The air compressor is a general-purpose construction machine with a wide range of applications and wide applications. In particular, the small direct-connected reciprocating piston air compressor is an indispensable mechanical equipment for indoor and outdoor decoration, painting, and mechanical maintenance. A large part of the share is in the foreign DIY home market, and some of them are limited to indoor use.
Therefore, the market has the following major requirements for such small air compressors: 1) electrical safety 2) environmental protection 3) high efficiency and energy saving 4) comfortable and convenient operation. Therefore, when we receive a new R&D design project for a small direct-connect reciprocating piston air compressor, we must first consider these requirements, but the above mentioned requirements are very general and broad, and need Transform it to be integrated into the design work. Let's take an actual case as an example to analyze and explain for you.
01
Market demand in the design document
When you get a R&D project of a small direct-connect reciprocating piston air compressor, the general marketing department staff has fully demonstrated the market prospects and sales expectations of this project. What we need to do is to carefully read the “Application for the Project” to find out where the sales area of the air compressor is. Understand what the key technical parameters of the air compressor are, and what the target price of the air compressor is.
Why do you need to know more about these issues? First, understand the sales area of air compressors. It is possible to directly derive the safety regulations and certification standards for this air compressor. For example, products sold in the United States need to meet UL, CSA or ETL certification, while gas cylinders need to be individually compliant with ASME certification, and products must meet flame retardant requirements (because there are more wooden structures in the United States). The main standards are: UL1450 And ANSI/UL94-1985 and so on. Products sold in Europe need to meet CE, GS, EMC and other certifications, gas tanks do PS certification, and related parts meet environmental requirements. The main implementation standards are: MD Directive 2006/42/EC, LVD Directive 2006/95/EC, EMC Directive 2004/108/EC and PED Directive 97/23/EC, and even some customers are required to meet ISO9000 certification.
Second, the key technical parameters of the air compressor. Generally include the working voltage, frequency, rated power, working system, insulation level, protection level, volume of the gas tank, maximum working pressure and displacement parameters of the air compressor. Sometimes there are special parameters and structural requirements and instructions. In fact, the requirements of these technical parameters of the second article have been limited by the sales area of the first article. For example, the air compressors sold in the United States have only Class B insulation, and the voltage is generally 120V/60HZ. However, the air compressors sold to Europe are different. The insulation grades are commonly used in Class B and Class F. The voltage is 230V and 240V, but it is 50HZ. There is also a need for attention in Europe and the United States regarding the volume of the gas tank, the maximum working pressure, and the difference in the unit of measurement of the displacement.
Third, the target price of the air compressor. Most of the factories can directly calculate the purchase cost of the air compressor by the target price of the air compressor. In fact, this is the overall goal of all our design work, and all the expenses cannot add up to the cost budget. "The cost of the product is designed." It is right to control the cost from the source of the design; it is better than the final prototype, and then try to reduce the cost.
In the "Application for the Project", it also reflects the requirements of the market for electrical safety and environmental protection. However, the requirements for high efficiency, energy saving and comfortable operation and convenience require a comprehensive design in combination with key technical parameters.
Energy efficiency is reflected in the air compressor's utilization of energy. There is a professional term called specific power. The air compressor specific power is an index for evaluating the performance of the compressor under the same exhaust pressure and the same exhaust pressure, and is also an important indicator for evaluating the energy efficiency of the compressor. The current standard in China is "GB19153 Volumetric Air Compressor Energy Efficiency Limit Value and Energy Efficiency Rating".
For the comfort and convenience of operation, it is necessary to combine design with some natural laws, mechanical principles and ergonomics. Empathy, if you use this air compressor, you need to achieve a state of self-satisfaction? With this kind of thinking to design, you will definitely get a satisfactory result.
Therefore, after we got the "Application for the Project", all the design work that follows is actually carried out around the four-point market demand, especially the energy-saving and comfortable use of operation and use. Below we will further explain the market requirements.
02
Market demand is characterized by technical parameters
To meet the energy-saving requirements of air compressors, it is necessary to quantify the key technical parameters of the air compressor. How efficient, how to save energy, in the end have to be converted into data for display. First, let's talk about the specific power of the air compressor. It is defined as follows: It refers to the total input power consumed by the actual volumetric flow gas of the compressor compression unit. The calculation formula for this parameter is: specific power = input power P ÷ volume flow Q; unit: kW / (m3 / min). The smaller the specific power of the air compressor, the higher the efficiency of the air compressor energy utilization and the lower the unit power consumption.
However, this specific power parameter, which is an intermediate characterization value, is calculated indirectly and is not directly designed. So, what design parameters are related to specific power and energy efficiency? It is not difficult to see through the above formula of specific power, except for the input power of the motor, that is the flow value.
However, when we design, it is generally assumed that the power is known to be constant to estimate the flow value. Combined with the formula of the following theoretical flow values, it is not difficult to see that the key parameters of the design of the specific power are the diameter of the cylinder and the stroke of the piston.
It is generally caused by machining errors, design cumulative tolerances, and assembly accuracy of parts involved in compressed gas. There is a certain difference between the theoretical displacement of the design and the measured displacement of the prototype (at 7 kg), which involves the efficiency of the mechanical structure (so be sure to reserve enough coefficients when designing Ensure that the measured prototype has a specific power rating.) The efficiency is low, and the consumption is large. The meaning is to patronize the fever, and the work is less. The phenomenon of characterization is a problem of temperature rise. In fact, the temperature rise directly corresponds to the requirements of energy conservation and environmental protection.
In addition, the energy saving and environmental protection characteristics of the air compressor can also be traced to the direct design parameters. The environmental protection mentioned here includes environmental protection of the air and environmental protection of noise. The relevant design parameters directly reflected are: 1) low temperature rise 2) low noise 3) low vibration.
Among them, the first temperature rise is low. From the perspective of energy conservation and environmental protection, the requirements for small air compressors are required. This type of power tools is required to do less heat work (useless work), reduce waste of energy, and reduce unnecessary Emissions reduce environmental impact. The second noise is small, but it only demands the small air compressor from the perspective of environmental protection. It is required to reduce the noise pollution while working on the work, and create a comfortable and pleasant environment for the operator. The third vibration is small, the main requirement is that the small direct-connected reciprocating piston air compressor itself should have a good mechanical balance. Generally speaking, it must have good running stability. With the increasingly fierce competition in the international market today, with the gradual improvement of energy conservation and environmental awareness in the world, the requirements for the above three performances of small direct-connect reciprocating piston air compressors will become more prominent.
Unexpectedly, while solving energy conservation and environmental protection, we also identified some design parameters related to the comfort and convenience of operation. The air compressor runs smoothly, the noise pollution is low, and the operating environment is comfortable and pleasant. This is a category of comfortable and convenient operation.
Finally, what needs to be said is the safety of electrical appliances. This is actually one of the most difficult and simple requirements. It is difficult to get high certification fees in the early stages of product design; if your customers can afford it, that is a good thing. Simplicity is simple. Most of the certified parts related to the product are menu-type standard parts. You can select them only when you design them. You don't need to perform separate design calculations.
On the other hand, regarding the safety requirements of electrical appliances, when you perform relevant certification and testing on the whole machine, the third-party testing organization will further examine and demonstrate your mechanical structure and electrical selection. Only when the electrical safety is up to standard, the air compressor products you design can enter the corresponding area for sale.
03
Conclusion
The design of the small direct-connected reciprocating piston air compressor is based on the market demand and is transformed into relevant technical documents for product development, which are characterized by relevant technical parameters, which are embodied in the specific mechanical structure design, the use of specific mechanical principles, and specific electrical appliances. The choice of parts.
In short, in order to design a small direct-connected reciprocating piston air compressor product, it is necessary to start from the details of material selection, structural design, tolerance process formulation, etc., and it is necessary to make the work fine, solid, and positional. In this way, we can design products with better performance and higher quality.
