Zhejiang Meizhoubao: Your Professional Piston Air Compressor Manufacturer!
Zhejiang Meizhoubao Industrial & Commercial Co.,Ltd. is one of the air compressor manufacturers in China that produces all kinds of air compressors. We are a modern enterprise combining with research, development, manufacture and trading. Meanwhile we have leading-edge workshop, leading-edge production assembling lines, precise testing equipments and skilled staffs.
Rich Experience
Founded in 2003, our company has 20 years experience in air compressor and 15 years OEM experience for more then 100 clients around the world.
Professional R&D Capability
There are professional R&D teams and independent research and development under the leadership of human resources such as Professor Xu Shiwei from the School of Mechanical and Vehicle Engineering of Hunan University and doctoral supervisor.
Integrated Team
Our company is an enterprise integrating production, scientific research, production, domestic and foreign trade and warehousing. The company team has sales center, foreign trade department, domestic sales department, R&D center, production department and after-sales department.
Strong Production Capacity
Our company has produced 1 million air compressors annually, with more than 200 product models. The products sell well all over the country and are exported to more than 60 countries and regions in the world.
Complete Qualifications
Our company designs and manufactures high quality products with 12 R&D engineers. We have CE, CCC, ISO9001, ROHS certificate and so on.
A piston air compressor, also known as reciprocating air compressor, is a type of positive displacement type of air compressor in which air is sucked into a chamber and compressed with the help of a reciprocating piston. The basic working principle of a piston type air compressor is similar to that of a crankshaft piston. The air flows into the compressing cylinder after passing through the air filter and via a suction valve. The air is then compressed using a crankshaft and a piston and leaves through a discharge valve. The compressed air is then stored in a storage tank.
Body
The compressor body includes the cylinder block and crankcase. Generally, it is made of high strength grey cast iron.
Cylinder
The cylinder is a key component of a piston compressor. According to different pressure, discharge capacity and gas properties of the compressor, users should select cylinders made of different materials and with appropriate structures.
Basic requirements for cylinders are: strength and stiffness, good cooling, lubrication and wear resistance.
Crankshaft
By changing the rotary motion of the motor into reciprocating linear motion of the piston through the connecting rod, the crankshaft transmits the full power of the compressor. It is one of the key components of the motion system of the compressor.
Connecting Rod
Connecting rod is the connecting piece between the crankshaft and piston, which transforms the rotary motion of the crankshaft into the reciprocating motion of the piston, and transfers power to the piston to work on gas.
The connecting rod comprises a connecting rod body, a small end bush, a big end bearing bush and a bolt.
Piston Group
Piston group is the generic name of the piston, including piston pin and piston ring. Driven by the connecting rod, the piston group makes reciprocating linear motion in the cylinder, so as to form a variable working volume together with the cylinder, and therefore to complete the process of suction, compression and exhaust.
Piston
The piston can be divided into cylinder and disc. Piston material is generally aluminium alloy or cast iron.
Piston Pin
The piston pin is used to connect the small end of the piston and the connecting rod. It bears a complex alternating load when working.
Piston Ring
It is a circular ring with a cut on it, and the cut may be straight, inclined or overlap. The angle of the inclined cut is 45 degrees.
The piston ring is comprised of a gas ring and an oil ring. The gas ring works as a seal between the piston and the cylinder wall to prevent the compressed air from leaking from the gap between the piston and the cylinder wall. The oil ring is to distribute oil and scrape off the excess lubricating oil on the cylinder wall.
Shaft Seal
A shaft seal is for preventing compressed gas from leaking out along the extended end of the crankshaft, and also for preventing outside air from leaking in when the pressure in the crankcase is lower than atmospheric pressure.
Crankcase Heater
The crankcase heater ensures the normal lubrication of the refrigerant heater in the crankcase by separating the refrigerant in the crankcase.
Users should install a crankcase heater in any environment. When the compressor runs with the crankcase temperature 20 ℃ higher than the environment temperature, the crankshaft heater will be powered off. When the compressor stops, the heater will be powered on.
Compressor Motor Protection Device
To prevent overload or overheating of the compressor, the motor is built-in with 6 PTC thermistors.
Oil Pressure Safety Device
The oil pressure safety device monitors the pressure difference between the inlet and outlet of the oil pump to ensure the lubrication of the compressor. It is usually less than 0.7 bar and has 90 ± 10 seconds’ delay. The oil pressure difference of the compressor is 2.5 ~ 3 kg/cm.
The oil pressure difference of a single-stage compressor is calculated as:
Δ P = Oil Pump Outlet Pressure — Suction Pressure.
The oil pressure difference of the two-stage compressor is calculated as:
Δ P = Oil Pump Outlet Pressure — Intermediate Pressure.
The working process of a compressor starts with sucking in gas from the outside environment, which enters the system through a suction valve. When the piston moves downward, the pressure inside the cylinder decreases. This shift encourages the gas to enter the cylinder, filling up the void created by the movement of the piston.
When the cylinder fills with the gas, the compression process starts. The piston then starts moving upward, consequently increasing the pressure within the cylinder. Compressing the gas increases its temperature, which can be dangerous, leading to possible explosions in some cases. This is why manufacturers often incorporate cooling systems in these compressors to keep temperatures under control.
When the gas is adequately compressed, it’s time to discharge it from the cylinder through an outlet valve. As the piston reaches the peak, the high pressure causes the outlet valve to open releasing the compressed gas into the output system. The compressor continues to follow this routine process of intake, compression, and discharge to perform its function.
Common Types of Piston Air Compressor
Single-acting Piston Air Compressor
A single-acting compressor is a type of air compressor that uses only one end of the piston for the suction and compression. So the first stroke of the piston sucks the air inside the compressor while the air compression occurs in the second stroke. A single-acting piston air compressor has a set of valves at the top and there is one compression cycle for every revolution of the crankshaft.
To explore the internals a bit closer, a mechanical linkage, or connecting rod, is attached to a piston and a crankshaft. For every rotation of a motor, the piston will move up and down. Air is being drawn into the cylinder and then compressed. The volume of the cylinders, the number of cylinders, and the rotations per minute will determine the amount of compressed air that can be produced. The advantages with reciprocating compressors are that they can produce high pressure, compress different types of gases, and have a cheap and rugged design.
Double-acting Piston Air Compressor
Double-Acting piston air compressors are a subset of the larger family of positive displacement compressor types. In positive displacement compressors, air is drawn into a chamber where the volume is then mechanically reduced. The energy used to displace the air volume is converted to an increase in air pressure.
The Double-Acting Reciprocating compressor is a close relative to the Single-Acting Reciprocating compressor. In these types of compressors, an “automotive-type” piston driven by a crankshaft provides the compression. In a Double-Acting Reciprocating compressor, air is compressed as the piston moves in each direction. Hence the name, “double-acting”. In a Single-Acting Reciprocating compressor, air is only compressed on each full revolution of the piston. This makes the Double-Acting Reciprocating compressor much more efficient than its brethren.
Diaphragm Piston Air Compressor
A diaphragm piston air compressor is a variant of the classic piston compressor with backup and piston rings and rod seal. The compression of gas occurs by means of a flexible membrane, instead of an intake element. The back and forth moving membrane is driven by a rod and a crankshaft mechanism.
Diaphragm compressors move (and compress) gas using a set of three, flexible diaphragm membranes. Gas enters the compressor’s process head from an external tank or process on its down-stroke. On the up-stroke, the diaphragms flex, reducing the area inside the chamber, pushing the gas out of the compressor (and on to the process/application).
The oscillating movement of the diaphragms is driven by a reciprocating piston and crankshaft mechanism. Only the process diaphragm and the compressor’s process head come in contact with the gas. This is important because the diaphragms prevent hydraulic fluid (or oil from the compressor) from coming in contact with the process gas. This eliminates any potential contamination of the gas, which is critical with Hydrogen applications, because the purity of the gas has a direct impact on the process. For these reasons, diaphragm compressors are also preferred for pumping toxic or explosive gases. The diaphragm must be reliable enough to resist fatigue while also having adequate chemical properties for corrosion resistance.
Diaphragm Compressors combine two systems – a hydraulic system and a gas compression system. A series of metal diaphragms isolate components between the two systems.
The gas compression system consists of three flat metal diaphragms, which are clamped between two precisely contoured and concaved cavities, and the process gas inlet and outlet check valves.
The hydraulic system includes a motor-driven crankshaft, which reciprocates a piston in the hydraulic fluid medium. This positive displacement piston causes the hydraulic fluid to be compressed against the lower side of the diaphragm group which, in turn, causes the diaphragm group to sweep the cavity, displacing the process gas.
Single-stage Piston Air Compressor
A single-stage piston air compressor has one or multiple cylinders connected parallelly. Here the air is compressed only once before it is moved to the final storage tank.
The discharge pressure achieved by a single-stage piston air compressor is limited by its design, and the maximum pressure may be 125 PSI (increasing the pressure beyond this may increase the temperature of the cylinder).
Advantages
They are simple in construction and are less expensive compared to multi-stage alternatives.
Disadvantages
Single-stage compressors have a lower pressure-ratio and low volumetric efficiency. The lack of inter-cooling will result in higher temperatures that can lower the life of the equipment.
Two-Stage Compressors
In the case of a two-stage or dual-stage piston air compressor, there will be two cycles of compression occurring in two cylinders that are connected in series. The gas is compressed in one cylinder (first stage), and the discharged gas is further compressed in the second cylinder (second stage), to a higher pressure.
The diameter of the second-stage cylinder is smaller than the first-stage cylinder. There will be an intercooler to cool the gas in between the stages.
Tandem Piston Compressor
As the name implies, a tandem piston compressor is an arrangement of two or more pistons on the same rod. It is generally used for double-acting compressors, where one side will serve as the first stage while the other end will be for the final or second stage.
V-Shaped Compressor
A V-shaped air compressor, is typically an air-cooled compressor with valves mounted on each cylinder unit. Its distinct feature is meant for achieving better torque and balancing by displacing units at some 90 degrees angle. It has higher capacity, therefore cooling is required.
In-Line Compressor
In this compressor, the cylinders of various stages are arranged in a straight line when viewed from the top, this structure only clarifies the name of this variant. An in-line compressor is often used in tasks that call for varying pressures. It also runs on electric motors or diesel engines.
Benefits of Piston Air Compressor
Flexibility
This type of air compressor comes in both oil-flooded and oil-free varieties. This means that if you prefer a reciprocating compressor for your application, you do not have to be limited by the constraint of oil contamination.
In addition, reciprocating compressors can be tank mounted or base mounted, so that decreases the constraints of placement.
Produces Higher Pressures
Piston air compressors can produce higher pressures than other compressors like rotary screw varieties. In fact, pressures range all the way up to 30,000 PSI. However, they are also suitable to climate control applications requiring 60-90 PSI.
High Efficiency
Piston air compressors can produce higher pressures while simultaneously using less energy to run. This makes this type of compressor extremely advantageous for applications where intermittent use with high pressure is needed.
Great for Intermittent Tasks
Piston air compressors are best used for tasks where intermittent use is performed. Due to the operation style of a reciprocating compressor, they maintain high efficiency when running intermittently. This means that if your compressor is not running continuously, you will enjoy energy savings over other types of compressors.
Applications and Uses of Piston Air Compressor
Agriculture/Farming
For productive and profitable farming operations, compressed air provides long-lasting performance and a low cost of ownership. Compressed air is used for:
● Moving feed and grain to and from silos with conveyors.
● Glasshouse ventilation systems.
● Spraying crops.
● Powering dairy machines.
● Operating pneumatic material handling equipment.
Manufacturing
Whether in refineries, plastics, assembly plants or metal fabrication, an air compression system is the central power source that keeps a business in production. Powerful air compressors aid in manufacturing by:
● Operating air tools on production lines.
● Cutting and welding equipment.
● Ejecting pieces from production molds.
● Monitoring production.
● Adjusting roller and feed machinery.
● Blowing a molded gas tank or plastic bottle.
● Efficiently performing basic tasks such as driving screws and turning nuts.
● Increasing production efficiency with air cylinders that power positioners, clamps, air chucks, and air knives.
● Finishing and packaging with pneumatic devices used for liquid padding, carton stapling, appliance sanding, dry powder transporting and fluidizing.
● Sandblasting and finishing metal.
● Operating automated machinery.
Dry Cleaning
Reliable air supply and a dependable system are required for the dry cleaning industry, which demands quality cleaning of garments. Compressed air is used for:
● Delivering chemical applications through cleaning guns.
● Operating laundry presses and steam cleaners.
Pharmaceutical
Remaining clean, dry and oil-free are top priorities for this highly regulated industry that needs precision equipment and high-performance systems. A pharmaceutical air compressor setup works by:
● Moving product on conveyor systems.
● Spraying coatings on pharmaceuticals.
● Maintaining pressure in mixing and holding tanks.
● Bottling and packaging products.
Energy Exploration
The remote nature of energy exploration requires the most dependable power to minimize repair and maintenance costs. An air compressor will be:
● Powering pneumatic tools and equipment in onshore and offshore operations.
● Compensating for motion caused by turbulent seas.
● Inserting and withdrawing reactor rods.
● Controlling valves in steam and coolant circuits remotely.
● Powering ventilation systems for boiler houses.
Food And Beverage
All types of food and beverage manufacturing facilities use air compressor systems for various production tasks. They need contaminate-free and consistent compressed air to run their constant operations. Compressed air is used for:
● Packing and palleting products.
● Closing and checking devices.
● Filling equipment for drinks.
● Cooling and freezing products.
Questions To Consider Before Purchasing a Piston Compressor
What size piston compressor is right for my business?
Piston air compressors are available in a wide range of sizes, and it’s typically the application itself that is the most critical factor in determining the size air compressor you should buy. Larger units can generally deliver air at a higher cubic feet per minute (CFM) but are less portable; this means you’ll want to think about your need for portability versus your required CFM output. Piston compressors can also come with a horizontal or a vertical tank. While each delivers equal volumes of compressed air, a vertical tank can be a space-saver in smaller shops or other facilities where footprint size is important. Your choice will likely depend on whether space or location considerations exist in your facility.
What type of piston compressor do I need?
If the compressor will be used indoors and generally remain in the same place, your best choice is likely an electric piston air compressor. These are the most common types of compressors used in auto-body shops, manufacturing businesses, and repair and maintenance operations. When ventilation is a concern, electric compressors are the appropriate choice because they do not produce emissions. This type of compressor also tends to be quieter than their gas-powered counterparts. When portability is a priority, a gas-powered piston compressor is the better choice because it doesn’t require a source of electricity. Gas-driven compressors are commonly used to power contractors’ equipment on work sites and repair trucks.
Should I choose oil-free or oil-injected piston technology?
A major decision you will have to make is whether to use an oil-lubricated or oil-free air compressor. Oil-lubricated compressors, which leverage oil to lubricate and seal the compressors’ mechanisms and also to cool the compressed air, are suitable for a range of jobs in which traces of oil in the delivered air would cause no harm to the finished product. Examples include auto shops, woodworking and metalworking shops, as well as the majority of manufacturing, industrial and small workshops. Generally, oil-lubricated compressors are also quieter than their oil-free counterparts. But an oil-free compressor would be a better fit where delivering higher-quality, oil-free air is vital. This would include any application in which oil contact with the finished product would cause risk such as food production settings, paint shops, breweries, dental labs, and snowmaking operations.
Is the initial cost or lifecycle cost more important?
Though more expensive at the onset, keep in mind that high-quality piston compressors use durable and long-lasting components. For example, a cast iron pump on a compressor will typically last longer than an aluminum pump featuring cast iron piston sleeves. Higher-quality compressors also typically have longer warranties (usually a minimum of two years). The best warranties will cover all compressor parts against anything that might go wrong rather than specific parts with a limited range of problems. And don’t forget noise and efficiency. Typically, higher quality piston compressors offer improved efficiency and reduced levels of noise.
Maintenance Tips for Piston Air Compressor
Follow Instructions
It may seem obvious, but reading the manual for your air compressor is a small time investment with a big payoff. You’ll learn the maintenance schedule as well as operating guidelines for your compressor. With this information, you can extend the life of your equipment and minimize downtime.
Check Oil Levels Daily
For compressors that use oil, check the oil before every use. Operating with insufficient oil is a quick way to seriously damage your compressor. If oil levels are low, add more oil to top it off. (However, do not overfill — this may result in the air compressor “spitting” oil.)
Also, monitor the oil quality. If it is dirty or seems degraded, plan an oil change at the earliest opportunity. Oil should be changed for a rotary screw compressor at least annually or every 8,000 hours (every 3 months or 2,000 hours for food-grade compressor oil).
Clean Intake Vents
Keep your air intake clean, especially if your environment is dirty or dusty. Particulate from industrial processes, pollen and pollutants from the outdoors, and other indoor air contaminants (such as particulate from diesel engines) can build up on intake vents and filters. This will force your compressor to work harder and rob it of pressure. Cleaning out the intake vent and changing intake filters will reduce wear and tear on the compressor motor and extend its lifespan.
Replace the Separator Element
This separator element needs to be replaced every 2,000-8,000 hours of use (depending upon the make and model of the compressor) and prevents excessive oil usage. Analysis has shown that compressor energy costs rise by 1% for each 2 PSI of separator pressure drop.
Keep Things Tight
Vibration from compressor operation can loosen screws, nuts and bolts. Check them periodically and tighten anything that has wiggled loose. Also, listen to your compressor; excess noise or rattling may indicate that something is loose and needs to be tightened.
FAQ
Q: What is a Piston Air Compressor?
Q: What is the life expectancy of a piston air compressor?
Q: What are the 4 types of air compressor?
Rotary Screw Compressors.
Reciprocating Air Compressors.
Axial Compressors.
Centrifugal Compressors.
Q: Where are piston compressors used?
Q: What are the advantages of piston compressors?
The piston compressor has high thermal efficiency and low unit power consumption.
Strong adaptability. That is, the exhaust range of the piston compressor is wide and will not be affected by the pressure, which makes the compressor capacity meet a wide range of pressure and cooling capacity requirements.
The material requirements for piston compressor are relatively low, and it can be made by common steel materials, and it’s easy to manufacture at low cost.
The technology of piston compressor is mature, with rich experience accumulated in production and application.
The device system of piston compressor is relatively simple.
Q: What are the main steps of piston air compressor work?
Intake Stroke
In the intake stroke the piston moves from the Top Date Center ( TDS ) To the Bottom Date Center ( BDS ), which means the piston moves from top to bottom. When the piston moves to the bottom it creates a small vacuum on the cylinder head so the intake valve opens and allows the atmospheric air to enter inside the cylinder.
Compression Stroke
The compression stroke happens between BDS to TDS, which means the piston moves from bottom to top. When the piston moves to TDS the intake valve closes and the volume of air decreases due to compression. The decrease in volume causes the increase its pressure.
Discharge Stroke
The Discharge stroke happens between TDS and BDS. Which means the piston again moves from top to bottom. During this process the discharge valve opens and all compressed air moves to the storage tank through the discharge valve.
Exhaust Stroke
After the discharge stroke the piston reaches to bottom and the discharge valve closes. After this, the piston again starts moving from bottom to top, during this process the exhaust valve opens at the cylinder head and all the air ( remaining air after the closing of discharge ) valve is released into the atmosphere through the exhaust valve.
These are the four strokes the piston compressor follows to compress the air. After four strokes, the cycle continues to intake stroke, until the required amount of air is compressed. The electric motor is used to rotate the shaft, then the shaft moves the piston up and down.
Q: How can I Choose the right air compressor for my Industry?
Q: How are single-acting and double-acting different?
The single-acting model is the most common compressor, found in applications like small hobby air compressors to trucks in their pneumatic systems - even within a refrigerator. These single-acting compressors are generally oil lubricated, air-cooled with a power output limitation.
The double-acting compressors are different in that they have crossheads that generate a pure strait movement after the crankshaft & connection rod, the technology used primarily in heavy-duty industrial and process compressors ranging from 45KWA upwards.
Q: What is the working principle of single-acting piston compressor?
Single-acting recip compressors only have valves on top of the cylinder, so there is one compression cycle for every turn of the crankshaft.
Q: What are the advantages of single-acting piston air compressors?
They are typically easy to maintain.
They work great for medium duty applications
They require less traveling of the compressed air.
Q: What are the advantages of a double acting compressor?
Q: What is the difference between a single stage and two stage air compressor?
The process within a two-stage compressor is similar to that of a single-stage, but with one variation: the compressed air isn’t sent to a storage tank; it’s instead sent to a smaller piston for a second stroke, this time at roughly 175 psi. From there, the double-pressurized air is cooled and delivered to a storage tank, where it serves as energy for vast arsenals of high-powered equipment.
Q: What industry uses air compressors?
Q: What are the benefits of a piston compressor?
High pressure and high power is possible.
Can be located close to point-of-use. This avoids lengthy piping runs and pressure drops.
Affordable, durable and efficient.
Product life is significant.
Q: What factors influence the lifespan of piston air compressors?
Q: What are the functions of piston compressor?
Q: What are the main components of a piston air compressor?
Q: How to maintain a piston air compressor?
One of the most common issues with piston compressors is air leaks. To check for leaks, apply a soapy water solution to connections, hoses, and fittings. Bubbles will appear where there are leaks, allowing you to identify and repair them promptly. Addressing air leaks is crucial as they can lead to energy wastage and reduced compressor efficiency.
Change the Air Filter
The air filter in your piston compressor prevents dirt, dust, and contaminants from entering the system. Over time, these filters can become clogged, reducing airflow and causing your compressor to work harder. Regularly inspect and change the air filter according to the manufacturer's recommendations to maintain optimal performance.
Keep the Compressor Clean
Dust and debris can accumulate on the compressor's exterior, and if not removed, can make its way into the inner workings. Use a cloth or compressed air to keep the compressor clean. A clean compressor not only operates more efficiently but also extends its lifespan.
Monitor Oil Levels
If your piston compressor is oil-lubricated, it's essential to monitor oil levels regularly. Running the compressor with low or dirty oil can lead to overheating and internal damage. Check the oil level as recommended by the manufacturer and change it at specified intervals.
Tighten Loose Bolts and Fasteners
Vibrations from the compressor's operation can cause bolts and fasteners to become loose over time. Inspect and tighten all bolts and fasteners to prevent equipment damage and ensure safe operation.
Drain the Tank
Condensation can build up in the compressor's tank, leading to rust and reduced tank life. Regularly drain the tank to remove moisture and prevent corrosion. Remember to do this when the compressor is not in use to avoid accidental water discharge.
Inspect Belts and Hoses
Examine belts and hoses for wear, cracks, or damage. Replace any parts that show signs of wear and tear. Faulty belts and hoses can lead to decreased efficiency and even compressor failure.
Keep Proper Records
Maintaining records of your compressor's maintenance and performance can be a valuable tool. Note when maintenance tasks were performed and any issues or irregularities encountered. This documentation helps in troubleshooting and ensures timely maintenance.
Follow Manufacturer Recommendations
Manufacturers provide guidelines and maintenance schedules for their piston compressors. It's essential to adhere to these recommendations. They are tailored to your specific compressor model and are the best source of information for maintaining your equipment effectively.
Professional Servicing
While many maintenance tasks can be performed in-house, it's wise to have a professional compressor technician perform regular servicing. They have the expertise to identify and address potential issues and can ensure your compressor remains in top working condition.
Q: What should I pay attention to when installing a piston air compressor?
Make sure your compressor room has the equipment you need to lift heavy parts.
When you install your air compressor, leave space around the unit for proper air flow and easy access for maintenance.
Leave the red transport spacers in place during the installation process.
Keep the compressor room well-ventilated to guarantee the optimal performance of your compressor.
Make sure your main switch allows you to use lock-out tag-out protocols. Double-check you have the proper fuses installed too.
We highly recommend using cable glands. They help to protect your air compressor’s electrical wires. At the same time, they also prevent dust from sneaking into your air compressor.
Perform a rotation direction check after you’ve installed your air compressor – and every time you need to connect or reconnect the unit.
Q: What may cause the excessively hot emissions of the piston compressor?
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