Purdue University Purdue e-pubs International Compressor Engineering Conference School of Mechanical Engineering 2002 The Design Of A New Generation Of Twin Screw Refrigeration Compressors Z. Xing Xi an Jiaotong University H. Wu Xi an Jiaotong University P. Shu Xi an Jiaotong University Follow this and additional works at: http://docs.lib.purdue.edu/icec Xing, Z.; Wu, H.; and Shu, P., " The Design Of A New Generation Of Twin Screw Refrigeration Compressors " (2002). International Compressor Engineering Conference. Paper 1594. http://docs.lib.purdue.edu/icec/1594 This document has been made available through Purdue e-pubs, a service of the Purdue University Libraries. Please contact epubs@purdue.edu for additional information. Complete proceedings may be acquired in print and on CD-ROM directly from the Ray W. Herrick Laboratories at https://engineering.purdue.edu/ Herrick/Events/orderlit.html
C21-5 THE DESIGN OF A NEW GENERATION OF TWIN SCREW REFRIGERATION COMPRESSORS Ziwen Xing, Huagen Wu, Pengcheng Shu Division of Compressor, School of Energy and Power Engineering, Xi'an Jiaotong University, Xi an, The People s Republic of China, 710049 Tel: 086-29-2664952, Fax: 086-29 2668724, E-mail: zwxing@mail.xjtu.edu.cn ABSTRACT The design of two series of twin screw compressors for being used in refrigeration applications are reported in this paper. The capacity range for the open type series is from 85 to 3 3 4300 m / h, and for the semi-hermetic series from 120 to 2600 m / h. The rotor profile and other design parameters are optimized with the help of the software package SCCAD. Many new features are adopted in the design such as variable built-in volume ratio, anti-friction bearing and automatic capacity control. The new compressors are also suitable for operating with economizer and liquid refrigerant injection systems. The design guidelines discussed in this paper are very helpful for the design of other kind of twin screw refrigeration compressors. INTRODUCTION Twin screw compressor has many advantages, such as simple construction, convenient operation and reliable working. It has been widely used as air, refrigeration and process compressors [1]. In recent years, with the development of design methods, machining tools and measuring equipment, the performance of twin-screw compressors has been improved greatly. More and more new compressors are designed with the help of mathematical modeling and parameters optimization [2]. In order to meet the demand for twin screw compressors being used in industrial refrigeration and air-conditioning systems, two series of twin screw refrigeration compressors are designed in Xi an Jiaotong University. The capacity range for the open type series is from 85 to 3 3 4300 m / h, and for the semi-hermetic series from 120 to 2600 m / h. The rotor profile and other design parameters are optimized with the help of the software package SCCAD developed by the authors [3]. Many new features are adopted in the design such as variable built-in volume ratio, anti-friction bearing and automatic capacity control. The new compressors are also suitable for operating with economizer and liquid refrigerant injection systems. The design guidelines discussed are very helpful for the design of other kind of twin screw refrigeration compressors.
THE SERIES OF OPEN TYPE TWIN SCREW CONPRESSORS The open type twin screw refrigeration compressors have simple and robust construction. They are especially suitable being used in various industrial refrigeration applications with evaporating temperature from 40 to 5. These types of twin screw refrigeration compressors have been used in industrial for many years. However, with the recent development in design method, bearing and control technology, a new generation of open type twin screw refrigeration compressors should be developed to meet the demand for higher efficiency. Therefore, a new series of open type twin screw refrigeration compressors is designed. Capacity Range The new series of open type twin screw refrigeration compressors includes 12 models with 6 different rotor diameters, and two L/D ratios for each rotor diameter. The compressors are supposed to be driven by direct coupling to a standard electric motor, although they can also be driven by other prime movers such as diesel engines. Figure 1 shows the theoretical displacements for various models with the capacity range from 85 to 4300m 3 / h. Displacement 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 0 K100 K125 K160 K200 K250 K315 Fig. 1 Capacity range of the open type twin screw compressors Rotor Profile The design of rotor profile is the most important part in a twin screw compressor design since the profile can affect the compressor performance and manufacture cost significantly. The rotor profile designed for the open type twin screw refrigeration compressors is shown in Figure 2. All the segments consisting the profile are circular arcs and their conjugating curves. The SCCAD software package is used extensively to optimize the profile parameters such as the rotor lobe combination, center distance between the rotors, radius of the male rotor crest, addendum of the female rotor. The contact line shape between the rotors is also shown in Figure 2, and it can be seen this kind of profile will provide a smooth operation.
Fig.2 Rotor profile and contact line for the open type compressors Compressor Design The rotor parameters such as L/D ratio and wrap angle of the compressors are also optimized with the software package SCCAD. As shown in Figure 3, in order to reduce the flow losses, a combination of axial and radial suction port is designed on the suction end plate and the casing. Axial discharge port with a higher built-in volume ratio is located on the discharge end plate, together with a radial discharge port on the capacity control slide valve, which can provide a continuous capacity control from 15% to 100% automatically. Also, a built-in volume ratio control slide valve incorporated in the compressors. The ratio can vary from 2.6 to 5 by moving the built-in volume control slide valve together with the capacity control valve. Fig.3 The vertical cross-sectional drawing of the open type compressors As shown in Figure 4, all the bearings in the new series of open type twin screw refrigeration are anti-frication bearings instead of journal bearings, which are often used in the conventional open type machines. The radial load of the compressor is carried out by cylindrical roller bearings, and the axial load by four-point contact ball bearings. A balance piston is designed on the suction end of the male rotor to reduce the axial load acting on the bearing and increase the reliability of the compressors. Moreover, a mechanical shaft seal lubricated with forced oil is used to minimize the leakage.
Fig.4 The horizontal cross-sectional drawing of the open type compressors Figure 5 show the port positions for economizer superfeed, liquid refrigerant injection and oil injection. Again, the positions and dimensions of these ports are optimized with the help of SCCAD together with the experimental research work carried out by the authors [4]. Fig.5 The side-view cross section of the open type compressors Parts Manufacturing The roughing machining operation for the rotors is by hobbing, and the finishing machining by grinding. As shown in Figure5, the hobbing cutter profiles are also calculated by the authors according to the rotor profile designed for the open type twin screw refrigeration compressors. Figure 6 shows a photograph of the hobbing cutter and the rotor during machining operation. Figure 7 shows a photograph of the casing and end plate for the open type compressors. The materials used for the parts of the open type compressors are suitable for various refrigerants such as NH 3, R22, R134a, etc.
a) Male rotor hobbing cutter profile b) Female rotor hobbing cutter profile Fig.5 The axial profile of the hobbing cutter for the open type compressors Fig.6 Photograph of the hobbing cutter and the rotor for the open type compressors Fig.7 Photograph of the casing and end plate for the open type compressors
THE SERIES OF SEMI-HERMETIC TWIN SCREW COMPRESSORS With the continuous improvements both in performance and reliability, the small and medium sized semi-hermetic twin screw refrigeration compressors have been used more and more especially in various refrigeration and air-conditioning applications. In order to meet the demand for this kind of machines used both in air-source heat pump and water chillers, a new series of semi-hermetic twin screw refrigeration compressors is designed in Xi an Jiaotong University. Capacity Range The new series of semi-hermetic twin screw refrigeration compressors includes 10 models with 5 different rotor diameters, and two L/D ratios for each rotor diameter. The compressors are designed to be driven by two-pole standard electric motors with the nominal speed of 3000 rpm. Figure 8 shows the theoretical displacements for various models with the capacity range from 3 120 to 2600 m / h. 3000 2500 Displacement 2000 1500 1000 500 0 BF10 BF14 BF16 BF20 BF25 Fig. 8 Capacity range of the semi-hermetic twin screw compressors Rotor Profile Figure 9 shows the contact line and the rotor profile designed for the semi-hermetic twin screw refrigeration compressors. The segments consisting the profile are circular arcs, ellipse and their conjugating curves. The rotor lobe combination is selected as 5+7 to make the female rotor with better stiffness. So the deflection of the female rotor will still be within the tolerance even working under very high condensing temperature, e.g. 70 with R134a, 55 with R22, R407C and R404A. Once again, the SCCAD software package is used extensively to optimize the profile parameters such as center distance between the rotors, radius of the male rotor crest, addendum of the female rotor, etc.
Fig.9 Rotor profile and contact line for the semi-hermetic compressors Compressor Design As shown in Figure 10, a large axial suction port is designed in the casing to reduce the flow losses, and a combination of axial and radial discharge port is designed on the discharge end plate and the capacity control slide valve, which can provide a continuous capacity control from 15% to 100% automatically. The positions of suction and discharge ports are selected with the help of SCCAD and the p-v diagrams recorded in the experimental study carried out on semi-hermetic twin screw refrigeration compressors [5]. The open flash type economizer system is designed in the semi-hermetic twin screw refrigeration compressors as shown in Figure 10. The motor is cooled by the liquid refrigerant, and the flash gas is supplied to the compressor through a superfeed port located on the slide valve. Also, an oil separator utilizing the centrifugal mechanism is integrated in the compressor. Fig.10 The vertical cross-sectional drawing of the semi-hermetic compressors As shown in Figure 11, all the bearings in the series of semi-hermetic twin screw refrigeration compressors are anti-frication bearings which can carried the loads generated under different working conditions with various refrigerants such R134a, R22, R407C and R404A. The
radial load of the compressor is carried out by cylindrical roller bearings, and the axial load by angular contact ball bearings. Fig.11 The horizontal cross-sectional drawing of the semi-hermetic compressors CONCLUSIONS Two series of twin screw compressors have been designed to meet the demands in refrigeration and air-conditioning applications. The open type series covers the capacity range 3 from 85 to 4300 m / h, and the semi-hermetic series from 120 to 2600 m 3 / h. The software package SCCAD is used extensively in the design to optimize rotor profiles and other design parameters. The design guidelines discussed in this paper are very helpful for the design of other kind of twin screw refrigeration compressors. REFERENCES 1. Ziwen Xing, Screw Compressors: Theory, Design and Application, China Machine Press, Beijing, 2000(In Chinese) 2. K Venu Madhav, N Stosic, I K Smith and A Kovacevic, The Design of a Family of Screw Compressors for Oil-flooded Operation, Proceedings of the International Conference on Compressors and Their Systems, City University, London, Sept. 2001 3. Ziwen Xing, Xueyuan Peng and Pengcheng Shu, Development and Application of a Software Package for the Design of Twin Screw Compressors, Proceedings of the International Compressor Engineering Conference at Purdue, July 2000 4. Xueyuan Peng, Ziwen Xing, et al, Experimental Study of Oil Injection and its Effect on Performance of Twin Screw Compressors, Proceedings of the International Compressor Engineering Conference at Purdue, July 2000 5. Huagen Wu, Tiansheng Cui, Xueyuan Peng and Ziwen Xing, Experimental Study On The Performance Characteristics Of Twin Screw Compressor In Air-Source Heat Pump System Proceedings of the International Compressor Engineering Conference at Purdue, July 2002