Fluid power pumps

A fluid power system’s prime mover is a pump or compressor that converts electricity or some form of heat energy into hydraulic or pneumatic energy. These devices can be rotary or reciprocating, single or multiple stage, and fixed or variable volume. They may move a variety of fluids and come in many different designs. Some pump designs offer unique features that make them especially suitable for a particular application.

Figure 8-1 shows several types of compressors in simplified cutaway form. These cutaways represent many standard designs used in industrial applications. They are not complete representations but simply show general working principles.

 

 

 

 

 

 

 

 

 

Reciprocating-piston air compressors

The single-piston/single-stage, dual-piston/single-stage, and dual-piston/dual-stage compressors illustrated in Figure 8-1 are typical designs for piston-type air pumps. Compressors of these designs may be rated as low as horsepower or as high as 1000 or more horsepower. The smaller sizes are air cooled while larger ones are water cooled.

Single-stage compressors normally operate at 125 psi or less and produce approximately 4 scfm (standard cubic feet per minute) of flow at 100 psi. (One scfm is 1 ft3 of gas at 68°F, 14.69 psia, and a relative humidity of 36%.

Diaphragm air compressors keep lubricating fluids out of the air or gas they are compressing. This arrangement often makes the air suitable for breathing and it can be used in applications where contamination from compressor oil cannot be tolerated. The cutaway view in Figure 8-1 shows an oil-driven diaphragm compressor that is capable of very high pressure. As the oil piston extends, it forces oil against the diaphragm to compress the gas. On the retract stroke, pressure inside the diaphragm plus vacuum returns the bladder to pick up more atmospheric air.

Piston-type reciprocating compressors below a 15- to 25-hp range usually start and stop at preset low and high pressure settings. Larger reciprocating compressors typically continue to run after pressure reaches the preset maximum, but they then stop compressing by holding their inlet valves open. This arrangement is called unloading. It saves wear on the electric motor because the motor only has to start one time.

Rotary compressors

Rotary compressors employ lobed rotors, vanes, screws, or impellers to draw in ambient air and compress it. Figure 8-1 also shows these devices. While these types of air pump are more compact and produce less vibration, they have lower efficiency than other types. All these designs (except the multi-stage centrifugal compressor) are limited to a maximum of 150 to 200 horsepower.

Rotary compressors run continuously and are capable of no flow to full flow at any time. An inlet-restricting valve closes or opens in response to pressure changes. Many rotary compressor installations do not require a receiver tank, due to their ability to change flow in relation to demand.

Pneumatic pump efficiency

Using atmospheric air as a means to transmit energy is very inefficient. A 1-hp air motor requires between 7 and 15 compressor hp while it runs. A hydraulic motor that produces the same output would only need 1½ to 2 hp input.

Air cylinders are more efficient than air motors, but still require three to four times more prime mover energy than their hydraulic counterparts. The general rule of thumb is: use hydraulic cylinders when an air-cylinder circuit would require a 4- or 5-in. or larger bores to produce the necessary force. This is especially important when the cylinders must operate at high cycle rates. Up-front cost of the hydraulic system is more, but operating cost savings soon pay for the added expense.

On the other hand, a 20-in. bore air cylinder used to maintain tension on a conveyor belt (with minimal cycling) would be a very efficient system.