Single Stage Air Compressor

7/30/2019 Single Stage Air Compressor

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1.0 ABSTRACT

A vital part of many commercial, manufacturing, industrial, and automotive

applications is an air compressor. Air compressors are versatile mechanical tools that use

one or numerous pistons to pump compressed air into a defined space.

There are three basic types of air compressors: reciprocating, rotary, and centrifugal.

These general types of air compressors can be further categorized into single or multi

stage, packaged or non-packaged, air cooled or water cooled, and lubricated or non-

lubricated.

There are two types of piston-like air compressors: single-stage, and two-stage. These

piston-like air compressors will keep the storage tank at a predetermined PSI (Pounds per

Square Inch). The air compressors motor will turn off and turn on as needed to insure the proper PSI. Single-stage air compressors have one or more cylinders that pump air

directly into the storage tank. Two-stage air compressors use two or more cylinders to

pump air into another cylinder before pumping the air into the storage tank. Most single-

stage air compressors are sufficient for normal use. Two-stage air compressors are used

primarily by industries that have applications that require high-pressure.

Compact air compressors are popular for easy around-the-home projects. These small

air compressors do not have a storage tank; therefore they must always be running tosupply the air needed for a project. Many glue guns, caulking guns, and painting guns use

compact air compressors.

Air compressors require the proper size hoses for optimal performance. Purchasing

the right size and length of hose will keep PSI loss to a minimal. Check the hose for

cracks, sun damage, or cuts often. If any of these are found, replace your hose

immediately. Any leaks that may be caused by a faulty hose will add to an air

compressors operating cost. Air compressors should be approached with caution. Secure

the hose to guarantee minimal damage should your hose break free from the air

compressor.

Aftercoolers are heat exchangers that cool the heated compressed air. Once the

compressed air has been condensed, the removal of the excess moisture can follow.

Keeping the compressed air free from moisture is essential to most applications requiring

air compressors. Air compressors will last much longer, and be more efficient, if they

remain free from moisture.
http://www.thomasnet.com/products/air-compressors-17092800-1.htmlhttp://www.thomasnet.com/products/air-compressors-17092800-1.html


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Air compressors range in horse power, performance, price, operating cost, and ease of

use. Always check hoses, values, bearings, and the electrical outlet of all air compressors.

This will not only add to the longevity of the air compressor, but keep the operator safe.

2.0 OBJECTIVE

2.1 EXPERIMENT 1

To investigate the motor output power.

2.2 EXPERIMENT 2

To investigate the air flow rate and volume discharge of compressor cylinder.

2.3 EXPERIMENT 3

To investigate the compressor indicated power and mechanical efficiency of

compressor.

2.4 EXPERIMENT 4

To investigate the compressor isothermal power and isothermal efficiency.

2.5 EXPERIMENT 5

To investigate the time taken to fully occupied the compressor receiver tank.

3.0 PROCEDURE

3.1 EXPERIMENT 1

1. Connect plug to 1 phase 240V AC power supply

2. Switch on ELCB and main switch on the control panel.

3. Make sure all the meters is showing zero before experiment except

temperature meter. If the meter initial value is not zero set it by press the up

button.

4. Adjust the compressor to desirable speed by the speed controller on the

inverter.

5. Push the run button on the inverter operation panel and ensure that the run key

is light.

6. Record down motor speed (RPM), power (Watt),and torque (Nm) each 30s

time interval

7. The data continuous mark down until the pressure is automatically cut off.

8. Release air in receiver tank before next experiment.

9. Repeat step 3 to 7 by changing the speed of compressor to next desirablespeed.


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10. Plot graph of the pressure against temperature, indicated power against

compressor speed and efficiency of compressor against compressor speed.

3.2 EXPERIMENT 2



3. Make sure all the meters is showing zero before experiment except temperature

meter. If the meter initial value is not zero set it by press the up button.


inverter.


is light.

6. Record down motor speed (RPM), power (Watt), and torque (Nm) each 30s

time interval



9. Repeat step 3 to 7 by changing the speed of compressor to next desirable speed.



3.3 EXPERIMENT 3





button.


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inverter.


is light.

6. Record down the pressure (P 1, P2) motor speed (RPM), power (Watt),and

torque (Nm) each 30s time interval



9. Repeat step 3 to 7 by changing the speed of compressor to next desirable

speed.



3.4 EXPERIMENT 4





button.


inverter.


is light.

6. Record down the pressure (P 1,P2)each 30s time interval


8. Release air in receiver tank before next experiment.9. Repeat step 3 to 7 by changing the speed of compressor to next desirable

speed.



3.5 EXPERIMENT 5

1. Connect plug to 1 phase 240V AC power supply2. Switch on ELCB and main switch on the control panel.


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button.


inverter.


is light.

6. Record down the tank pressure (P 1) each 30s time interval



9. Repeat step 3 to 7 by changing the speed of compressor to next desirable

speed.

10. Plot graph of the tank pressure against time (s).


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4.0 RESULTS AND DISCUSSION

Experiment 1

Motor Speed Controller = 10Hz

Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

RPM 0 464 442 418 366 218 139 80 40Torque (NM) 0 2.1 2.35 2.52 2.93 3.27 3.93 4.1 4.25Motor Input Power

(kW)0 0.588 0.735 0.818 0.969 1.389 1.322 1.457 1.437

Motor OutputPower (kW)

0 0.108 0.114 0.110 0.112 0.074 0.057 0.034 0.017

Motor Efficiency

(%)0 18.501 15.510 13.486 11.590 5.375 4.327 2.357 1.239


TimeData

0 30s 60s 90s 120s 150s 180s 210s 240s

RPM 0 987 916 872 898 763 752 749 743

Torque (NM) 0 3.06 3.49 3.97 4.2 4.43 4.7 4.81 4.95

Motor Input Power

(kW)0 0.815 0.941 1.021 1.101 1.183 1.295 1.434 1.394

Motor Output

Power (kW)0 0.33 0.11 0.36 0.40 0.35 0.37 0.38 0.39

Motor Efficiency

(%)0 41.08 12.11 35.51 35.88 29.92 28.58 26.31 27.63


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Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

RPM 0 1507 1450 1406 1361 1323 1277 1232 1200

Torque (NM) 0 3.92 4.47 4.81 5.11 5.34 5.59 5.73 4.95

Motor Input Power

(kW)0 0.999 1.145 1.244 1.332 1.404 1.466 1.589 1.593

Motor Output

Power (kW)0 0.68 0.11 0.71 0.73 0.74 0.75 0.74 0.62

Motor Efficiency

(%) 0 67.95 9.96 56.94 54.68 52.70 51.00 46.53 39.05


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

RPM 0 1998 1935 1878 1819 1765 1718 - -

Torque (NM) 0 4.61 5.09 5.44 5.75 5.95 6.13 - -Motor Input Power

(kW)0 1.199 1.336 1.447 1.542 1.619 1.681 - -

Motor Output

Power (kW)0 1.03 0.11 1.07 1.10 1.10 1.10 - -

Motor Efficiency

(%)0 86.03 8.53 73.95 71.04 67.94 65.61 - -


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

RPM 0 2636 2583 2514 2453 2395 2332 - -

Torque (NM) 0 4.22 4.7 5.21 5.59 5.9 6.07 - -

Motor Input Power 0 1.065 1.345 1.307 1.416 1.426 1.506 - -


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(kW)

Motor Output

Power (kW)0 1.27 0.11 1.37 1.44 1.48 1.48 - -

Motor Efficiency(%)

0 119.39 8.48 104.96 101.42 103.78 98.44 - -

As we can see from the graph, the output power increases over time. The output power for

50Hz is higher than the others because of the compressor need lot of energy for running at

speed.

Experiment 2


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

RPM (motor) 0.00 464.00 442.00 418.00 366.00 218.00 139.00 80.00 40.00RPM (compressor) 0.00 176.78 168.40 159.26 139.45 83.06 52.96 30.48 15.24Air Flow Indicated 0.00 49.50 47.15 44.59 39.04 23.26 14.83 8.53 4.27

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

0 30 60 90 120 150 180 210

O u t p u t P o w e r

Time

Output Power vs Time

10Hz

20Hz

30Hz

40Hz

50Hz


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Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

RPM (motor) 0 987 916 872 898 763 752 749 743RPM (compressor) 0.00 376.05 349.00 332.23 342.14 290.70 286.51 285.37 283.08Air Flow Indicated 0.00 105.29 97.72 93.02 95.80 81.40 80.22 79.90 79.26


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s



TimeData

0 30s 60s 90s 120s 150s 180s 210s 240s



Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

RPM (motor) 0 2636 2583 2514 2453 2395 2332 - -

RPM (compressor) 0.00 1004.32 984.12 957.83 934.59 912.50 888.49 - -

Air Flow Indicated 0.00 281.21 275.55 268.19 261.69 255.50 248.78 - -


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The pattern of air flow indicator for 10Hz, 20Hz, 30Hz, 40Hz and 50Hz are increasing at the

beginning and slowly decreasing at the end. This is because the compressor need a lot of air

at the beginning to full the tank and when tank are filled the air intake to the compressor

reduce.

Experiment 3


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

P1 (bar) 0 -0.09 -0.08 -0.06 -0.01 -0.01 -0.01 -0.01 -0.01

P2 (bar) 0 0.4 0.6 0.8 0.8 0.9 1.0 0.8 0.6

RPM0 464 442 418 366 218 139 80 40Torque (Nm) 0 2.1 2.35 2.52 2.93 3.27 3.93 4.1 4.25

Power (kW) 0 0.108 0.114 0.110 0.112 0.074 0.057 0.034 0.017

Indicated Power 0 3.192 7.307 14.393 17.542 10.451 9.100 2.753 0.662

0

50

100

150

200

250

300

0 30 60 90 120 150 180 210

A i r F l o w

I n

d i c a t e

d

Time

Air Flow Indicated vs Time

10Hz

20Hz

30Hz

40Hz

50Hz


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Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

P1 (bar) 0 -0.4 -0.33 -0.31 -0.2 -0.21 -0.17 -0.16 -0.13

P2 (bar) 0 0.9 1.5 2.0 2.5 2.9 3.3 3.7 4.0

RPM 0 987 916 872 898 763 752 749 743

Torque (Nm) 0 3.06 3.49 3.97 4.2 4.43 4.7 4.81 4.95

Power (kW) 0 0.33 0.11 0.36 0.40 0.35 0.37 0.38 0.39

Indicated Power 0.00 47.31 229.73 651.47 1,687.092,738.

454,839.

938,208.

0811,791

.35


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

P1 (bar) 0 -0.71 -0.64 -0.54 -0.52 -0.43 -0.46 0.41 0.37

P2 (bar) 0 1.5 2.3 3.0 3.7 4.4 5.0 5.6 6.1

RPM 0.00 574.17 552.45 535.69 518.54 504.06 486.54 469.39 457.20Torque (Nm) 0 1507 1450 1406 1361 1323 1277 1232 1200

Power (kW) 0 3.92 4.47 4.81 5.11 5.34 5.59 5.73 4.95

Indicated Power 0.00 247.53 1,210.353,641.

099,841.

4719,194

.9435,544

.5362,644

.8196,232

.12


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

P1 (bar) 0 -0.104 -0.097 -0.086 -0.080 -0.068 -0.065 - -

P2 (bar) 0 2.5 3.4 4.3 5.2 6.0 6.7 - -

RPM 0 1998 1935 1878 1819 1765 1718 - -

Torque (Nm) 0 4.61 5.09 5.44 5.75 5.95 6.13 - -

Power (kW) 0 1.03 0.11 1.07 1.10 1.10 1.10 - -

Indicated Power0.00

1,854.21

6,765.13

19,613.14

51,655.70

90,781.27

158,333.64 - -


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Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

P1 (bar) 0 -0.154 -0.141 -0.130 -0.120 -0.112 -0.108 - -

P2 (bar) 0 1.6 2.4 3.6 4.6 5.6 6.6 - -

RPM 0 2636 2583 2514 2453 2395 2332 - -

Torque (Nm) 0 4.22 4.7 5.21 5.59 5.9 6.07 - -

Power (kW) 0 1.27 0.11 1.37 1.44 1.48 1.48 - -

Indicated Power 0.00 313.11 1,446.968,401.

9728,084

.9463,820

.87146,40

9.08 - -

For experiment 3 its show that power consumption increasing with time increase. Its because

single air compressor need high power to generate the compress air inside the tank. The

higher the Hz the higher power need.

0

20000

40000

60000

80000

100000

120000

140000

160000

180000

0 50 100 150 200

I n d i c a t e

d P o w e r

Time

Indicated Power vs Time

10 Hz

20Hz

30Hz

40Hz

50Hz


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Experiment 4


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

T1 (C) 0 38.0 38.7 39.2 39.4 38.7 37.6 37.3 37.2

P1 (bar) 0 -0.09 -0.08 -0.06 -0.01 -0.01 -0.01 -0.01 -0.01

P2 (bar) 0 0.4 0.6 0.8 0.8 0.9 1.0 0.8 0.6

RPM 0 464 442 418 366 218 139 80 40Torque (Nm) 0 2.1 2.35 2.52 2.93 3.27 3.93 4.1 4.25


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

T1 (C) 0 44.2 47.2 49.6 51.7 53.7 55.6 57.2 58.7

P1 (bar) 0 -0.09 -0.08 -0.06 -0.01 -0.01 -0.01 -0.01 -0.01

P2 (bar) 0 0.4 0.6 0.8 0.8 0.9 1.0 0.8 0.6

RPM 0 448 428 378 244 54 164 170 25

Torque (Nm) 0 1.70 2.10 2.47 3.49 3.50 3.57 3.58 3.71


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

T1 (C) 0 63.6 68.6 73.2 77.2 80.6 83.6 86.3 88.4

P1 (bar) 0 -0.76 -0.67 -0.61 -0.52 -0.52 -0.41 -0.44 -0.39

P2 (bar) 0 1.2 2.0 2.8 3.5 4.1 4.8 5.3 5.9

RPM 0 1538 1468 1420 1370 1326 1280 1235 1185

Torque (Nm) 0 3.51 4.11 4.50 4.85 5.06 5.30 5.52 5.66


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Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

T1 (C) 0 90.4 95.9 100.3 104.3 107.9 110.9 - -

P1 (bar) 0 -0.76 -0.67 -0.61 -0.52 -0.52 -0.41 - -

P2 (bar) 0 1.2 2.0 2.8 3.5 4.1 4.8 - -

RPM 0 1538 1468 1420 1370 1326 1280 - -

Torque (Nm) 0 3.51 4.11 4.50 4.85 5.06 5.30 - -


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

T1 (C) 0 91.1 97.1 104.2 110.5 116.0 121.4 - -

P1 (bar) 0 -1.51 -1.37 -1.29 -1.19 -1.11 -1.00 - -

P2 (bar) 0 1.61 2.70 3.80 4.90 5.80 6.80 - -

RPM 0 2625 2552 2487 2430 2368 2306 - -

Torque (Nm) 0 4.17 4.83 5.26 5.62 5.86 6.05 - -

Experiment 5 show that torque increase when time increase. As rotational motion increases,

the amount of friction and constraints on the materials. If torque were to increases linearly,

0

1

2

3

4

5

6

7

0 50 100 150 200

T o r q u e

Time

Torque vs Time

10Hz

20Hz

30Hz

40Hz

50Hz


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the amount of the friction would also increase, and depending on the amount of friction/heat

the materials could take, would eventually cause a breakdown.

Experiment 5


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

Pt (bar) 0 0.10 0.40 0.80 1.00 1.10 1.18 1.19 1.20


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

Pt (bar) 0 0.85 1.55 1.90 2.70 3.40 4.00 4.60 5.25


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

Pt (bar) 0 1.15 2.05 2.80 3.60 4.40 5.00 5.60 6.25


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s

Pt (bar) 0 1.30 2.55 3.50 4.60 5.30 6.30 - -


Time

Data0 30s 60s 90s 120s 150s 180s 210s 240s


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Pt (bar) 0 1.60 2.90 4.10 5.20 6.20 7.30 - -

For experiment 5 the pressure increase with increase of time. To compress air inside the tank

need pressure so to achieve desire amount of air compressor pressure will increase until its

full fill the quantity its need.

5.0 CONCLUSION

In this experiment we learn that the relationship between the RPM, motor output

power, air flow rate and volume discharge of compressor cylinder, mechanical efficiencyof compressor, compressor isothermal power and isothermal efficiency and time taken to

fully occupied the compressor receiver tank. We also learn how to operate the

compressor and its safety and precaution steps.

0

2

4

6

8

0 50 100 150 200

T a n

k P r e s s u r e

Time

Tank Pressure vs Time

10Hz

20Hz

30Hz

40Hz

50Hz

Single Stage Air Compressor

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