The compressor is a machine used to improve gas pressure and transport gas.From the perspective of energy, compressor is a machine that transforms the power of the original motivation into gas pressure energy.With science and technology ...
Causes and countermeasures of the compressor
The compressor is a machine used to improve gas pressure and transport gas.From the perspective of energy, compressor is a machine that transforms the power of the original motivation into gas pressure energy.With the development of science and technology, the application of pressure can become one of the essential equipment in many departments of the national economic construction.During the operation of the compressor, there will inevitably be some failures or even accidents.Failure refers to the abnormal situation of the compressor during operation. Once the compressor is excluded, the normal work can be restored, and the accident means that the damage occurs.The two are often associated. If they encounter a failure, they will cause major accidents.
Common faults and reasons and measures
Insufficient exhaust volume:
Insufficient exhaust capacity is compared with the design gas of the compressor.Mainly considers from the following aspects:
1 The failure of the intake filter: the stuffing is blocked to reduce the exhaust volume; the inhalation tube is too long and the pipe diameter is too small, which causes the aspirational resistance to increase the amount of gas. It is necessary to regularly clean the filter.
2 Decrease in the speed of the compressor to reduce the exhaust volume: Improper use of the air compressor, because the exhaust volume of the air compressor is designed according to a certain altitude, ashable temperature, and humidity. When the altitude of the altitude that exceeds the above standardsAt the time of ones, the inhalation pressure is reduced, and the exhaust volume will inevitably decrease.
3 cylinders, pistons, and piston rings are severely abrasion, ultra -difference, increasing related gaps, increasing leaks, and affecting the amount of exhaust.When it belongs to normal grinding, it needs to be replaced in time, such as the piston ring.When the installation is incorrect, when the gap is not appropriate, it should be corrected according to the drawings. If there is no drawing, it is advisable to be experienced.0.06/100 ～ 0.09/100; For aluminum alloy pistons, the gap is 0.12/100 ～ 0.18/100; the steel piston can take the smaller value of the aluminum alloy piston.
4 The filling letter does not cause a leak to reduce the amount of gas.The reason is that the filling letter itself does not meet the requirements when it is manufactured; secondly, it may be because during installation, the piston rod and the filling letter center are not good, resulting in wear, strain, etc.It is lubricating, sealing, and cooling.
5 The impact of the failure of the compressor and the exhaust valve on the exhaust volume.Falling metal fragments or other debris between the valve seat and the valve tablet, the shutdown is not strictly closed, forming air leakage.This not only affects the exhaust volume, but also affects the changes in the interstitial pressure and temperature; the contact with the valve seat and the valve chip is not strictly formed, which affects the exhaust capacity.Second, the air leakage is formed due to the severe wear of the valve seat and the valve sheet.
6 The air valve spring force is not well matched with gas.If the elasticity is too strong, the valve sheet is slow. If the elasticity is too weak, the valve sheet is not closed in time. These not only affect the amount of gas, but also affect the increase in power, as well as the life of the air valve slice and spring.At the same time, it will also affect changes in gas pressure and temperature.
7 The pressure of the pressure valve is improper.If the pressure is small, the air is leaked. Of course, it is too tight or not. It will deform and damage the valve cover. Generally, the pressure can be calculated by the lower formula: P = Kπ/4d2p2, D is the diameter of the valve cavity, P2 is the maximum gas pressure, K is the value of greater than 1, generally take 1.5 to 2.5, K = 1.5 ～ 2.0 during low pressure, and K = 1.5 ～ 2.5 at high pressure.Take K in this way, the practice proves that it is good.The air valve has faults, the valve cover must be fever, and the pressure is not normal.
The exhaust temperature is abnormal
The abnormal exhaust temperature refers to it higher than the design value.Theoretically, the factors that affect the increase in exhaust temperature are: intake temperature, pressure ratio, and compression index (for air compression index K = 1.4).The actual situation affects factors that have high aspiration temperature, such as: low coolant efficiency in the middle, or the scale of scale in the medium cold device affects heat exchange, then the rear -level inhalation temperature must be high, and the exhaust temperature will be high.The air valve leaks and the piston loop leaks, which not only affects the increase in exhaust temperature, but also changes the pressure of the level. As long as the pressure ratio is higher than the normal value, the exhaust temperature will be increased.In addition, water -cooled machines, lack of water or lack of water, will increase the exhaust temperature.
Abnormal pressure and decreased exhaust pressure
The amount of gas discharged by the compressor cannot meet the users traffic requirements under the rated pressure. The exhaust pressure must be reduced. The reduction of exhaust pressure is the phenomenon. The essence is that the exhaust volume cannot meet the users requirements.At this time, it had to change a machine with the same exhaust pressure and large exhaust volume.The main reason for the abnormal pressure of the inter -level pressure is that the air valve leaks or the piston ring is worn, so it should be found from these aspects and take measures.
Abnormal noise
If a compressor fails, an abnormal noise will be made. Generally speaking, the operator can judge the abnormal noise.The gap between the piston and the cylinder head is too small and hit directly; the piston rod and the piston connect the nuts loose or remove, the piston end surface is blocked, the piston strings up the collision cylinder head, the metal fragments and the accumulated water in the cylinder, etc.Tap can be made in the cylinder.The crankshaft tile bolts, nuts, connecting bolts, cross bolts, loosening, deduction, fracture, etc.A hit sound was made in the cranks box.The exhaust valve sheet is broken, the valve spring is soft or damaged, the load regulator is not adjusted properly, etc. All can make a hit in the valve cavity.From this to find faults and measures.
Overheating
At frictions such as cranks and bearings, cross heads and skateboards, fillers, and piston rods, the temperature exceeds the specified value as overheating.The consequences brought by overheating: one is to speed up the wear between the rubbing sidelines, and the other is that the heat of overcatience continues to accumulate and cause the fringe surface of the fringe and the burning surface to cause a major accident.The main reasons for the overheating of the bearing are: uneven fit between the bearing and the neck or the contact area of ??the contact; the bearing biased crankshaft bending and twisting; the lubricating oil viscosity is too small, the oil circuit is blocked, the oil pump has faults caused by oil breaks, etc. When installation, etc.There was no flat, no gap, the main axis and the motor shaft were not found, and the two axes were inclined.
Compressor accident
Fracture accident
Caulft break: Most of its breaks are at the corner transition of the neck and crank arm. The reasons are roughly as follows: the transitional corner is too small, R <0.06d (D is the cranium); during thermal treatment, the corner is not at the corner at the corner.To deal with the stress concentration at the junction; irregular rounded processing, there are local sessions mutations; long -term overload operation, and some users in order to increase the output, randomly increase the speed to worsen the stress condition; the material itself has defects, such as the defects, such asThe castings include sand eye, shrinking pine.In addition, the oil hole on the crankshaft is cracking, which can also be seen.
Fragmentation of the link: There are several cases in the following situations: the connecting rod screw is broken. The reasons are: the long -term use of the rod screw produces plastic deformation; the screw head or the screw or the large head end is exposed to the poor end of the surfaceThere are as many as seven times that of simple axial tension. Therefore, no small skew is allowed, the contact should be evenly distributed, and the distance between the contact point must not exceed 1/8 of the circular week, that is, 450;
Pistons break: The main breaks are the threads connected to the cross head and the thread of the piston. These two are the weak links of the piston rod.Fracture more often.If there is no problem in ensuring design, processing, and material, the pre -tightening force must not be too large during installation, otherwise the maximum force will achieve the time -to -daemon piston rod that will break.After long -term operation, due to the daily wear of the cylinder, the piston in the horizontal column will sink, so that the additional load is generated at the connected thread, and then running will be broken, which may break the piston rod. This should pay special attention during maintenance.In addition, due to the damage of other parts, when the piston rod is strongly impacted, it may break the piston rod.
Broken cylinder and cylinder head: Main reasons: For water -cooled machines, after running in winter, if you forget the cooling water in the cylinder and cylinder head, the cooling water will freeze and break through the cylinder and cylinder head, especially in In the northern region of my country, cooling water must be kept after parking; it is not found because it is interrupted and not discovered in time, which increases the temperature of the cylinder, and suddenly puts in cooling water to make the cylinder burst; because the gap between the dead point is too small, the piston is too small, the piston is too small, the piston is too small, the piston is too small, the piston is too small, and the piston is too small, and the piston is too small. Reasons such as the loosening of the nut, and the reasons such as falling into the metal object and the piston blocking on the piston will cause the piston to hit the cylinder head and break it.
Burning and explosion accidents
There are often carbon accumulation problems in the oil lubrication compressor. This is what we do not want, because carbon deposits will not only make the piston ring stuck in the groove, the air valve work is abnormal and the airflow channel area will be reduced.Carbon deposits will burn under certain conditions, causing the compressor to explode.Therefore, the lubricating oil in the cylinder cannot be provided too much, and it cannot be allowed to inhale the cylinder without filtering and containing a large amount of dust.In order to prevent burning and explosion, it is necessary to plan for maintenance and regularly clean the oil storage tanks and pipelines.China
In addition, there are also reasons for the combustion and explosion of compressors: The compressor did not use low -pressure nitrogen to remove the air with low -pressure nitrogen before the hydrogen, oxygen, and nitrogen hydrogen load was tested with hydrogen, oxygen, and nitrogen hydrogen.Due to the lack of operational knowledge, the valve was not opened to the gas storage tank after driving, causing the exhaust pressure to rise sharply and the explosion.Therefore, to prevent such accidents, we must be familiar with operating procedures before driving. After driving, pay close attention to the pressure gauge value.In general small and medium -sized compressors, it is best to cancel the compressor to the gate valve on the pipeline of the gas storage tank, leaving only the inverse stop valve.In addition, the compressor operator should be trained before the job.
Because the high -pressure air valve of the compressor is not tight, the high -pressure and high temperature gas returns the cylinder and generates high temperature near the exhaust valve. When there is carbon deposits, it will cause explosion.To avoid accidents, at this time, the exhaust valve must be maintained and the leakage site must be inspected to eliminate the failure.

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