A variable-speed drive (VSD) air compressor is an air compressor that takes advantage of variable-speed drive technology. This type of compressor uses a special drive to control the speed (RPM) of the unit, which in turn saves energy compared to a fixed speed equivalent. [1] This is done to improve the efficiency of the compressor as varying the displacement or compression ratio of a compressor generally introduces significant inefficiency, or is impractical to implement.
The most common form of VSD technology in the air compressor industry is a variable-frequency drive, which converts the incoming AC power to DC and then back to a quasi-sinusoidal AC power using an inverter switching circuit. The variable-frequency drive article provides additional information on electronic speed controls used with various types of AC motors.
The benefits of this technology included reducing power cost, reducing power surges (from starting AC motors), and delivering a more constant pressure. The down side of this technology is the heavy expense associated with the drive, and the sensitivity of these drives – specifically to heat and moisture.
Typically a fifth of a factory's electricity bill is attributed to the production of compressed air. The majority of modern factories are heavily involved in cutting costs, and energy awareness should be a key concern. For example, 10–12% of all power generated in the UK is dedicated to the production of compressed air and a portion of this power is wasted energy.
Large electrical cost savings can be achieved by installing a variable speed drive compressor in place of an existing rotary screw or piston machine. Because of this, many governments, including the US and UK, are pushing the industries to move towards this technology in hopes of reducing wasted energy. Governments offer various incentives, such as tax rebates or interest free loans, to cover the upgrades.
However, variable speed drive compressors are not necessarily appropriate for all industrial applications. If a variable speed drive compressor operates continuously at full speed, the switching losses of the frequency converter result in a lower energy efficiency than an otherwise identically sized fixed speed compressor. Where demand remains constant within 5–15% of the total free air delivery flow rate, dual-control compressors configured in a split solution can provide higher efficiency than a VSD.
A professional air audit is the best way to identify if a VSD compressor is most appropriate for any given compressed air application. [2] These audits are available from various companies that specialize in the implementation of compressed air equipment, which can determine the most efficient controls for a compressed air system – including variable speed, variable capacity or using storage and flow controllers. [3]
An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a wire winding to generate force in the form of torque applied on the motor's shaft. An electric generator is mechanically identical to an electric motor, but operates in reverse, converting mechanical energy into electrical energy.
A power inverter, inverter or invertor is a power electronic device or circuitry that changes direct current (DC) to alternating current (AC). The resulting AC frequency obtained depends on the particular device employed. Inverters do the opposite of rectifiers which were originally large electromechanical devices converting AC to DC.
An air compressor is a machine that takes ambient air from the surroundings and discharges it at a higher pressure. It is an application of a gas compressor and a pneumatic device that converts mechanical power into potential energy stored in compressed air, which has many uses. A common application is to compress air into a storage tank, for immediate or later use. When the delivery pressure reaches its set upper limit, the compressor is shut off, or the excess air is released through an overpressure valve. The compressed air is stored in the tank until it is needed. The pressure energy provided by the compressed air can be used for a variety of applications such as pneumatic tools as it is released. When tank pressure reaches its lower limit, the air compressor turns on again and re-pressurizes the tank. A compressor is different from a pump because it works on a gas, while pumps work on a liquid.
An actuator is a component of a machine that produces force, torque, or displacement, usually in a controlled way, when an electrical, pneumatic or hydraulic input is supplied to it in a system. An actuator converts such an input signal into the required form of mechanical energy. It is a type of transducer. In simple terms, it is a "mover".
The Brayton cycle is a thermodynamic cycle that describes the operation of certain heat engines that have air or some other gas as their working fluid. The original Brayton Ready Motor used a piston compressor and piston expander, but modern gas turbine engines and airbreathing jet engines also follow the Brayton cycle. Although the cycle is usually run as an open system, it is conventionally assumed for the purposes of thermodynamic analysis that the exhaust gases are reused in the intake, enabling analysis as a closed system.
A compressor is a mechanical device that increases the pressure of a gas by reducing its volume. An air compressor is a specific type of gas compressor.
A brushless DC electric motor (BLDC), also known as an electronically commutated motor, is a synchronous motor using a direct current (DC) electric power supply. It uses an electronic controller to switch DC currents to the motor windings producing magnetic fields that effectively rotate in space and which the permanent magnet rotor follows. The controller adjusts the phase and amplitude of the DC current pulses to control the speed and torque of the motor. This control system is an alternative to the mechanical commutator (brushes) used in many conventional electric motors.
A compressed-air vehicle (CAV) is a transport mechanism fueled by tanks of pressurized atmospheric gas and propelled by the release and expansion of the gas within a pneumatic motor.
A chiller is a machine that removes heat from a liquid coolant via a vapor-compression, adsorption refrigeration, or absorption refrigeration cycles. This liquid can then be circulated through a heat exchanger to cool equipment, or another process stream. As a necessary by-product, refrigeration creates waste heat that must be exhausted to ambience, or for greater efficiency, recovered for heating purposes. Vapor compression chillers may use any of a number of different types of compressors. Most common today are the hermetic scroll, semi-hermetic screw, or centrifugal compressors. The condensing side of the chiller can be either air or water cooled. Even when liquid cooled, the chiller is often cooled by an induced or forced draft cooling tower. Absorption and adsorption chillers require a heat source to function.
A recuperator is a special purpose counter-flow energy recovery heat exchanger positioned within the supply and exhaust air streams of an air handling system, or in the exhaust gases of an industrial process, in order to recover the waste heat. Generally, they are used to extract heat from the exhaust and use it to preheat air entering the combustion system. In this way they use waste energy to heat the air, offsetting some of the fuel, and thereby improve the energy efficiency of the system as a whole.
A variable-frequency drive is a type of AC motor drive that controls speed and torque by varying the frequency of the input electricity. Depending on its topology, it controls the associated voltage or current variation.
Motor drive means a system that includes a motor. An adjustable speed motor drive means a system that includes a motor that has multiple operating speeds. A variable speed motor drive is a system that includes a motor and is continuously variable in speed. If the motor is generating electrical energy rather than using it – this could be called a generator drive but is often still referred to as a motor drive.
A rotary-screw compressor is a type of gas compressor, such as an air compressor, that uses a rotary-type positive-displacement mechanism. These compressors are common in industrial applications and replace more traditional piston compressors where larger volumes of compressed gas are needed, e.g. for large refrigeration cycles such as chillers, or for compressed air systems to operate air-driven tools such as jackhammers and impact wrenches. For smaller rotor sizes the inherent leakage in the rotors becomes much more significant, leading to this type of mechanism being less suitable for smaller compressors than piston compressors.
Vapour-compression refrigeration or vapor-compression refrigeration system (VCRS), in which the refrigerant undergoes phase changes, is one of the many refrigeration cycles and is the most widely used method for air conditioning of buildings and automobiles. It is also used in domestic and commercial refrigerators, large-scale warehouses for chilled or frozen storage of foods and meats, refrigerated trucks and railroad cars, and a host of other commercial and industrial services. Oil refineries, petrochemical and chemical processing plants, and natural gas processing plants are among the many types of industrial plants that often utilize large vapor-compression refrigeration systems. Cascade refrigeration systems may also be implemented using two compressors.
In an internal combustion engine, a supercharger compresses the intake gas, forcing more air into the engine in order to produce more power for a given displacement.
A free-piston engine is a linear, 'crankless' internal combustion engine, in which the piston motion is not controlled by a crankshaft but determined by the interaction of forces from the combustion chamber gases, a rebound device and a load device.
Voltage optimisation is a term given to the systematic controlled reduction in the voltages received by an energy consumer to reduce energy use, power demand and reactive power demand. While some voltage 'optimisation' devices have a fixed voltage adjustment, others electronically regulate the voltage automatically.
In air conditioning, an inverter compressor is a compressor that is operated with an inverter.
Sullair is a major American manufacturer of portable and stationary rotary screw air compressors designed for commercial and industrial use. Founded in 1965 in the town of Michigan City, Indiana U.S.A., Sullair has manufacturing facilities in Michigan City that distribute and service air compressor packages and systems worldwide. Sullair also has manufacturing facilities in Suzhou, Jiangsu and Shenzhen, Guangdong China that service the Asian and Australasian markets. Sullair also has offices in Dandenong South, Australia near Melbourne, and in Sunderland, United Kingdom that services markets in the EMEA and Russia.
Inverterization is the process of using an inverter-based motor drive intended to operate an electric motor at a variable speed for the sake of improved efficiency. The main job of the inverter is to control the speed and torque of the motor to match work requirements.