U.S. patent application number 13/866499 was filed with the patent office on 2013-11-07 for system and method for a compressor.
The applicant listed for this patent is GENERAL ELECTRIC COMPANY. Invention is credited to NEIL W. BURKELL, MILAN KARUNARATNE, RICHARD C. PEOPLES, DAVID E. PETERSON, JASON M. STRODE, BRET DWAYNE WORDEN.
Application Number | 20130294936 13/866499 |
Document ID | / |
Family ID | 48326433 |
Filed Date | 2013-11-07 |
United States Patent
Application |
20130294936 |
Kind Code |
A1 |
WORDEN; BRET DWAYNE ; et
al. |
November 7, 2013 |
SYSTEM AND METHOD FOR A COMPRESSOR
Abstract
Systems and methods of the invention relate to removing fluid
from a compressor to mitigate condensation accumulated for a
compressor. A controller can be configured to actuate a drain valve
coupled to an aftercooler of a compressor and actuate a check valve
to isolate air pressure of the aftercooler from a reservoir of the
compressor. Through control of the drain valve of the aftercooler
and the check valve, the controller removes fluid from the
aftercooler to facitliate thermal management of a compressor.
Inventors: |
WORDEN; BRET DWAYNE; (ERIE,
PA) ; PEOPLES; RICHARD C.; (GROVE CITY, PA) ;
PETERSON; DAVID E.; (LAWRENCE PARK, PA) ; STRODE;
JASON M.; (LAWRENCE PARK, PA) ; BURKELL; NEIL W.;
(LAWRENCE PARK, PA) ; KARUNARATNE; MILAN;
(LAWRENCE PARK, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GENERAL ELECTRIC COMPANY |
Schenectady |
NY |
US |
|
|
Family ID: |
48326433 |
Appl. No.: |
13/866499 |
Filed: |
April 19, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61636192 |
Apr 20, 2012 |
|
|
|
Current U.S.
Class: |
417/53 ;
417/364 |
Current CPC
Class: |
F16K 37/0091 20130101;
F04B 49/10 20130101; F04B 2205/063 20130101; F04B 49/02 20130101;
F04B 49/065 20130101; F04B 23/02 20130101; G01M 3/2876 20130101;
F04B 41/02 20130101; F04B 49/022 20130101; F04B 2201/0605 20130101;
F15B 19/005 20130101; F04B 51/00 20130101; F04B 25/00 20130101 |
Class at
Publication: |
417/53 ;
417/364 |
International
Class: |
F04B 17/05 20060101
F04B017/05 |
Claims
1. A system comprising: a compressor operatively connectable to an
engine, wherein the compressor includes a reservoir configured to
store compressed air, an aftercooler that is configured to change a
temperature of air that is delivered to the reservoir via an air
line, and a first drain valve coupled to the aftercooler; a check
valve in line between the aftercooler and at least one of the air
line or the reservoir, wherein the check valve is configured to
isolate air pressure within the aftercooler and air pressure within
the at least one of the air line or the reservoir; and a controller
that is configured to: actuate the check valve to isolate air
pressure within the aftercooler and air pressure within the at
least one of the air line or the reservoir; and actuate the first
drain valve coupled to the aftercooler to enable removal of fluid
accumulated within the aftercooler.
2. The system of claim 1, further comprising a filter that is
external to the compressor that filters oil used with the engine,
wherein the filter is coupled to an external surface of the
compressor through a manifold.
3. The system of claim 2, wherein the manifold further includes a
vent pin that enables oil to flow from the filter to the
engine.
4. The system of claim 3, wherein: the vent pin, in a first mode of
operation, is configured to restrict a flow of oil from the filter
to the engine via an oil vent; and the vent pin, in a second mode
of operation, is configured to enable the flow of oil from the
filter to the engine via the oil vent.
5. The system of claim 2, wherein the manifold further includes a
pre-filter port that is configured to be utilized with an external
oil pump application that access a portion of oil prior to entering
the filter.
6. The system of claim 1, wherein the aftercooler is coupled to a
high pressure cylinder of the compressor with a single exhaust
pipe.
7. The system of claim 1, further comprising an intercooler coupled
to at least two low pressure cylinders of the compressor and a high
pressure cylinder of the compressor.
8. The system of claim 1, further comprising: an actuation line
connecting at least one first unloader valve of at least one low
pressure cylinder of the compressor to at least one second unloader
valve of at least one high pressure cylinder of the compressor; a
drain line connecting a second drain valve of an intercooler of the
compressor to the first drain valve of the aftercooler of the
compressor; and a discharge line that is coupled to at least one of
the actuation line or the drain line, wherein the discharge line
flows to the atmosphere for release thereto.
9. The system of claim 8, wherein the controller is further
configured to: actuate the at least one first unloader valve of the
at least one low pressure cylinder, the at least one second
unloader valve of the at least one high pressure cylinder, the
first drain valve of the aftercooler, and the second drain valve of
the intercooler at substantially the same time.
10. The system of claim 9, wherein the actuation opens each valve
to the discharge line for flow to the atmosphere.
11. The system of claim 9, wherein the controller is further
configured to actuate the check valve and the first drain valve
when the compressor is in an unloaded condition.
12. The system of claim 9, wherein the controller is further
configured to actuate at least one of the check valve or the first
drain valve prior to starting of the compressor.
13. The system of claim 9, wherein the controller is further
configured to determine a cylinder discharge valve leak based upon
a flow from at least one of the check valve, the first drain valve,
or the second drain valve to the atmosphere.
14. A propulsion system that includes the system of claim 1, and
further comprising: a crankshaft; and a thermal clutch configured
to engage the crankshaft to activate a fan for the compressor,
wherein the thermal clutch is configured to engage the crankshaft
based upon a temperature of an air flow discharged from the
compressor.
15. A method for a compressor, comprising: reducing a temperature
of air that is delivered to a reservoir in the compressor;
isolating air pressure within an aftercooler of the compressor from
air pressure within at least one of an air line or the reservoir;
and removing a portion of fluid from the aftercooler while
maintaining air pressure in at least one of the air line or the
reservoir.
16. The method of claim 15, further comprising removing the portion
of fluid from the aftercooler prior to starting the compressor to
reduce air pressure resisting a cylinder head.
17. The method of claim 15, further comprising: measuring a flow of
the portion of fluid from the aftercooler; and identifying a
cylinder discharge valve leak based upon the measured flow.
18. The method of claim 15, further comprising: engaging a thermal
clutch with a crankshaft of the compressor based upon a temperature
of an air flow discharged from the compressor; and activating a fan
based upon the engagement of the thermal clutch.
19. The method of claim 15, further comprising: filtering a portion
of oil with an external oil filter for use with an engine of the
compressor; flowing air from at least one first unloader valve of a
first low pressure cylinder to a drain valve coupled to at least
one of the aftercooler or an intercooler of the compressor; flowing
air from at least one second unloader valve of a second low
pressure cylinder to the drain valve; flowing air from at least one
third unloader valve of a first high pressure cylinder to the drain
valve; and flowing air or the portion of fluid through the drain
valve of the aftercooler to the atmosphere.
20. A system for a compressor, comprising: means for delivering air
under pressure to a reservoir; means for changing a temperature of
the air that is delivered to the reservoir; means for isolating air
pressure within the temperature changing means from air pressure
within the reservoir; and means for removing a portion of fluid
from the temperature changing means while maintaining air pressure
in the reservoir.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 61/636,192, filed Apr. 20, 2012, and entitled
"SYSTEM AND METHOD FOR A COMPRESSOR." The entirety of the
aforementioned application is incorporated herein by reference.
BACKGROUND
1. Technical Field
[0002] Embodiments of the subject matter disclosed herein relate to
air compressors.
[0003] 2. Discussion of Art
[0004] Compressors compress gas, such as air. An air compressor can
include three cylinders with two stages, and may be air cooled and
driven by an electric motor. For example, the compressor can have
two low pressure cylinders which deliver an intermediate pressure
air supply to a single high pressure cylinder for further
compression for final delivery to an air reservoir. Compressor and
compressor components are subject to various failure modes, which
increase difficulties in maintaining a healthy compressor.
[0005] It may be desirable to have a system and method that differs
from those systems and methods that are currently available.
BRIEF DESCRIPTION
[0006] In an embodiment, a system is provided that includes a
compressor operatively connectable to an engine, wherein the
compressor includes a reservoir configured to store compressed air,
an aftercooler that is configured to change a temperature of air
that is delivered to the reservoir via an air line, and a first
drain valve coupled to the aftercooler. The system further includes
a check valve in line between the aftercooler and at least one of
the air line or the reservoir, wherein the check valve is
configured to isolate air pressure within the aftercooler and air
pressure within the at least one of the air line or the reservoir.
The system further includes a controller that is configured to
actuate the check valve to isolate air pressure within the
aftercooler and air pressure within the at least one of the air
line or the reservoir, and to actuate the first drain valve coupled
to the aftercooler to enable removal of fluid accumulated within
the aftercooler. (For example, the check valve may first be
actuated to isolate air pressure within the aftercooler and air
pressure within the at least one of the air line or the reservoir,
and then while the check valve is actuated and the air pressure
isolated, the first drain valve may be actuated to enable removal
of the fluid.)
[0007] In an embodiment, a method is provided (e.g., a method for
controlling and/or operating a compressor) that includes at least
the steps of: reducing a temperature of air that is delivered to a
reservoir in the compressor; isolating air pressure within an
aftercooler of the compressor from air pressure within at least one
of an air line or the reservoir; and removing a portion of fluid
from the aftercooler while maintaining air pressure in the at least
one of the air line or the reservoir.
[0008] In an embodiment, a system for a compressor is provided and
includes means for delivering air under pressure to a reservoir,
means for changing a temperature of the air that is delivered to
the reservoir, means for isolating air pressure within the
temperature changing means from air pressure within the reservoir,
and means for removing a portion of fluid from the temperature
changing means while maintaining air pressure in the reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Reference is made to the accompanying drawings in which
particular embodiments and further benefits of the invention are
illustrated as described in more detail in the description below,
in which:
[0010] FIG. 1 is an illustration of an embodiment of a vehicle
system with a compressor;
[0011] FIG. 2 is an illustration of an embodiment of system that
includes a compressor;
[0012] FIG. 3 is an illustration of an embodiment of a
compressor;
[0013] FIGS. 4A-4D are illustrations of views of a check valve for
a compressor;
[0014] FIGS. 5A-5B are illustrations of views of a check valve for
a compressor;
[0015] FIG. 6 is an illustration of a system with a discharge line
for a compressor;
[0016] FIG. 7 is an illustration of a system with a drain valve for
an aftercooler of a compressor;
[0017] FIGS. 8A-8B are illustrations of views of an external oil
filter utilized with a compressor;
[0018] FIGS. 9A-9B are illustrations of a view of an oil filter and
a manifold for a compressor;
[0019] FIG. 10 is an illustration of a view of a manifold used to
couple an oil filter to a compressor;
[0020] FIGS. 11A-11B are illustrations of views for an exhaust pipe
for a high pressure cylinder to an aftercooler of a compressor;
[0021] FIG. 12 is an illustration of a view of an exhaust pipe for
a compressor;
[0022] FIG. 13 is an illustration of a view of an exhaust pipe for
a compressor;
[0023] FIG. 14 is an illustration of a view of an intercooler for a
compressor;
[0024] FIG. 15 is an illustration of a view of an intercooler for a
compressor;
[0025] FIG. 16 is an illustration of a view of a crankshaft
interface for a thermal clutch of a compressor;
[0026] FIG. 17 is an illustration of a view of a thermal clutch and
crankshaft interface for a compressor;
[0027] FIG. 18 is an illustration of a view of a thermal clutch for
a compressor; and
[0028] FIG. 19 is a flow chart of an embodiment of a method for
removing fluid from an aftercooler while maintaining pressure in a
reservoir of a compressor.
DETAILED DESCRIPTION
[0029] Embodiments of the subject matter disclosed herein relate to
systems and methods that facilitate removing fluid from a
compressor to mitigate condensation accumulated in the compressor.
A controller can be configured to actuate a drain valve coupled to
an aftercooler of the compressor and to actuate a check valve to
isolate air pressure of the aftercooler from a reservoir of the
compressor. Through control of the drain valve of the aftercooler
and the check valve, the controller removes fluid from the
aftercooler to facitliate thermal management of the compressor.
Moreover, a detection component can be configured to monitor at
least one of a flow of air from an aftercooler drain valve, a flow
from a drain valve, a flow from a discharge line, a flow from an
exhaust port of a high pressure cylinder, among others. Based upon
the detection component, the controller can further be configured
to determine the presence of a high pressure cylinder discharge
valve leak, based upon a flow from at least one of the check valve
or the drain valve to the atmosphere. In an embodiment, the
controller can be further configured communicate an alert related
to the detected condition (e.g., discharge leak valve, exhaust port
leak, among others). The alert can be a signal (e.g., diagnostic
code, audio, text, visual, haptic, among others) that indicates a
change in the monitored pressure of the intermediate stage of the
compressor. This alert can be utilized to provide maintenance on
the compressor or a portion thereof In an embodiment, the
controller can be configured to schedule a maintenance operation
based upon the detected condition and/or the communicated alert in
order to perform preventative maintenance.
[0030] With reference to the drawings, like reference numerals
designate identical or corresponding parts throughout the several
views. However, the inclusion of like elements in different views
does not mean a given embodiment necessarily includes such elements
or that all embodiments of the invention include such elements.
[0031] The term "component" as used herein can be defined as a
portion of hardware, a portion of software, or a combination
thereof A portion of hardware can include at least a processor and
a portion of memory, wherein the memory includes an instruction to
execute. The term "vehicle" as used herein can be defined as any
asset that is a mobile machine that transports at least one of a
person, people, or a cargo, or that is configured to be portable
from one location to another. For instance, a vehicle can be, but
is not limited to being, a locomotive or other rail vehicle, an
intermodal container, a marine vessel, a mining equipment, a
stationary portable power generation equipment, an industrial
equipment, a construction equipment, and the like. The term
"loaded" as used herein can be defined as a compressor system mode
where air is being compressed into the reservoir. The term "loaded
start" as used herein can be defined as a compressor system mode in
a loaded condition during a starting phase of the compressor. The
term "unloaded" as used herein can be defined as a compressor
system mode where air is not being compressed into the reservoir.
The term "connector" or "coupling" can be a mechanism or device to
join one or more pipes or tubes and is to include a cock-type
connector or mechanism.
[0032] A compressor compresses gas, such as air. In some
embodiments, the compressed gas is supplied to operate pneumatic or
other equipment powered by compressed gas. A compressor may be used
for mobile applications, such as vehicles. By way of example,
vehicles utilizing compressors include locomotives, on-highway
vehicles, off-highway vehicles, mining equipment, and marine
vessels. In other embodiments, a compressor may be used for
stationary applications, such as in manufacturing or industrial
applications requiring compressed air for pneumatic equipment among
other uses. The compressor depicted in the below figures is one
which utilizes spring return inlet and discharge valves for each
cylinder, wherein the movement of these valves is caused by the
differential pressure across each cylinder as opposed to a
mechanical coupling to the compressor crank shaft. The subject
invention can be applicable to machines with either type of valve
(e.g., spring return valves, mechanical coupled valves, among
others) and the spring return valve is depicted solely for example
and not to be limiting on the subject innovation.
[0033] The components of a compressor may degrade over time,
resulting in performance reductions and/or eventual failure of the
compressor. In vehicle applications, for example, a compressor
failure may produce a road failure resulting in substantial costs
to the vehicle owner or operator. In this context, a road failure
includes a vehicle, such as a locomotive, becoming inoperative when
deployed in service as a result of the failure or degradation of a
compressor system that prevents operation or requires shutting down
the vehicle until repairs can be made. Prior to a total failure,
the detection of degraded components or other deterioration of the
compressor may be used to identify incipient faults or other
conditions indicative of deterioration. In response to detecting
such conditions, remedial action may be taken to mitigate the risk
of compressor failure and associated costs.
[0034] The systems and methods presently disclosed can also be used
to diagnose and/or prognoses problems in a compressor prior to
total compressor failure. If deterioration or degradation of the
compressor is detected in the system, action can be taken to reduce
progression of the problem and/or further identify the developing
problem. In this manner, customers realize a cost savings by
prognosing compressor problems in initial stages to reduce the
damage to compressor components and avoid compressor failure and
unplanned shutdowns. Moreover, secondary damage to other compressor
components (e.g., pistons, valves, liners, and the like) or damage
to equipment that relies upon the availability of the compressed
gas from the compressor may be avoided if compressor problems are
detected and addressed at an early stage.
[0035] FIG. 1 illustrates a block diagram of an embodiment of a
vehicle system 100. The vehicle system 100 is depicted as a rail
vehicle 106 (e.g., a locomotive) configured to run on a rail 102
via a plurality of wheels 108. The rail vehicle includes a
compressor system with a compressor 110. In an embodiment, the
compressor is a reciprocating compressor that delivers air at high
pressure. In another embodiment, the compressor is a reciprocating
compressor with a bi-directional drive system that drives a piston
in a forward direction and the reverse direction. In an embodiment,
the compressor receives air from an ambient air intake 114. The air
is then compressed to a pressure greater than the ambient pressure
and the compressed air is stored in reservoir 180, which is
monitored by a reservoir pressure sensor 185. In one embodiment,
the compressor is a two-stage compressor (such as illustrated in
FIG. 2) in which ambient air is compressed in a first stage to a
first pressure level and delivered to a second stage, which further
compresses the air to a second pressure level that is higher than
the first pressure level. The compressed air at the second pressure
level is stored in a reservoir. The compressed air may then be
provided to one or more pneumatic devices as needed. In other
embodiments, the compressor 110 may be a single stage or
multi-stage compressor.
[0036] The compressor includes a crankcase 160. The crankcase is an
enclosure for a crankshaft (not shown in FIG. 1) connected to
cylinders (not shown in FIG. 1) of the compressor. A motor 104 is
employed to rotate the crankshaft to drive the pistons within the
cylinders. In embodiments, the motor 104 may be an electric motor.
In another embodiment, the crankshaft may be coupled to a drive
shaft of an engine or other power source configured to rotate the
crankshaft of the compressor. In each embodiment, the crankshaft
may be lubricated with compressor oil that is pumped by an oil pump
(not shown) and sprayed onto the crankshaft. The crankshaft is
mechanically coupled to a plurality of pistons via respective
connecting rods. The pistons are drawn and pushed within their
respective cylinders as the crankshaft is rotated to compress a gas
in one or more stages.
[0037] The rail vehicle further includes a controller 130 for
controlling various components related to the vehicle system. In an
embodiment, the controller is a computerized control system with a
processor 132 and a memory 134. The memory may be computer readable
storage media, and may include volatile and/or non-volatile memory
storage. In an embodiment, the controller includes multiple control
units and the control system may be distributed among each of the
control units. In yet another embodiment, a plurality of
controllers may cooperate as a single controller interfacing with
multiple compressors distributed across a plurality of vehicles.
Among other features, the controller may include instructions for
enabling on-board monitoring and control of vehicle operation.
Stationary applications may also include a controller for managing
the operation of one or more compressors and related equipment or
machinery.
[0038] In an embodiment, the controller receives signals from one
or more sensors 150 to monitor operating parameters and operating
conditions, and correspondingly adjust actuators 152 to control
operation of the rail vehicle and the compressor. In various
embodiments, the controller receives signals from one or more
sensors corresponding to compressor speed, compressor load, boost
pressure, exhaust pressure, ambient pressure, exhaust temperature,
or other parameters relating to the operation of the compressor or
surrounding system. In another embodiment, the controller receives
a signal from a crankcase pressure sensor 170 that corresponds to
the pressure within the crankcase. In yet another embodiment, the
controller receives a signal from a crankshaft position sensor 172
that indicates a position of the crankshaft. The position of the
crankshaft may be identified by the angular displacement of the
crankshaft relative to a known location such that the controller is
able to determine the position of each piston within its respective
cylinder based upon the position of the crankshaft. In some
embodiments, the controller controls the vehicle system by sending
commands to various components. On a locomotive, for example, such
components may include traction motors, alternators, cylinder
valves, and throttle controls among others. The controller may be
connected to the sensors and actuators through wires that may be
bundled together into one or more wiring harnesses to reduce space
in vehicle system devoted to wiring and to protect the signal wires
from abrasion and vibration. In other embodiments, the controller
communicates over a wired or wireless network that may allow for
the addition of components without dedicated wiring.
[0039] The controller may include onboard electronic diagnostics
for recording operational characteristics of the compressor.
Operational characteristics may include measurements from sensors
associated with the compressor or other components of the system.
Such operational characteristics may be stored in a database in
memory. In one embodiment, current operational characteristics may
be compared to past operational characteristics to determine trends
of compressor performance.
[0040] The controller may include onboard electronic diagnostics
for identifying and recording potential degradation and failures of
components of vehicle system. For example, when a potentially
degraded component is identified, a diagnostic code may be stored
in memory. In one embodiment, a unique diagnostic code may
correspond to each type of degradation that may be identified by
the controller. For example, a first diagnostic code may indicate a
malfunctioning exhaust valve of a cylinder, a second diagnostic
code may indicate a malfunctioning intake valve of a cylinder, a
third diagnostic code may indicate deterioration of a piston or
cylinder resulting in a blow-by condition. Additional diagnostic
codes may be defined to indicate other deteriorations or failure
modes. In yet other embodiments, diagnostic codes may be generated
dynamically to provide information about a detected problem that
does not correspond to a predetermined diagnostic code. In some
embodiments, the controller modifies the output of charged air from
the compressor, such as by reducing the duty cycle of the
compressor, based on parameters such as the condition or
availability of other compressor systems (such as on adjacent
locomotive engines), environmental conditions, and overall
pneumatic supply demand.
[0041] The controller may be further linked to display 140, such as
a diagnostic interface display, providing a user interface to the
operating crew and/or a maintenance crew. The controller may
control the compressor, in response to operator input via user
input controls 142, by sending a command to correspondingly adjust
various compressor actuators. Non-limiting examples of user input
controls may include a throttle control, a braking control, a
keyboard, and a power switch. Further, operational characteristics
of the compressor, such as diagnostic codes corresponding to
degraded components, may be reported via display to the operator
and/or the maintenance crew.
[0042] The vehicle system may include a communications system 144
linked to the controller. In one embodiment, communications system
may include a radio and an antenna for transmitting and receiving
voice and data messages. For example, data communications may be
between vehicle system and a control center of a railroad, another
locomotive, a satellite, and/or a wayside device, such as a
railroad switch. For example, the controller may estimate
geographic coordinates of a vehicle system using signals from a GPS
receiver. As another example, the controller may transmit
operational characteristics of the compressor to the control center
via a message transmitted from communications system. In one
embodiment, a message may be transmitted to the command center by
communications system when a degraded component of the compressor
is detected and the vehicle system may be scheduled for
maintenance.
[0043] As discussed above, the term "loaded" refers to a compressor
mode where air is being compressed into the reservoir. The
compressor depicted is one which utilizes spring return inlet and
discharge valves for each cylinder in which the movement of these
valves is caused by the differential pressure across them as
opposed to a mechanical coupling to the compressor crank shaft. The
subject disclosure may be applicable to machines with either type
of valve, but the spring return type will be illustrated here for
the sake of brevity.
[0044] The controller can be configured to adjust at least one of
the following: an actuation of a drain valve; an actuation of a
check valve; an operation of the compressor; a scheduled
maintenance for the compressor; a maintenance for the compressor; a
service for the compressor; a diagnostic code of the compressor; an
alert for the compressor; among others. In an embodiment, the
controller can be configured to actuate a drain valve of an
aftercooler for a compressor and a check valve that isolates the
aftercooler from a reservoir of the compressor. In a more
particular embodiment, the controller can be configured to identify
a leak condition based upon a flow associated with a drain valve of
the aftercooler. For instance, the controller can actuate the check
valve to isolate pressure and actuate the drain valve of the
aftercooler at the substantially same time to remove fluid from the
aftercooler without losing pressure in the reservoir of the
compressor. Moreover, the flow of the drain valve of the
aftercooler and/or a discharge line (discussed in more detail
below) can be monitored to determine a leak condition of a
compressor or determine a potential leak condition of a compressor.
In such case, an alert can be generated for the compressor.
[0045] The compressor 110 can include a detection component 128
that can be configured to detect at least one of a flow of a drain
valve or a flow of a discharge line, wherein such detection is
indicative of a leak condition for the compressor (discussed in
more detail below). The detection component can be employed with
the compressor to collect data that is indicative of a condition
such as exhaust port leak, high pressure cylinder discharge valve
leak, among others. In an embodiment, the controller can be
configured to adjust the compressor based upon the detection
component.
[0046] The detection component can be a stand-alone component (as
depicted), incorporated into the controller component, or a
combination thereof The controller component can be a stand-alone
component (as depicted), incorporated into the detection component,
or a combination thereof In another embodiment, the detection
component can be a stand-alone component (as depicted),
incorporated into the controller component, or a combination
thereof
[0047] FIG. 2 illustrates a detailed view of the compressor set
forth in FIG. 1 above. The compressor includes three cylinders 210,
220, 230. Each cylinder contains a piston 218, 228, 238 that is
coupled to a crankshaft 250 via connecting rods 240, 242, 244. The
crankshaft is driven by the motor to cyclically pull the respective
pistons to a Bottom-Dead-Center (BDC) and push the pistons to a
Top-Dead-Center (TDC) to output charged air, which is delivered to
the reservoir via air lines 280, 282, 284, 286. In this embodiment,
the compressor is divided into two stages: a low pressure stage and
a high pressure stage to produce charged air in a stepwise
approach. The low pressure stage compresses air to a first pressure
level which is further compressed by the high pressure stage to a
second pressure level. In this example, the low pressure stage
includes cylinders 220, 230 and the high pressure stage includes
cylinder 210.
[0048] In operation, air from the ambient air intake is first drawn
into the low pressure cylinders via intake valves 222, 232, which
open and close within intake ports 223, 233. The ambient air is
drawn in as the low pressure cylinders are pulled towards BDC and
the intake valves 222, 232 separate from intake ports 223, 233 to
allow air to enter each cylinder 220, 230. Once the pistons reach
BDC, the intake valves 222, 232 close the intake ports 223, 233 to
contain air within each cylinder. Subsequently, pistons 228, 238
are pushed toward TDC, thereby compressing the ambient air
initially drawn into the cylinders. Once the cylinders have
compressed the ambient air to a first pressure level, exhaust
valves 224, 234 within exhaust ports 225, 235 are opened to release
the low pressure air into low pressure lines 280, 282.
[0049] The air compressed to a first pressure level is routed to an
intermediate stage reservoir 260. The intermediate stage reservoir
260 received air from one stage of a multistage compressor and
provides the compressed air to a subsequent stage of a multistage
compressor. In an embodiment, the intermediate stage reservoir 260
is a tank or other volume connected between successive stages by
air lines. In other embodiments, the air lines, such as low
pressure lines 280, 282 provide sufficient volume to function as an
intermediate stage reservoir without the need for a tank or other
structure.
[0050] In an embodiment, the compressor system also includes an
intercooler 264 that removes the heat of compression through a
substantially constant pressure cooling process. One or more
intercoolers may be provided along with one or more intercooler
controllers 262. In some embodiments, the intercooler 264 is
integrated with the intermediate stage reservoir 260. A decrease in
the temperature of the compressed air increases the air density
allowing a greater mass to be drawn into the high pressure stage
increasing the efficiency of the compressor. The operation of the
intercooler is controlled by the intercooler controller 262 to
manage the cooling operation. In an embodiment, the intercooler
controller 262 employs a thermostatic control through mechanical
means such as via thermal expansion of metal. In a multistage
compressor system having more than two stages, an intercooler may
be provided at each intermediate stage.
[0051] The air at a first pressure level (e.g., low pressure air)
is exhausted from the intercooler into low pressure air line 284
and subsequently drawn into the high pressure cylinder 210. More
particularly, as piston 218 is pulled toward BDC, the intake valve
212 opens, thereby allowing the low pressure air to be drawn into
the cylinder 210 via intake port 213. Once the piston 218 reaches
BDC, the intake valve 212 closes to seal the low pressure air
within the cylinder 210. The piston is then pushed upward thereby
compressing the low pressure air into high pressure air. High
pressure air is air at a second pressure level greater than the
first pressure level, however the amount of compression will vary
based upon the requirements of the application. As compression
increases, the exhaust valve 214 is opened to allow the high
pressure air to exhaust into high pressure line 286 via exhaust
port 215. An aftercooler 270 cools the high pressure air to
facilitate a greater density to be delivered to the reservoir via
high pressure air line 288.
[0052] The above process is repeated cyclically as the crankshaft
250 rotates to provide high pressure air to the reservoir 180,
which is monitored by the reservoir pressure sensor 185. Once the
reservoir reaches a particular pressure level (e.g., 140 psi), the
compressor operation is discontinued.
[0053] In some embodiments, the compressor includes one or more
valves configured to vent compressed air from intermediate stages
of the compressor system. The unloader valves and/or relief valves
may be operated after compressor operations are discontinued, or
may be operated during compressor operations to relieve pressure in
the compressor system. In an embodiment, an unloader valve 268 is
provided in the intermediate stage reservoir 260 and configured to
vent the low pressure compressed air from the intermediate stage
reservoir, low pressure air lines 280, 282 and intercooler 264.
Venting compressed air reduces stress on system components during
periods when the compressor is not in use and may extend the life
of the system. In another embodiment, the unloader valve 268
operates as a relief valve to limit the buildup of pressure in the
intermediate stage reservoir 260. In yet another embodiment, intake
valves 222, 232 operate as unloader valves for the cylinders 220,
230 allowing compressed air in the cylinders to vent back to the
ambient air intake 114. In another embodiment, the system 200 can
include relief valves such as breather valve 174, a relieve valve
on the intercooler 264 (shown in FIG. 4), a relieve valve for air
line 286, a rapid unloader valve on the intercooler 264 (shown in
FIG. 4)
[0054] A compressor, such as the compressor illustrated in FIG. 2,
operates to charge the reservoir 180 with compressed air or other
gas. Once the compressor charges the reservoir to a determined
pressure value the compressor operation is discontinued. In some
embodiments, when compressor operations are discontinued, one or
more unloader valves are opened to vent intermediate stages of the
compressor to the atmosphere. The intake valves of the cylinders as
well as unloader valves of the intermediate stage reservoirs may
all operate as unloader valves to vent the cylinders of the
compressor to the atmosphere. Once the unloader valves are actuated
and the cylinders and intermediate stages of the compressor have
been vented to the atmosphere the pressure within the reservoir is
expected to remain constant as previously discussed.
[0055] The compressor 110 can include additional features and/or
components that are not illustrated in FIGS. 1 and 2. For instance,
the system may include a Control Mag Valve (CMV), a
Thermostatically Controlled Intercooler System (TCIS) bypass, a
rapid unloader valve, an unloader valve for cylinder 230, an
unloader valve for cylinder 220, a relief valve(s), among
others.
[0056] The crankshaft can include a first end opposite a second end
in which the first end is coupled to one or more connecting rods
for each respective cylinder. The crankshaft, cylinders, and
pistons are illustrated in BDC position based upon the location of
the first end. BDC position is a location of the first end at
approximately negative ninety degrees (-90 degrees) or 270 degrees.
A TDC position is a location of the first end at approximately
ninety degrees (90 degrees) or -270 degrees.
[0057] As discussed above, the controller can be configured to
actuate a check valve 290 and a drain valve 292 of the aftercooler
270 to facilitate removing fluid from the compressor and in
particular the aftercooler. In an embodiment, the drain valve can
be coupled to a drain line 294 that can include a first end coupled
the drain valve and a second end opposite the first end open to the
atmosphere. In another embodiment, a discharge line (not shown) can
tie into the drain line 294 for discharge into the atmosphere. In
such embodiment, one or more additional lines or valves (e.g.,
drain valve for intercooler, actuator lines, among others) can be
coupled to the discharge line for release to the atmosphere.
[0058] In an embodiment, the controller can actuate the check valve
290 and/or the drain valve 292 prior to a starting of the
compressor. In another embodiment, the controller can actuate the
check valve 290 and/or the drain valve 292 while the compressor is
in an unloaded condition.
[0059] FIGS. 3-7 illustrate the check valve 290, the drain valve
292, and other components of the compressor. In a view 300 of FIG.
3, an actuation line 302 can interconnect one or more unloader
valves of the compressor. (View 300 of FIG. 3 shows the compressor
generally, which may be the compressor 110 of FIG. 2.) The view 300
illustrates the compressor with the high pressure cylinder 210 and
at least one low pressure cylinder (e.g., low pressure cylinder
230, low pressure cylinder 220). The intercooler 264 can include a
drain valve 296 that is connected to a discharge line 298. The
discharge line 298 can open to the atmosphere to allow release of
at least one of the actuation line 302, the drain valve 292 of the
aftercooler 270, and/or the drain line 294. In an embodiment, the
actuation line can connect to the drain line via one or more
couplings or connectors. As depicted, the actuation line 302 can
meet with the drain line 294 at the drain valve 296, which ties
into the discharge line 298. In an embodiment, the routing of the
actuation line 302 can be fitted to the cylinder style head and to
minimize handling damage.
[0060] Turning to FIGS. 4A-4D, the check valve 290 is illustrated.
In view 400 (FIG. 4A), an adapter plate 402 is illustrated. In an
example, the adapter plate 402 can be hydro-formed. In view 404
(FIG. 4B), a gasket 406 can be used with the adapter plate 402. For
instance, the gasket 406 can be an o-ring. View 408 (FIG. 4C)
illustrates the check valve 290 and the adapter plate 402. View 412
(FIG. 4D) illustrates a gasket 414 with the check valve 290,
wherein the gasket 414 can be a snap-ring for example. In an
embodiment, the check valve 290 is an inlet discharge check valve
that addresses leakage issues with cylinder heads and allows for
the addition of the drain valve 292 by isolating the pressure in
the aftercooler 270 from the pressure in the reservoir 180. Turning
to FIGS. 5A and 5B, a view 500 depicts the check valve 292 within
the aftercooler 270 affixed to the aftercooler with one or more
screws 504. A view 502 illustrates the adapter plate 402 as well as
the drain valve 292.
[0061] FIG. 6 illustrates a system 600 that includes the drain
valve 296 for the intercooler 264. The drain valve 296 can be
coupled to the discharge line 298 that opens to the atmosphere. In
this embodiment, the discharge line 298 is a pipe that is
directionally angled away from the compressor to avoid clogging the
aftercooler 270. The drain valve 296 can further include connectors
or couplings that tie in the actuation lines 302 and/or the drain
line 294. In an embodiment, the discharge line 298 can be a
non-conductive nylon tubing in which the opening to the atmosphere
is away from the aftercooler and from a potential user. Continuing
with illustrations of the lines, FIG. 7 depicts a system 700 that
includes the drain line 294 connected to the drain valve 292
associated with the aftercooler 270. The drain valve 292 can be
coupled to the drain line 294 via a connector or coupling. For
instance, the coupling or connector can be an isolation cock. For
example, the drain line 294 can include a connector 702 to couple
to the drain valve 292 and/or a pipe that connects to the drain
valve 292. A connector 704 can be an isolation cock connector that
can be used for diagnostics. The isolation cock connector can be a
discharge isolation cock. A mounting bracket 706 can further be
included with the drain valve 292.
[0062] FIGS. 8A-10 relate to an oil filter for the compressor. In
FIG. 8A, a view 800 illustrates an oil filter 802 and a manifold
804, wherein the oil filter is external to the compressor 110 (see
FIGS. 1 and 2). The oil filter can be utilized to filter oil that
is used with the motor 104 (see FIG. 1). A view 808 (FIG. 8B)
illustrates lines associated with the oil filter 802 and at least
one connection 806 at an oil pump. Turning to FIG. 9A, the oil
filter 802 is illustrated in view 900. The oil filter 802 includes
the manifold 804 (see also FIG. 9B) that allows attachment of the
oil filter 802 for use with the compressor 110 and/or motor 104.
The oil filter 802 can further include at least one of a gasket 902
(e.g., a square cut gasket), a connector (e.g., an adapter for oil
in), a fastener 906 (e.g., 3/8-16 fastener), a relief valve 908
(e.g., an inline pressure relief valve), a port 910 (e.g., a
plugged port that provides access to vent pin), an oil vent 912
(e.g., filter removal oil vent), a vent pin 914 (e.g., filter
removal oil vent valve), or a pressure port 916 (e.g., post filter
pressure port). FIG. 10 illustrates a view 1000 that depicts the
vent pin 914 and a pre-filter port 1004, wherein the pre-filter
port 1004 can be an external pre-filter port provided for external
oil pump application(s). For example, the pre-filter port allows
connectivity to access a source of the oil before the oil enters
the filter. In another example, the pre-filter port allows a test
device to connect. In another embodiment, the pre-filter port is an
auxiliary access to the oil. In an embodiment, the oil can be
drained from the oil filter 802 by creating a vent hole on a top
portion (side that is not connected to the manifold 804) and
activating the vent pin 914 to equalize pressure to enable flow of
oil from the oil filter 802 into at least one of the motor, oil
pump, among others.
[0063] FIGS. 11A-13 depict an exhaust pipe 1104 for the compressor
110. FIG. 11A illustrates a view 1100 of the compressor that
includes the high pressure cylinder 210, the low pressure cylinder
230, the intercooler 264, and the aftercooler 270. The view 1100
further illustrates the exhaust pipe 1104 that connects the high
pressure cylinder 210 to the aftercooler 270. A view 1102 (FIG.
11B) further illustrates a perspective of the exhaust pipe 1104
that connects the high pressure cylinder 210 to the aftercooler
270. The view 1102 also illustrates low pressure cylinder 220. The
exhaust pipe 1104 is routed to minimize access to burn surfaces and
to provide accessible location for an aftercooler pressure relief
valve. The routing of the exhaust pipe 1104 facilitates a location
for the aftercooler bypass. FIG. 12 illustrates a perspective view
1200 of the exhaust pipe 1104. The exhaust pipe 1104 can include
one or more pre-formed elbows 1202, an inline pressure relief valve
1206 (e.g., as well as aftercooler by-pass), and tubing 1208 that
bypasses and provides access for oil servicing. In an embodiment,
the tubing 1208 can be 3/4 inch (20 mm) tubing with fire sleeve
protection, and the like. In an example, the exhaust pipe 1104 can
include one or more bends 1204 and can be, for instance, 2 inch (50
mm) pipe. In an embodiment, the in-line pressure relief valve and
aftercooler bypass 1206 can be located on a warm side to minimize
freezing and eliminate continual bypass design. Turning to FIG. 13,
a view 1300 illustrates an embodiment of the exhaust pipe 1104
which can include a heat shield 1302, a relief valve (e.g.,
aftercooler pressure relief valve in a position to eliminate
removal while compressor is removed/installed), and a pressure port
1306. For instance, the pressure port 1306 can provide diagnostics
including, but not limited to, discharge check valve (discussed
above).
[0064] FIGS. 14 and 15 illustrate an intercooler for the
compressor. FIG. 14 illustrates a view 1400 of the intercooler 264
that includes a high pressure cylinder connector 1402, a low
pressure cylinder connector 1404, and a low pressure cylinder
connector 1406. In an embodiment, the intercooler 264 is sized to
meet requirements of motor-driven applications and/or load. In
particular, the intercooler 264 can eliminate one or more cooler
covers required by a dual cooler design. Turning to FIG. 15, a
perspective view 1500 is provided of the intercooler 264. The view
1500 illustrates an embodiment of the intercooler 264 that includes
a drain valve or drain port 1502 (e.g., drain port with a connector
to accept the drain valve and eliminates the use of a heater), a
pressure relief valve 1504 (e.g., an inter-stage pressure relief
valve that provides improved access for servicing or repair),
and/or a pressure connect port 1506 (e.g., pressure connect port
provided for diagnostics).
[0065] FIGS. 16-18 relate to a thermal clutch and interface for the
compressor and in particular the crankshaft of the compressor. FIG.
16 is a cross-sectional view of a crankshaft interface 1600 that
can connect to the crankshaft 250 of the compressor. Turning to
FIG. 17, a cross-sectional view 1700 illustrates the crankshaft
250, a fan blade 1706, a fan blade 1708, a thermal clutch 1702, and
the crankshaft interface 1600. FIG. 18 illustrates a view 1800 of
the thermal clutch 1702 with a clutch mechanism 1804. In an
embodiment, the thermal clutch 1702 can engage the crankshaft 250
to activate a fan (e.g., to rotate one or more fan blades 1706,
1708 for the compressor, wherein the thermal clutch 1702 engages
the crankshaft 250 based upon a temperature of an air flow
discharged from the compressor. By utilizing the thermal clutch
1702 with the compressor, a Revolutions Per Minute (RPM) can be
reduced and/or a Horse Power (HP) can be reduced. In an embodiment,
the cooling fan can be run at a reduced rate when the compressor is
cold (e.g., 20% synchronous speed, for instance) and a higher rate
when the compressor is hot (e.g., 90% synchronous speed, for
instance). One or more clutch ducts on the thermal clutch 1702
allows the cooling fan discharge air flow to be directed
continually to the thermal clutch and away from the compressor
which minimizes hardware changes utilized to implement such control
technique.
[0066] In various other embodiments, the aspects of the systems and
methods previously described may also be employed individually or
in combination to diagnose the condition of a compressor. In one
embodiment, a method for diagnosing a compressor includes operating
a compressor in an unloaded condition by cycling the pistons within
their respective cylinders, monitoring at least the reservoir
pressure and the crankcase pressure, and determining a condition of
the compressor based on an analysis of both the monitored reservoir
pressure and crankcase pressure. In another embodiment, a method
for diagnosing a compressor includes operating a multi-stage
compressor to charge a reservoir with compressed air, monitoring at
least a crankcase pressure and an intermediate stage pressure, and
determining a condition of the compressor based on an analysis of
both the monitored crankcase pressure and the monitored
intermediate stage pressure. In yet another embodiment, a method
for diagnosing a compressor includes monitoring signals from at
least two of a primary reservoir pressure sensor, an intermediate
reservoir pressure sensor, a crankcase pressure sensor, and a
crankshaft position sensor, and correlating the monitored signals
to identify a failure condition of the compressor. In yet another
embodiment, a method of diagnosing a compressor includes actuating
an unloader valve, monitoring at least a reservoir pressure sensor
and a crankshaft position sensor, and identifying a leak condition
of a valve disposed between a cylinder and a reservoir of a
compressor. By way of example and not limitation, the subject
disclosure can be utilized alone or in combination with a system
and/or method disclosed in U.S. Provisional Application Serial No.
61/636,192, filed Apr. 20, 2012, and entitled "SYSTEM AND METHOD
FOR A COMPRESSOR" in which the entirety of the aforementioned
application is incorporated herein by reference.
[0067] The methods and systems disclosed herein may be applied to a
reciprocating compressor having one or more compressor stages, such
as the compressor illustrated in FIG. 2. In other embodiments, the
methods and systems may be applied to other types of compressors.
For example, the compressor may be a diaphragm or membrane
compressor in which the compression is produced by movement of a
flexible membrane. The compressor may also be a hermetically sealed
or semi-hermetically sealed compressor. In addition, the compressor
types may include centrifugal compressors, diagonal or mixed flow
compressors, axial flow compressors, rotary screw compressors,
rotary vane compressors, and scroll compressors, among others.
[0068] The methods presently disclosed may also include generating
a signal corresponding to the failure condition and alerting an
operator or other personnel so that remedial action may be taken.
Each of these systems and methods described above may also be
implemented on a vehicle system such as the rail vehicle 106
described above. In still yet other embodiments, a test kit is
provided that includes a controller having a memory and a processor
configured to perform the methods described above.
[0069] In each of the embodiments presently disclosed, component
fault data may be recorded. In one embodiment, component fault data
may be stored in a database including historical compressor data.
For example, the database may be stored in memory 134 of controller
130. As another example, the database may be stored at a site
remote from rail vehicle 106. For example, historical compressor
data may be encapsulated in a message and transmitted with
communications system 144. In this manner, a command center may
monitor the health of the compressor in real-time. For example, the
command center may perform steps to diagnose the condition of the
compressor using the compressor data transmitted with
communications system 144. For example, the command center may
receive compressor data including cylinder pressure data from rail
vehicle 106, reservoir pressure, intermediate stage pressure,
crankcase pressure, displacement of one or more pistons, and/or
movement of the crankshaft to diagnose potential degradation of the
compressor. Further, the command center may schedule maintenance
and deploy healthy locomotives and maintenance crews in a manner to
optimize capital investment. Historical compressor data may be
further used to evaluate the health of the compressor before and
after compressor service, compressor modifications, and compressor
component change-outs.
[0070] If a leak or other fault condition exists, further
diagnostics and response may be performed. For example, a potential
faulty valve condition can be reported to notify appropriate
personnel. In an embodiment, reporting is initiated with a signal
output to indicate that a fault condition exists. The report is
presented via display 140 or a message transmitted with
communications system 144, as examples. Once notified, the operator
may adjust operation of rail vehicle 106 to reduce the potential of
further degradation of the compressor.
[0071] In one embodiment, a message indicating a potential fault is
transmitted with communications system 144 to a command center.
Further, the severity of the potential fault may be reported. For
example, diagnosing a fault based on the above described methods
may allow a fault to be detected earlier than when the fault is
diagnosed with previously available means. In some applications,
the compressor is permitted to continue operating when a potential
fault is diagnosed in the early stages of degradation. In other
applications, the compressor is stopped or maintenance may be
promptly scheduled, such as when the potential fault is diagnosed
as severe. In this manner the cost of secondary damage to the
compressor can be avoided by early and accurate detection.
[0072] The severity of the potential fault may be determined based
upon an analysis of one or more parameters from one or more
diagnostic methods. For example, it may be more desirable to switch
off the compressor than to have a degraded cylinder fail in a
manner that may cause additional damage to the compressor. In one
embodiment, a threshold value or one or more monitored parameters
may be determined that indicates continued operation of the
compressor is undesirable because the potential fault is severe. As
one example, the potential fault may be judged as severe if the
leakage of an exhaust valve exceeds a predetermined threshold.
[0073] In some embodiments, a request to schedule service is sent,
such as by a message sent via communications system 144. Further,
by sending the potential fault condition and the severity of the
potential fault, down-time of rail vehicle 106 may be reduced. For
example, service may be deferred on rail vehicle 106 when the
potential fault is of low severity. Down-time may be further
reduced by derating power of the compressor, such as by adjusting a
compressor operating parameter based on the diagnosed
condition.
[0074] In yet other embodiments, backup or redundant systems may be
available. In an example, backup systems can be evaluated to
determine if adequate substitute resources exist to replace the
compromised compressor. In some instances, a pre-ordered list of
backup systems is used to prioritize the use of backup systems,
such as other compressors configured to supply compressed air to
pneumatic devices on a plurality of rail vehicles. Various backup
systems may be employed including stopping the faulty compressor
and receiving charged air from another source. In one example, the
other source is a compressor that is disposed on an adjacent
locomotive engine. In another example, the other source is a
redundant compressor on the same locomotive that is used for this
purpose. The backup procedure can be designed to minimize negative
system-wide consequences to operation of the locomotive. This is
useful for mission critical systems.
[0075] The aforementioned systems, components, (e.g., controller,
detection component, among others), and the like have been
described with respect to interaction between several components
and/or elements. Such devices and elements can include those
elements or sub-elements specified therein, some of the specified
elements or sub-elements, and/or additional elements. Further yet,
one or more elements and/or sub-elements may be combined into a
single component to provide aggregate functionality. The elements
may also interact with one or more other elements not specifically
described herein.
[0076] In view of the exemplary devices and elements described
supra, methodologies that may be implemented in accordance with the
disclosed subject matter are described with reference to the flow
chart of FIG. 19. The methodologies are shown and described as a
series of blocks, the claimed subject matter is not limited by the
order of the blocks, as some blocks may occur in different orders
and/or concurrently with other blocks from what is depicted and
described herein. Moreover, not all illustrated blocks may be
required to implement the methods described hereinafter. The
methodologies can be implemented by a component or a portion of a
component that includes at least a processor, a memory, and an
instruction stored on the memory for the processor to execute.
[0077] FIG. 19 illustrates a flow chart of a method 1900 for
removing fluid from an aftercooler while maintaining pressure in a
reservoir of a compressor. At reference numeral 1902, a temperature
of a high pressure air that is delivered to a reservoir in the
compressor can be reduced. In an embodiment, the temperature can be
reduced by an aftercooler. At reference numeral 1904, air pressure
within an aftercooler of the compressor can be isolated from air
pressure within at least one of a high pressure air line or the
reservoir. In an embodiment, the air pressure can be isolated with
a check valve between the reservoir and the aftercooler. At
reference numeral 1906, a portion of fluid can be removed from the
aftercooler while maintaining air pressure in at least one of the
high pressure air line or the reservoir.
[0078] In an embodiment, a system is provided that includes a
filter that is external to the compressor that filters oil used
with an engine, wherein the filter is coupled to an external
surface of the compressor through a manifold. In the embodiment,
the manifold can include a vent pin that enables oil to flow from
the filter to the engine. In such embodiment, the vent pin can be
configured to restrict a flow of oil from the filter to the engine
via an oil vent and to enable oil flow from the filter to the
engine via an oil vent. In the embodiment, the manifold can further
include a pre-filter port that is configured to be utilized with an
oil pump.
[0079] In an embodiment, the system can include an aftercooler
coupled to o a high pressure cylinder of the compressor with a
single exhaust pipe. In an embodiment, the system can include an
intercooler coupled at least two low pressure cylinders of the
compressor and a high pressure cylinder of the compressor. In an
embodiment, the system can include an actuation line connecting at
least one unloader valve of at least one low pressure cylinder of
the compressor to at least one unloader valve of at least one high
pressure cylinder of the compressor; a drain line connecting a
drain valve of an intercooler of the compressor to the drain valve
of the aftercooler of the compressor; and a discharge line that is
coupled to at least one of the actuation line or the drain line
that flows to the atmosphere for release thereto. In the
embodiment, a controller can be configured to actuate the at least
one unloader valve of the at least one low pressure cylinder, the
at least one unloader valve of the at least one high pressure
cylinder, the drain valve of the aftercooler, the drain valve of
the intercooler, and the drain valve of the aftercooler at
substantially the same time. In the embodiment of the system, the
actuation can open each valve to the discharge line for flow to the
atmosphere. In the embodiment of the system, the controller can be
configured to actuate the check valve and the drain valve when the
compressor is in an unloaded condition.
[0080] In the embodiment, the controller can be further to actuate
at least one of the check valve or the drain valve prior to
starting of the compressor. In the embodiment, the controller
further configured to determine a high pressure cylinder discharge
valve leak with an exhaust port based upon a flow from at least one
of the check valve or the drain valve to the atmosphere. In an
embodiment, a propulsion system can be provided with the system and
can include a thermal clutch that engages a crankshaft to activate
a fan for the compressor, wherein the thermal clutch engages the
crankshaft based upon a temperature of an air flow discharged from
the compressor.
[0081] In an embodiment, a method is provided that includes a step
of removing the portion of fluid from the after cooler prior to
starting a compressor to reduce air pressure resisting a high
pressure cylinder head. In an embodiment, a method is provided that
includes the steps of measuring a flow of the portion of fluid from
the aftercooler; and identifying a high pressure cylinder discharge
valve leak with an exhaust port based upon the measured flow. In an
embodiment, a method is provide that includes the steps of engaging
a thermal clutch with a crankshaft of the compressor based upon a
temperature of an air flow discharged from the compressor; and
activating a fan based upon the engagement of the thermal clutch.
In an embodiment, a method is provided that includes the steps of
filtering a portion of oil with an external oil filter for use with
an engine of the compressor; flowing air from at least one unloader
valve of a first low pressure cylinder to a drain valve coupled to
at least one of the aftercooler or an intercooler of the
compressor; flowing air from at least one unloader valve of a
second low pressure cylinder to the drain valve; flowing air from
at least one unloader valve of a first high pressure cylinder to
the drain valve; or flowing air or the portion of fluid through the
drain valve of the aftercooler to the atmosphere.
[0082] As used herein, the terms "high pressure" and "low pressure"
are relative to one another, that is, a high pressure is higher
than a low pressure, and a low pressure is lower than a high
pressure. In an air compressor, low pressure may refer to a
pressure that is higher than atmospheric pressure, but that is
lower than another, higher pressure in the compressor. For example,
air at atmospheric pressure may be compressed to a first, low
pressure (which is still higher than atmospheric pressure), and
further compressed, from the first, low pressure, to a second, high
pressure that is higher than the low pressure. An example of a high
pressure in a rail vehicle context is 140 psi (965 kPa).
[0083] In an embodiment, a system is provided that includes at
least one of the following: means for delivering air under pressure
to a reservoir (e.g., compressor, air line, high pressure air line
286, high pressure air line 288, among others); means for changing
a temperature of the air that is delivered to the reservoir (e.g.,
aftercooler 270); means for isolating air pressure within the
temperature changing means from air pressure within the reservoir
(e.g., check valve 290); and means for removing a portion of fluid
from the temperature changing means while maintaining air pressure
in the reservoir (e.g., drain valve 292, drain line 294).
[0084] In the specification and claims, reference will be made to a
number of terms that have the following meanings. The singular
forms "a", "an" and "the" include plural referents unless the
context clearly dictates otherwise. Approximating language, as used
herein throughout the specification and claims, may be applied to
modify a quantitative representation that could permissibly vary
without resulting in a change in the basic function to which it is
related. Accordingly, a value modified by a term such as "about" is
not to be limited to the precise value specified. In some
instances, the approximating language may correspond to the
precision of an instrument for measuring the value. Moreover,
unless specifically stated otherwise, a use of the terms "first,"
"second," etc., do not denote an order or importance, but rather
the terms "first," "second," etc., are used to distinguish one
element from another.
[0085] As used herein, the terms "may" and "may be" indicate a
possibility of an occurrence within a set of circumstances; a
possession of a specified property, characteristic or function;
and/or qualify another verb by expressing one or more of an
ability, capability, or possibility associated with the qualified
verb. Accordingly, usage of "may" and "may be" indicates that a
modified term is apparently appropriate, capable, or suitable for
an indicated capacity, function, or usage, while taking into
account that in some circumstances the modified term may sometimes
not be appropriate, capable, or suitable. For example, in some
circumstances an event or capacity can be expected, while in other
circumstances the event or capacity cannot occur--this distinction
is captured by the terms "may" and "may be."
[0086] This written description uses examples to disclose the
invention, including the best mode, and also to enable one of
ordinary skill in the art to practice the invention, including
making and using a devices or systems and performing incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to one of
ordinary skill in the art. Such other examples are intended to be
within the scope of the claims if they have structural elements
that do not differentiate from the literal language of the claims,
or if they include equivalent structural elements with
insubstantial differences from the literal language of the
claims.
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