action occurs due to movement of the vanes along
a cam ring. The rotor is eccentric to the cam ring. As the rotor rotates, the vanes
follow the inner surface of the cam ring. The space between the vanes decreases near
the outlet due to the eccentricity. This causes compression of the air. These
compressors are free from pulsation. If the eccentricity is zero no flow takes place.
Lobe compressor
The lobe compressor is used when high delivery volume but low pressure is needed. It
consists of two lobes with one being driven and the other driving. Figure 6.2.5 shows
the construction and working of Lobe compressor. It is similar to the Lobe pump used
in hydraulic systems. The operating pressure is limited by leakage between rotors and
housing. As the wear increases during the operation, the efficiency falls rapidly
Air filter and water trap:
Air filter and water trap is used to • prevent any solid contaminants from entering in
the system. • condense and remove water vapor that is present in the compressed air.
Lubricators
The compressed air is first filtered and then passed through a
lubricator in order to form a mist of oil and air to provide
lubrication to the mating components. Figure 6.3.6 shows the
schematic of a typical lubricator. The principle of working of
venturimeter is followed in the operation of lubricator. The
compressed air from the dryer enters in the lubricator. Its
velocity increases due to a pressure differential between the
upper and lower changer (oil reservoir). Due to the low pressure
in the upper chamber the oil is pushed into the upper chamber
from the oil reservoir through a siphon tube with check valve.
The main function of the valve is to control the amount of oil
passing through it. The oil drops inside the throttled zone where
the velocity of air is much higher and this high velocity air
breaks the oil drops into tiny particles. Thus a mist of air and oil
is generated. The pressure differential across chambers is
adjusted by a needle valve. It is difficult to hold an oil mixed air
in the air receiver as oil may settle down. Thus air is lubricated
during secondary air treatment process
FRL Unit:
During the preparation of compressed air, various processes such as
filtration, regulation and lubrication are carried out by individual components. The
individual components are: separator/filter, pressure regulator and lubricator.
Preparatory functions can be combined into one unit which is called as „service unit‟.
Figure 6.3.10 shows symbolic representation of various processes involved in air
preparation and the service unit.
Relief valve:
It is the simplest type of pressure regulating device. The schematic of its construction
and working is shown in the Figure 6.3.8. It is used as a backup device if the main pressure
control fails. It consists of ball type valve held on to the valve seat by a spring in tension. The
spring tension can be adjusted by using the adjusting cap. When the air pressure exceeds the
spring tension pressure the ball is displaced from its seat, thus releasing the air and reducing the
pressure. A relief is specified by its span of pressure between the cracking and full flow, pressure
range and flow rate. Once the valve opens (cracking pressure), flow rate depends on the excess
pressure. Once the pressure falls below the cracking pressure, the valve seals itself.
Non-relieving Pressure Regulator
In a non-relieving pressure regulator (Fig. 6.3.9) the outlet pressure is sensed
by a diaphragm which is preloaded by a pressure setting spring. If outlet pressure is
too low, the spring forces the diaphragm and poppet to move down thus opening the
valve to admit more air and raise outlet pressure. If the outlet pressure is too high the
air pressure forces the diaphragm up hence reduces the air flow and causing a
reduction in air pressure. The air vents away through the load. At steady state
condition the valve will balance the force on the diaphragm from the outlet pressure
with the preset force on the spring
Actuators
Actuators are output devices which convert energy from pressurized compressed air
into the required type of action or motion. In general, pneumatic systems are used for
gripping and/or moving operations in industry. These operations are carried out by
using actuators.
Actuators can be classified into three types.
1. Linear actuators: These devices convert hydraulic/pneumatic energy into linear
motion.
2. Rotary actuators: These devices convert hydraulic/pneumatic energy into rotary
motion.
3. Actuators to operate flow control valves: these are used to control the flow and
pressure of fluids such as gases, steam or liquid.
1. Single acting cylinder:
These cylinders produce work in one direction of motion
hence they are named as single acting cylinders. Figure shows
the construction of a single acting cylinder. The compressed air
pushes the piston located in the cylindrical barrel causing the
desired motion. The return stroke takes place by the action of a
spring. Generally the spring is provided on the rod side of the
cylinder.
2. Double acting cylinder
The piston rod is connected to piston head and the other end extends out of
the cylinder. The piston divides the cylinder into two chambers namely the rod end
side and piston end side. The seals prevent the leakage of air between these two
chambers. The cylindrical tube is fitted with end caps. The pressurized air enters the
cylinder chamber through the ports provided. In the rod end cover plate, a wiper seal is
provided to prevent the leakage of oil and entry of the contaminants into the cylinder.
Cylinder end cushions
Cylinder end cushions
Double acting cylinders generally contain cylinder cushions at the end of
the cylinder to slow down the movement of the piston near the end of the stroke.
Figure 6.4.3 shows the construction of actuating cylinder with end cushions.
Cushioning arrangement avoids the damage due to the impact occurred when a fast
moving piston is stopped by the end caps. Deceleration of the piston starts when the
tapered plunger enters the opening in the cap and closes the main fluid exit. This
restricts the exhaust flow from the barrel to the port. This throttling causes the initial
speed reduction. During the last portion of the stroke the oil has to exhaust through
an adjustable opening since main fluid exit closes. Thus the remaining fluid exists
through the cushioning valve. Amount of cushioning can be adjusted by means of
cushion screw. A check valve is provided to achieve fast break away from the end
position during retraction motion. A bleed screw is built into the check valve to
remove the air bubbles present in a hydraulic type system.
 Gear motor: a rotary actuator
Rotary actuators convert energy of pressurized fluid into rotary motion.
Rotary actuators are similar to electric motors but are run on hydraulic or
pneumatic power.

It consists of two inter meshing gears inside a housing with one gear attached to
the drive shaft. Figure 6.4.4 shows a schematic diagram of Gear motor. The air enters
from the inlet, causes the rotation of the meshing gear due to difference in the pressure
and produces the torque. The air exists from the exhaust port. Gear motors tend to leak
at low speed, hence are generally used for medium speed applications.
Vane motor: a rotary actuator
A rotary vane motor consists of a rotor with sliding vanes in the slots provided
on the rotor (Fig. 6.4.5). The rotor is placed eccentrically with the housing.
Air enters from the inlet port, rotates the rotor and thus torque is produced. Air
is then released from the exhaust port (outlet).
Limited rotation actuators
It consists of a single rotating vane connected to output shaft as
shown in Figure 6.4.6. It is used for double acting operation and has a
maximum angle of rotation of about 270°. These are generally used to
actuate dampers in robotics and material handling applications. Other type
of limited rotation actuator is a rack and pinion type actuator.
Accumulator:
A Hydraulic Accumulator is energy storage
device.
 It is pressure storage reservoir in which a
non compressible hydraulic fluid is held
under pressure by an external source.
 The external source used can be a spring, a
raised weight, or a compressed gas.
 The main reasons that an accumulator is
used in a hydraulic system, is that the pump
doesn‟t need to be so large to cope with
extremes of demand and supply circuit can
respond quickly to any temporary demand
and to smooth pulsation.
Use of Accumulator
1. Energy Accumulation:
Accumulators are widely used as a supplementary
energy source. The system in which pressurized oil discharged
from accumulators is used to operate cylinders enables pumps to
be smaller, shortens their cycles, and conserves energy

2. Pulse Absorption:
All pressurized fluid discharged from pumps has a pulse.
Pulses produce noise or vibrations that can cause instability or
damage devices. The use of an accumulator can attenuate pulses.
3. Impact Absorption:
The rapid closure of valves or sudden changes in load
within a hydraulic circuit can result in impact pressure in pipes,
which can then lead to noise or damage to those pipes or devices.
The use of an accumulator can mitigate any such internal shock.

4. Equilibrium Action:
The accumulators can be used as counter balances. The
accumulators smoothly balance the weight or impact of products
and machinery via gas pressure.
 5. Leak Compensation :
The accumulators can compensate for any decreases in
pressure due to internal leaks and thus retain the pressure of
pressure control circuits or during any maintenance work.

6. Gas Spring:
The use of the accumulators as a gas spring
rather than a metal spring enables larger load systems to
be downsized.
 Thermal expansion: An accumulator can absorb the
pressure differences caused by temperature variations in a
closed hydraulic system.
 Energy conservation: An accumulator can be used to
supplement a pump during peak demand thereby
reducing the size of the pump and motor required. The
accumulator is charged during low demand portions of
the pump cycle time and then discharges during the high
demand portions of the system.
 Improved response times: An accumulator (bladder
type) has virtually instantaneous response time that can
provide fluid very quickly to fast-acting valves such as
servos and proportional to improve their effectiveness.
 Emergency and safety: An accumulator which is kept
constantly under pressure is valuable in the event of an
electrical power failure as it can provide flow and pressure to
perform an additional function or complete a machine cycle.
Dead Weight type accumulator –

It consists of a piston which is loaded with a

dead weight and moving within a cylinder this
tends to exert pressure on the hydraulic fluid.
Potential energy to compress the fluid is
generated by the dead weight present on the
piston. Concrete block, iron or steel is
generally used as dead weight. The piston is
made to move in the accumulator in precision
fit in order to reduce the leakage. One side of
the accumulator is connected to the fluid
source and other to the machine.
The ram is at the lower most
position at the beginning of a
cycle. The fluid is admitted
continuously inside the cylinder
during the idling period where
the drive is provided by the
machine. This makes the ram to
reach the top most position, thus
the piston or the plunger gains its
potential energy. During the
working stroke the accumulator
is discharged to drive the
machine.
Advantages :
 Used to meet heavy industrial requirements.
 Extremely high capacity at low cost.
 Rugged and durable construction.
Limitations :
 Extremely bulky and heavy.
 Problem in sealing.
Spring type accumulator :
 It uses the energy stored in springs to create a
constant force on the liquid contained in an adjacent
ram assembly.
 The load characteristics of a spring are such that the
energy storage depends on the force required to
compress s spring.
 The free (uncompressed) length of a spring
represents zero energy storage.
 As a spring is compressed to the maximum installed
length, high pressure value of the liquid in a ram
assembly is established.
 As liquid under pressure enters the ram cylinder,
causing a spring to compress, the pressure on the
liquid will rise because of the increased loading
required to compress the spring.
Bladder Accumulators
 It is widely used accumulator in present
scenario.
 It is popularly known as “hydro-pneumatic
accumulator”. It apply force to the liquid by
using a compressed gas that acts as the spring.
 It uses inert gas (nitrogen) under pressure
that provides the compressive force on fluid.
 Oxygen is not used because oxygen and oil
can form an explosive mixture when
combined under pressure
 As the volume of the compressed gas
changes the pressure of the gas, and pressure
of the fluid, changes inversely.
In the bladder accumulators, the fluid area is
separated from the gas area by a flexible
bladder. The fluid around the bladder is in
contact with the circuit, so any increase in
pressure causes the entry of the fluid into the
accumulator and thereby compresses the gas.
Vice versa, every drop of pressure in the circuit
causes the expansion of the gas, resulting in
delivery of the fluid from the accumulator to
the circuit.
Twin Pressure Valve:-
A twin pressure valve, also known as a dual pressure
valve, is a pneumatic valve that limits flow in one
direction while allowing free return flow in the
opposite direction. It has two inputs and one output,
and functions by shifting a spool left or right
depending on which input has compressed air applied.
Quick Exhaust Valve:-
The function of a quick-release valve is to rapidly
exhaust air from the controlled device. It is normally located
adjacent to the controlled device, rather than requiring exhaust
air to return and exhaust through the control valve.
The quick exhaust valve is used to exhaust the cylinder
air quickly to atmosphere.
Hydraulic hose:-
Hydraulic hoses are typically constructed from flexible
rubber or wire, and feature a series of layers to give the hose its
strength and durability. These layers comprise of an inner tube,
a reinforced layer and an outer layer.
Hydraulic hoses are typically constructed from flexible
rubber or wire, and feature a series of layers to give the hose its
strength and durability. These layers comprise of an inner tube,
a reinforced layer and an outer layer.
Seals:-
It is an agent or element which prevents leakage of oil
from hydraulic elements & protect the system from dust & dirt.

Classification of seals:
Static seals: These are the seals which are used to 'seal' two
mating parts which are not moving or which do not having
any relative motion between them.

Eg. O Ring Seal

Dynamic seals:
These are the seals which are used to 'seal' two
mating parts which are having relative motion bet
them.
Types of Dynamic Seals:-
1) Rod Seals: Prevent fluid from leaking out of the cylinder around the
rod.
2) Piston Seals: Seal the piston to the cylinder wall, preventing fluid
transfer between the pressure sides.
3) Wiper Seals (Scrapers): Prevent dirt, dust, or debris from entering the
cylinder.
Classification based on
Degree of sealing:
Positive seals: Those seals
which do not allow any
leakage (Internal or
External).

Non-positive seals: Those

seals which permits a small
amount of any leakage.