U.S. patent number RE31,379 [Application Number 06/197,401] was granted by the patent office on 1983-09-13 for combined pressure matching and capacity control slide valve assembly for helical screw rotary machine.
This patent grant is currently assigned to Dunham-Bush, Inc.. Invention is credited to David N. Shaw.
United States Patent |
RE31,379 |
Shaw |
September 13, 1983 |
Combined pressure matching and capacity control slide valve
assembly for helical screw rotary machine
Abstract
A helical screw rotary compressor or expander rotatably mounts
intermeshed helical screw rotors within intersecting bores of a
casing. An axially extending recess provided within the barrel
portion of the casing in open communication with the bore bears a
slide valve member whose inner face is complementary to the
envelope of the casing. The slide valve member controls
communication between the working chamber defined by the rotors and
the casing to the outlet port and bears means at the end in
communication with the outlet port for sensing the closed thread
pressure adjacent to the end of the slide valve member closing off
the outlet port. Comparison of that closed thread pressure to the
outlet port pressure permits controlled shifting of the slide valve
member to prevent overcompression and undercompression, when the
unit acts as a compressor, or underexpansion or overexpansion when
the unit acts as an expander. The slide valve member carries a bore
parallel to its longitudinal axis which bears a cylindrical volume
capacity control valve body which shifts to vary flow through
axially spaced channels, selectively communicating the working
fluid inlet to the bores bearing the intermeshed helical screw
rotors. The slide valve member and the volume capacity control
valve body carried thereby are independently movable.
Inventors: |
Shaw; David N. (Unionville,
CT) |
Assignee: |
Dunham-Bush, Inc. (West
Hartford, CT)
|
Family
ID: |
26721549 |
Appl.
No.: |
06/197,401 |
Filed: |
October 16, 1980 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
Reissue of: |
044433 |
Jun 1, 1979 |
04222716 |
Sep 16, 1980 |
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Current U.S.
Class: |
417/310;
417/315 |
Current CPC
Class: |
F01C
20/125 (20130101) |
Current International
Class: |
F04B 049/02 () |
Field of
Search: |
;417/310,315,309
;418/201,202 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Jenkins; Robert W.
Attorney, Agent or Firm: Sughrue, Mion, Zinn, Macpeak &
Seas
Claims
What is claimed is:
1. In a positive displacement helical screw rotary machine for
functioning either as a compressor or an expander and including a
casing provided with a barrel portion defined by intersecting
bores, with coplanar axes located between axially spaced end walls
and having inlet and outlet ports in communication with the bores
at opposite ends, helical screw rotors each having grooves and
lands being mounted for rotation within respective bores with the
lands and grooves of respective rotors intermeshed, an axially
extending recess provided within the barrel portion of the casing
in open communication with said bores and a slide valve member
mounted for axial sliding within the recess with the inner face of
the slide valve member being complementary to the envelope of that
portion of the bores of the casing structure confronted by the
opening of the recess and with the slide valve member communicating
the bore portion of the casing structure with the slide valve
member in sealing relation with the confronting rotor structure,
the outlet port having at least a portion located in the barrel
portion of the casing structure, with the slide valve member being
movable between extreme positions in which the outlet port is open
and closed, said slide valve member being of sufficient length to
cover the entire remaining length of the confronting portion of the
rotor structure throughout the range of movement of the slide valve
member between its extreme positions, pressure sensing means
provided adjacent to the end of the slide valve member closing off
the outlet port to the closed thread for sensing the pressure of
the working fluid within the closed thread just upstream from the
outlet port, means for comparing the pressure of the outlet port to
the closed thread pressure at said outlet port, and means for
automatically shifting the slide valve axially to equalize these
pressures to prevent undercompression or overcompression of the
working fluid when the unit is functioning as a compressor and for
preventing underexpansion or overexpansion of the working fluid
when the unit is functioning as an expander to maximize machine
efficiency in respective modes, the improvement residing in an
axial bore within the slide valve member, a plurality of
longitudinally spaced overflow channels in the slide valve member
inner face communicating the inner face partially defining the
envelope of the intermeshed screw rotors to said axial bore and
means communicating the axial bore to the inlet port of said
machine, a cylindrical volumetric capacity control valve body
movably disposed within said slide valve member bore in sealing
fashion therewith and including means responsive to shifting of the
valve body for selectively covering and uncovering the overflow
channels and communicating the slide valve member bore to the
working chamber bearing the intermeshed helical screw rotors, and
means for effecting control movement of said valve body relative to
said valve member bore.
2. The positive displacement helical screw rotary machine as
claimed in claim 1, wherein said shiftable cylindrical valve body
is mounted within said slide valve member bore for rotation about
its axis, and wherein the periphery of said valve body is recessed
so as to define a control edge of varying axial extent from one end
face towards the other about the circumference thereof so as to
variably communicate said overflow channels to said inlet passage
as said cylindrical valve body is rotated about its axis.
3. The positive displacement helical screw rotary machine as
claimed in claim 1, wherein said means for moving said cylindrical
valve body with respect to said slide valve body member bore
comprises a rack bar mounted for axial movement along a path at
right angles to the axis of said cylindrical valve body to the side
of said valve body and including rack teeth on the side thereof
facing the periphery of the rotary cylindrical valve body, and
wherein said cylindrical valve body bears at least on a portion of
its periphery, gear teeth which are in mesh with the rack gear
teeth, and means for shifting said rack bar axially to cause said
rotary cylindrical valve body to rotate about its axis and to
selectively communicate an overflow channel to said inlet
passage.
4. The positive displacement helical screw rotary machine as
claimed in claim 1, further comprising a two speed synchronous
induction motor operatively coupled to one of said rotors to drive
said machine, such that when said inducation motor is operated at
high speed is essentially doubles the volumetric capacity of the
machine without adversely affecting the pressure matching function
of said slide valve member. .Iadd. 5. In a positive displacement
helical screw rotary machine functioning either as a compressor or
an expander and including a casing provided with a barrel portion
defined by intersecting bores with coplanar axes located between
axially spaced end walls and having inlet and outlet ports in
communication with the bores at opposite ends, helical screw
rotors, each having grooves and lands and being mounted for
rotation within respective bores with lands and bores of respective
rotors intermeshed, an axially extending recess provided within the
barrel portion of the casing in open communication with said bores,
and a slide valve member mounted for axial sliding within the
recess with at least a portion of the interface of the slide valve
member being complementary to the envelope of that portion of the
bores of the casing structure confronted by the opening of the
recess and with the slide valve member communicating the bore
portion of the casing structure with the slide valve member in
sealing relation with the confronting rotor structure, the outlet
port having at least a portion located in the barrel portion of the
casing structure, with the slide valve member being movable between
extreme positions in which the outlet port is open and closed, said
slide valve member being of sufficient length to cover the entire
remaining length of the confronting portion of the rotor structure
throughout the range of movement of said slide valve member between
extreme positions, pressure sensing means provided adjacent to the
end of the slide valve member closing off the outlet port to the
closed thread for sensing the pressure of the working fluid within
the closed thread just upstream from the outlet port, means for
comparing the pressure of the outlet port to the closed thread
pressure at the outlet port, and means for automatically shifting
the slide valve member axially to equalize these pressures to
prevent undercompression or overcompression of the working fluid
when the unit is functioning as a compressor and for preventing
underexpansion or overexpansion of the working fluid when the unit
is functioning as an expander to maximize machine efficiency in
respective modes, the improvement comprising:
an arcuate opening within said slide valve member,
an arcuate volumetric capacity control valve body slidably and
sealably fitting said arcuate opening within said slide valve
member,
means including said arcuate volumetric capacity control valve body
for communicating the inlet port of said machine to said working
chamber bearing the intermeshed helical screw rotors,
means responsive to shifting of the valve body relative to the
slide valve member for varying communication between said inlet
port of said machine and said working chamber, and
means for effecting controlled movement of said valve body relative
to said slide valve member for varying the capacity of said
positive displacement helical screw rotary machine. .Iaddend.
Description
FIELD OF THE INVENTION
This invention relates to helical screw positive displacement
rotary compressors and expanders, and more particularly to a
machine employing a single, composite slide valve assembly for
varying compressor capacity and for matching the discharge or
outlet pressure to the pressure of the machine at discharge
corresponding to load conditions of the system within which the
unit is employed.
DESCRIPTION OF THE PRIOR ART
Helical screw, positive displacement rotary compressors and
expanders have long employed longitudinally shiftable slide valves
mounted to the compressor casing and carried within longitudinally
extending recesses parallel to barrel portions of the casing which,
in turn, bear intermeshed helical screw rotors which rotate about
their parallel axes within suitable casing bores.
While such slide valves have been employed primarily to vary the
capacity of the machine, whether it be a compressor or expander as
in U.S. Pat. No. 3,088,659 to H. R. Nilson et al and entitled
"Means for Regulating Helical Rotary Piston Engine," slide valves
have been provided for other purposes. Specifically, in U.S. Pat.
No. 3,936,239 issuing to the applicant and assigned to the common
assignee on Feb. 3, 1976, and entitled "Undercompression and
Overcompression Free Helical Screw Rotary Compressor" the axially
shiftable slide valve bears a port at the end of the slide valve
adjacent to the discharge side of the machine which opens to the
trapped volume of the working fluid, in the case of the compressor
therefore opening to the compression process, just before
uncovering of the closed thread to the discharge port, and compares
that pressure with the line pressure at the discharge port. Means
are provided for shifting the slide valve to balance the pressures
and in the case of a unit functioning as a compressor to prevent
overcompression and undercompression of the working fluid.
Further, while U.S. Pat. No. 3,936,239 shows a machine of this type
in which multiple, separate slide valves of an identical nature are
employed, depending upon the direction of rotation of the unit
functioning as a compressor, the slide valves functioning
alternatively in a pressure matching mode.
Attempts have been made in such helical screw rotary compressors
and expanders to change the volume ratio of the unit and therefore
its capacity by permitting a portion of the uncompressed or
unexpanded refrigerant vapor, depending upon whether the unit is
functioning as a compressor or expander, to return to the inlet
side of the machine and to therefore vary the volumetric capacity
of the machine. U.S. Pat. No. 4,042,310 issuing Aug. 16, 1977, to
Hjalmar Schibbye entitled "Screw Compressor Control Means" is
representative of a positive displacement rotary helical screw
machine incorporating such means. In U.S. Pat. No. 4,042,310, a
plurality of longitudinally extending bores are provided within the
casing housing the intermeshed helical screw rotors and adjacent
intersecting bores with a plurality of longitudinally spaced slots
intercommunicating the rotor bearing bores with the smaller
diameter bores which slidably support a tubular piston functioning
as a spring biased valve member which is displaceable axially
within its bore to progressively open up the slot and thus a
portion of the compression or expansion chamber to the inlet side
of the machine and to thereby vary the volumetric capacity of the
unit, whether it be a compressor or expander.
It is, therefore, a primary object of this invention to provide an
improved positive displacement helical screw rotary machine which
employs a single slide valve assembly to provide both unit
volumetric capacity control and to balance the closed thread or
working chamber pressure to the line pressure on the discharge side
of the machine.
It is a further object of the present invention to provide an
improved, multiple function slide valve assembly for a positive
displacement helical screw rotary compressor or expander in which
capacity control and pressure matching functions are effected
independently and without interference with each other in a
simplified manner.
SUMMARY OF THE INVENTION
The present invention is directed to a positive displacement
helical screw rotary machine in either compressor or expander form
wherein a casing is provided with a barrel portion defined by
intersecting bores, with coplanar axes located between axially
spaced end walls and having inlet and outlet ports communicating
with the bores at opposite ends. Helical screw rotors, each having
grooves and lands, are mounted for rotation within respective bores
with the lands and grooves of respective rotors intermeshed. An
axially extending recess is provided within the barrel portion of
the casing in open communication with the bores and a slide valve
member is mounted for axial sliding within the recess, with the
inner face of the slide valve member being complementary to the
envelope of that portion of the bores of the casing structure
confronted by the opening of the recess. The slide valve member
communicates the bore portion of the casing structure with the
slide valve member in sealing relation with the confronting rotor
structure. The outlet port has at least a portion located in the
barrel portion of the casing structure with the slide valve member
being movable between extreme positions in which the outlet port is
opened and closed. The slide valve member is of sufficient length
to cover the entire remaining length of the confronting portion of
the rotor structure throughout the range of movement of the slide
valve member between its extreme positions. A port or other
pressure sensing means is provided adjacent to the end of the slide
valve member closing off the outlet port to the closed thread for
sensing the pressure of the working fluid within the closed thread
just upstream from the outlet port. Means are further provided for
comparing the pressure of the outlet port to the closed thread
pressure and for automatically shifting the slide valve member
axially to equalize these pressures to prevent undercompression or
overcompression of the working fluid when the unit is functioning
as a compressor and for preventing underexpansion or overexpansion
of the working fluid when the unit is functioning as an expander to
maximize the compression and expansion efficiency of the machine is
respective modes.
Preferably, the slide valve member carried a sensing port opening
to the closed thread and conduit means within the slide valve
member communicates with the closed pressure sensing port to the
means external of the unit for causing comparison of the unit
outlet pressure with the gas pressure of the closed thread just
upstream of the outlet port. The slide valve member is preferably
shifted axially by a power piston slidable within a cylinder and
connected to the slide valve member by a piston rod. A pilot valve
responsive to the pressure differential may control the flow of a
motive fluid to and from respective sides of the power piston to
shift the slide valve member so as to balance the two gas
pressures.
The improvement resides in providing an axial bore within the slide
valve member and a plurality of axially spaced overflow channels in
the slide valve inner face partially defining the envelope of the
intermeshed screw rotors and communicating the slide valve bore to
the intermeshed helical screw rotors through the inner face of the
slide valve. A shiftable cylindrical valve body is movably disposed
in the slide valve member bore in sealing fashion and bears means
responsive to shifting of the valve body for selectively covering
and uncovering the overflow channels and communicating the slide
valve member bore to the working chambers of the intermeshed
helical screw rotors. Means are provided for communicating the
slide valve member bore to the inlet port for returning some of the
working fluid to the machine inlet prior to being closed off by the
intermeshed helical screw rotors, thereby varying the volumetric
capacity of the machine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is vertical sectional view of a helical screw rotary machine
in compressor mode employing the combined pressure matching and
volumetric capacity control slide valve assembly of the present
invention and forming one embodiment of the present invention with
the machine functioning at full capacity.
FIG. 2 is a sectional view of a portion of the machine of FIG. 1
taken about line 2--2.
FIG. 3 is an enlarged sectional view of the machine similar to that
of FIG. 1 with the machine in compressor mode under reduced
capacity conditions.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 to 3 show one embodiment of the present invention in which
a helical screw rotary machine is illustrated as functioning as a
compressor under different capacity conditions. The figures are
otherwise identical in all respects. The helical screw rotary
machine, indicated generally at 10, comprises a casing or housing
structure having a central, cylindrical barrel section 12 located
between and sealingly connected to inlet end wall section or end
plate 14 and outlet end wall section or end plate 16 and defining
in this case a working fluid compression space or working space
formed by two intersecting bores. One bore 18 is illustrated as
carrying a helical screw rotor 20 in mesh with a second helical
screw rotor 21 having an axis coplanar thereto and extending
through the barrel portion 12 of the casing structure. Both male
and female rotors are provided with helical lands and intervening
grooves and are mounted for rotation in the bores, about their
axes, by way of suitable bearings. The helical screw rotor 20 is
mounted for rotation on shaft 22, being supported by a sleeve
bearing 24 defined by end wall section 14 and by means of
anti-friction bearings 26 mounted with a bore 29 of sleeve 30.
Sleeve 30 is an integral cast component of end bell 28 on the
discharge side of the machine. Shaft 22 extends through the end
bell 28 at the right and is connected by way of spline 32
preferably to a two speed synchronous induction electric drive
motor indicated schematically at M for providing the motive force
for driving the rotors when the machine is used as a compressor.
Alternatively, when the machine is used as an expander, if the two
speed electric motor comprises a synchronous induction electric
machine or its equivalent, it may function as a generator to permit
electrical output to the electrical network feeding the same.
The unit 10 is provided with an inlet or intake passage 34 within
the end wall section 14 and enters the working chamber by way of
inlet port 36 such that the working fluid in vapor form, as for
instance a refrigerant R22, may be compressed within a "closed
thread" working space formed by the intermeshed helical lands and
grooves or respective rotors 20 and 21.
It is a characteristic of the helical screw rotors of such machines
that the flanks of the lands of the male rotors are convexly curved
with their intervening grooves lying substantially outside the
pitched circle of the male rotor, while the lands of the female
rotor are concavely curved, with their intervening grooves lying
substantially inside the pitched circle of the female rotor. It is
a further characteristic of such rotors as in the illustrated
embodiment that the effective wrap angle of the lands is less than
360.degree..
The casing or housing structure is provided with a high pressure
discharge or outlet port 40, the major portion of which lies on one
side of a plane passing through the axes of the rotors 20, 21, with
the outlet or discharge port 40 being located at least partially
within the outlet end wall section 16 of the machine. The outlet
port 40 is in fluid communication with the outlet passage 42 which
extends from the outlet end wall section 16 of the machine to end
bell 28. It may be seen, therefore, that the inlet port 36 and the
outlet port 40 are on opposite sides of the plane passing through
the rotor axes. The machine as illustrated in FIGS. 1 and 2, is
oriented horizontally, and in the illustrated embodiment, the
barrel section 12 of the casing structure is further provided with
a centrally located, longitudinally extending, cylindrical recess
44 which is in open communication, at one end, with the outlet port
40 and at the other end extends beyond the end wall 45 of the inlet
end wall portion or section 14 of the casing structure and opens to
the inlet passage 34 of the machine. Recess 44 carries a
longitudinally slidable, slide valve member 38 of modified circular
cross-section and sealably slidable within that recess. The slide
valve member 38 bears a piston rod 46 to which it is fixed, and the
longitudinal position of the slide valve member 38 within recess 44
is adjusted by means of a linear fluid motor 51 connected to rod 46
at the end opposite slide valve member 38. A power piston cylinder
50 is fixedly mounted to the casing structure as an extension to
section 14, and slidably mounts a power piston 48 bearing a seal 49
on its periphery. A fixed end cap 52 closes off the left end of the
cylinder 50 and defines a sealed working chamber 54 within the
cylinder 50, along with end wall section 14. The end wall section
14 bears an opening 53 within which slides the piston rod 46 with
chamber 54 being sealed from the inlet passage 34 by way of an
O-ring seal member 55 suitably carried within the casing end wall
section 14 at opening 53. The inner face 56 of the slide valve
member 38 confronting the rotors 20, 21 is shaped to provide a
replacement for the cut-away portion of the casing section 12
defining the bore so as to complete the compression envelope for
the intermeshed helical screw rotors. The left end of the slide
valve member 38 slidably and sealably engages a recess portion 60
of the end wall section 14 of the casing, such that regardless of
the position of the slide valve member 38, the slide valve member
38 is of a sufficient length to cover the entire remaining length
of the confronting portion of the rotor structure throughout its
range of movement between extreme positions as determined by recess
portion 60 and the abutting contact or end face 62 of the slide
valve member 38 with the outlet end wall section 16 of the casing
structure which also sealably receives a portion of the same. Face
56 of the slide valve is chevron-shaped with its center line
constituting an apex at the point of intermesh between the
confronting rotors.
During compression, an elastic working fluid such as a gaseous
refrigerant R22 or the like is drawn into and fills the grooves of
the rotors 20, 21 through the inlet port 36. As the rotors revolve,
mating pairs of lands of the male and female rotors intermesh at
the bottom of the compressor to form chevron-shaped working
chambers. As the rotors continue to revolve, these working
chambers, which constitute compression chambers or closed threads
(when the machine is functioning as a compressor), diminish in
volume as the point of intermesh between any two lands determines
the apex end of the given compression chamber or thread, move
axially towards high pressure end wall 64 for casing section 16
(when the unit functions as a compressor) to diminish the volume of
the compression chamber until the compressor runs out to zero
bottom as the point of intermesh reaches the plane of the outlet
end wall 64. Closure of the compression chamber is effected by the
inner face of the slide valve member 38 which is in confronting and
sealing relation with the crest of the land defining the boundaries
of the compression chambers of closed threads.
Discharge of compressor working fluid in this case is effected when
the crests of the rotor lands defining the leading edge of the
compression chambers pass a control edge 66 of the slide valve
member 38 at right end 62 of that member to establish communication
between the closed thread or chamber just prior to discharge at the
outlet port 40 with the outlet port 40. Movement of slide valve 38
to the left shortens the time of compression, while movement to the
right increases the time of compression and increases the
compressor pressure ratio between suction and discharge of the
compressor when acting under compressor mode. Thus, assuming that
the initial volume of the closed thread prior to that thread
reaching edge 66 of the slide valve member 38 remains constant, the
slide valve member 38 may vary the compression ratio of the
compressor. This in effect controls the pressure of the discharge
gas from the closed thread to the outlet port 40.
One aspect of the present invention is therefore identical to that
of my earlier U.S. Pat. No. 3,936,239 in that the composite slide
valve assembly indicated generally at 11 utilizes the slide valve
member 38 to match a closed thread or working chamber fluid
pressure at its outlet or dicharge point, as determined by edge 66
of the slide valve member 38, to the outlet or discharge pressure
within the discharge passage 42 at the discharge port 40. This
permits efficiency of the system in which the machine is employed
to be improved since when the unit functions as a compressor, there
will be no working fluid undercompression or overcompression or,
alternatively, if the unit or machine 10 is employed as an
expander, there will be no working fluid underexpansion or
overexpansion as the high pressure working fluid expands from inlet
port 36 to outlet port 40. Thus, the machine of the illustrated
embodiment of the present invention may be utilized both as an
expander and compressor without physical change and employs
advantageously both volumetric capacity control and pressure
matching, with vapor inlet always through port 36.
With respect to the pressure matching function of the unitary slide
valve assembly 11, the slide valve member 38 is automatically
shifted to match the closed thread or working chamber pressure just
upstream from its outlet or discharge port to the discharge or
outlet passage pressure at the outlet port 43. A vertical small
diameter passage 70 in the form of a drilled hole, opens to the
inner surface 56 of the slide valve member 38 at sensing port 72,
just upstream of the edge 66 of that member, to permit sampling of
the pressure of the working fluid just prior to discharge. The
slide valve member 38 is longitudinally bored at 74 from left end
76 to passage 70.
Further, the piston rod 46 is hollow, being centrally bored at 80
and is provided with a radial port 82 which connects via tube 78 to
bore 74 carried by slide valve 38 such that the sensing port
pressure at sensing port 72 is transmitted through the length of
the hollow piston rod 46 towards piston 48. The piston rod bore 80
is plugged at one end as at 81. A yoke member 83 connects the
piston rod 46 to the slide valve member 38. Fixed to the end cap 52
at its center is a smaller diameter tube 84 which is slidably
received by bore 80 of the hollow piston rod 46 with which it makes
sealed surface contact. Further, the end cap 52 is provided with a
radial fluid passage 86 which opens to the end of the fixed tube
84.
The illustrated embodiment of the invention employs a pilot valve
indicated generally at 92 which operates in the identical manner to
my earlier U.S. Pat. No. 3,936,239. In that respect, the pilot
valve 92 is provided with a pilot valve casing 90 of cylindrical
form defining a longitudinal bore 94 within which lies an axially
shiftable pilot valve spool 96 comprising four axially spaced lands
98, 100, 102 and 104 which are in sealing contact with the bore 94
of the pilot valve casing 90. The lands are joined by reduced
diameter portions 106. The valve casing 90 at its ends is provided
with axial ports 108 and 110 to the left and right,
respectively.
In addition to the axial end ports 108 and 110 at the left and
right ends of the cylindrical pilot valve casing 90, there is
provided an inlet port 112 which opens up radially to the interior
of the casing intermediate of its ends. A hydraulic pressure
working fluid, indicated schematically by arrow 116, is fed to the
inlet port 112 through a line 114 leading from a supply (not
shown). Ports 118 and 120 open up radially to the interior of the
valve casing, to opposite sides of port 112, and constitute
discharge ports and are fluid connected to a common discharge line
122 discharging fluid from the pilot valve as indicated by arrow
124. On the opposite side of the pilot valve casing 90, there are
provided fluid ports 126 and 128 which lead by way of lines 130 and
132 to the chamber 54, and respectively to the left and right sides
of the power piston 48. Line 88 leads from passage 86 to axial port
108, and a line 136 leads from axial port 110 to the pilot valve to
the outlet passage 42 of the machine.
In the fashion of U.S. Pat. No. 3,936,239, lands 98 and 104
function, due to identical surface areas on their ends thereof, as
comparing means to compare the pressure of the closed thread at
sensing port 72 to the discharge or outlet pressure of the unit.
The pilot valve spool 96 shifts to the right or left, depending
upon whether the pressure within the discharge passage 42 of the
unit is higher than the pressure within the closed thread sensed by
port 72 at any instant, or vice versa. With the pilot valve spool
96 in the position shown, the working fluid 116 passes to the left
side of the power piston 48, causing the piston 48 to move to the
right as working fluid within chamber 54 to the right of that
piston passes to the outlet line 122 through line 132. This causes
the compression process to continue to discharge gas at a higher
pressure through the discharge port 40 into the outlet or discharge
passage 42. When that discharge pressure exceeds the pressure
exerted on the pilot valve spool 96 by way of the closed thread,
the power piston 48 is forced to move to the left, shifting the
slide valve member 38 to again balance these pressures by causing
the closed thread to open to the discharge port or outlet port 42
at lower compression, earlier in the compression cycle.
An important aspect of the present invention, in particular, is the
dual function of slide valve assembly 11, by the incorporation
within the slide valve member 38 of means for varying the
volumetric capacity of the machine independently of and without
interference with the function of the slide valve member 38 in
matching the pressures between the closed thread pressure just
prior to discharge and that of the discharge or outlet passage at
the outlet port 40. In this respect, the slide valve member 38 is
provided at its inner face 56 with two rows of inclined,
longitudinally spaced and generally parallel channels 140 which in
fact may be at some inclination angle to pressure sensing passage
70. The channels 140 which open to respective intermeshed rotors 20
and 21 at the inner face 56 of the slide valve member 38, extend
along the length of the slide valve member from just to the left of
the port 72 to very near the left end 76 of the slide valve member
38. Further, the slide valve member 38 is provided with a
relatively large circular bore as at 142 which extends inwardly and
to the right from end 76 of that member, preferably the full length
of the slide valve member 38. A cylindrical volumetric capacity
control valve body indicated generally at 146, having a bore 148 is
sized to match bore 142 of the slide valve member 38 within which
it is concentrically mounted for rotation about its axis. The
rotary volumetric capacity control valve member 146 is mounted for
relatively free rotation about the axis of the piston rod 46 but is
prevented from the shifting axially with respect to that member so
as to be maintained in an axially fixed position.
The valve body 146 periphery bears a recess 152 over a portion of
its periphery which follows a helical path about the periphery of
the valve body, conforming to the helical pitch for the lands and
grooves of the intermeshed helical screw rotors 20 and 21 forming a
helical flow control edge or helix 154. Thus, depending upon the
angular position of the valve body 146 with respect to the piston
rod 46 which rotatably supports the same, the radially inboard ends
of the channels 140 are selectively uncovered by control edge 154
to permit the flow of inlet working fluid prior to compression
(when the unit functions as a compressor) or prior to expansion
(when the unit functions as an expander) to return to the inlet or
suction passage 34, thus decreasing the volume of working fluid
discharging at edge 66 of the slide valve member 38.
As mentioned previously, the action of the capacity control slide
valve body 146 is independent of the action of the slide valve
member 38 which functions in pressure matching mode. In that
respect, the casing section 16 supports for sliding movement, a
rack bar 160. The rack bar 160 preferably is slidably mounted
within a bore 162 which is formed within the casing section 16 at
right angles to the axis of the piston rod 46 and its supported
cylindrical capacity control valve body 146, to the side of the
valve body 146 at one end thereof. The rack bar 160 bears rack
teeth 164 on the surface which faces the periphery of the valve
body 146, and the valve body 146 itself is provided with matching
gear teeth defining a pinion gear 147 for the rack such that as the
rack is moved in one direction along its longitudinal axis, the
valve body 146 rotates so that control edge 154 closes off in
succession the channels 140 from right to left, thereby increasing
the capacity of the machine. To the contrary, when the rack is
moved in an opposite direction and the valve body rotates clockwise
about its axis when viewed from the left end of the machine, FIG.
1, the helix 154 uncovers a larger number of the channels 140 from
left to right returning more of the working fluid prior to
compression and thereby decreasing the volumetric capacity of the
machine.
In order to effect volumetric capacity control, the rack bar 160
terminates at one end in a piston 166 forming a part of a hydraulic
linear motor 168. A cylinder 170 defines a working chamber 171
which carries piston 166. A first hydraulic port 172 opens to
cylinder 170 on one side of the piston 166, while a second
hydraulic line port 174 opens to the cylinder 170 on the opposite
side of piston 166. As indicated in FIG. 3, by the application of a
hydraulic fluid under pressure, as by way of arrow 176, and by
release of hydraulic fluid on the opposite side of piston 166
through port 172, as per arrow 178, the rack is moved upwardly with
respect to the valve body 146 and the valve body 146 is rotated
counterclockwise (when viewed from the right) to unload the
machine. By applying hydraulic liquid under pressure to port 172
and relieving it through port 174, loading is achieved, and the
cylinder valve body 146 will rotate in a clockwise direction about
its axis of rotation when viewed from the right end of the
apparatus. The rotary valve body 146 is sized so as to closely seal
off the bore 142, although rotation of the valve body 146 is
permitted relative to the slide valve member 38 bearing the same.
Further, the rack and pinion gear means permits the valve body to
be carried by the slide valve member 38 without interference to the
gear connection therebetween.
It is important to note that, not only is the efficiency of the
system improved by the pressure matching function of the slide
valve member 38, but the utilization of the rotary valve 146 for
varying the volumetric capacity of the machine when load
requirements are reduced greatly reduces the horsepower required to
effect the compression process, although compression ratio of the
compressor remains constant throughout the volumetric capacity
variation from full load to full unload. In that regard, FIG. 1
shows the helical screw positive displacement machine 10 under
conditions in which the unit is functioning as a compressor with
low volumetric capacity, the capacity control valve body 146
rotated counterclockwise to open most of the channels 140 to the
inlet passage 34. Slide valve member 38 is at near full
compression. In contrast, FIG. 3 shows the slide valve member 38
shifted to the left. The machine is unloaded completely, and the
rotary volumetric capacity control valve body 146 has been rotated
clockwise by applying high pressure hydraulic liquid to port 172 to
the upper side of the piston 166 and bleeding port 174 at the lower
face of the power piston 166, forcing that piston 166 downwardly
within cylinder 168 and causing the rotation of the valve body 146
clockwise when viewed from the right end of the assembly. This
uncovers all of the channels 140, permitting the compressor working
fluid to return to the inlet side of the machine by way of inlet
passage 34, along the surface portion 146a without compression.
As seen in FIG. 3, with the machine fully unloaded, there is
effectively a direct fluid path from the inlet port 36 to the
outlet port 40 of the machine by way of the helical recess 156 of
the rotary valve member 146 and partially by way of bore 142 within
slide valve 38. This permits at start up or prior to start up the
full unloading. In an operative system, check valves may be
provided at the inlet or outlet or both, the control system may
incorporate an electronic computer or the like for permitting under
certain circumstances such as start up or just prior to start up,
full unloading of the machine, while under other circumstances
regardless of normal system design, rotation of the capacity
control valve body 146 may be effected to in fact prevent full
unloading.
The effect is to maintain the same compression ratio of the machine
but reducing the work of the two speed synchronous induction motor
M acting to drive the compressor through shaft 22 by way of spline
32.
The unit of the illustrated embodiment may function either as a
compressor or an expander, with the working fluid at low pressure
when the unit functions as a compressor entering the inlet passage
34 at inlet port 36 for compression prior to discharge at outlet
port 40. Alternatively, if the unit is being employed as an
expander, in that case, the slide valve 38 functions as a pressure
matching control means for the expansion process, while the rotary
volumetric capacity control valve body 146 carried by the slide
valve member 38 functions to independently control the volumetric
capacity of the machine. If the unit is to be employed as an
expander, and there is no necessity to reverse the flow, that is,
cause the high pressure working fluid to enter the outlet passage
42 and flow to the inlet passage 34 or low pressure end of the
machine, as in conventional compressor/expander units, the inlet
passage 34 always receives the working fluid on the inlet side of
the machine, regardless of whether it is a high pressure or low
pressure fluid. Thus, with the positive displacement machine 10
functioning as an expander, the pressurized working fluid enters
the inlet 34 and expands forcing the rotors to rotate and in this
case to drive the two speed synchronous induction electric motor M
rotor R with respect to the stator 8 to deliver electrical current
through leads L. When using the unit as an expander, the slide
valve member 38 continues to function as a pressure matching means,
sensing the expanded working fluid within a closed thread at port
72 just before discharge at the outlet port 40 and making sure that
the pressure in the closed thread matches that at port 40 so that
there will be no underexpansion or overexpansion of the working
fluid being expanded. Likewise, depending upon the system load
being sensed by means (not shown), hydraulic liquid is delivered to
one side of the power piston 166 and relieved from the other side
to cause the rack bar 160 to rotate the rotary capacity control
valve body 146 about its axis to vary the volume of working fluid
being expanded and thus the capacity of the expander. In each case,
the efficiency of the machine and the efficiency of the system
employing that machine is maximized by the utilization of the
single assembly 11 to accomplish a two part purpose.
Further, in order to maintain sufficient variation in load bearing
capability of the machine, the two speed synchronous induction
range normally limited by the range of longitudinal movement of the
slide valve member 38 to effect pressure matching, such that by
doubling the speed of rotation of the intermeshed helical screw
rotors 20 and 21, the volumetric capacity of the machine may be
essentially doubled, regardless of pressure matching needs.
When using the unit as an expander, and also utilizing a reverse
flow direction, as compared to the flow direction when operating as
a compressor, slide valve 38 will function as an inlet volumetric
control and not as a pressure matching control. When operating with
this reverse flow direction, cylindrical valve body 146 will then
operate as an approximate pressure matching control. However, the
rotary position of cylindrical valve body 146 will be determined
via a preprogrammed relationship that will utilize inlet pressure,
outlet pressure, and position of slide valve 38 as sensory inputs.
In other words, the correct expansion ratio will be determined by
measuring the inlet pressure to the expander, the outlet pressure
the expander is dumping into, and the relative load on the expander
as measured by position of slide valve 38.
This reverse flow situation is desirable under conditions whereby
asymmetrical profile rotors are utilized and an unequal blowhole
relationship exists when operating as either as expander or a
compressor with no change in flow direction. Typical circular
profile rotors do not have this difference in blowhole size.
While the invention has been particularly shown and described with
reference to a preferred embodiment thereof, it will be understood
by those skilled in the art that the foregoing and other changes in
form and details may be made therein without departing from the
spirit and scope of the invention.
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