savremeni razvoj konstrukcije i proizvodnje vij^anih kompresora ...
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savremeni razvoj konstrukcije i proizvodnje vij^anih kompresora ...
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Ma{instvo 2(3), 63 - 78, (1999)<br />
N.Sto{i},..: SAVREMENI RAZVOJ KONSTRUKCIJE...<br />
SAVREMENI RAZVOJ KONSTRUKCIJE I PROIZVODNJE<br />
VIJ^ANIH KOMPRESORA<br />
Prof. dr Nikola Sto{i} i mr Ahmed Kova~evi}, Centre for Positive Displacement<br />
Compressor Technology, City University, London EC1V OHB, U.K.<br />
REZIME<br />
PREGLEDNI RAD<br />
Vij~ani kompresori dominiraju u oblasti kompresije zraka, procesnih plinova i u rashladnoj tehnici.<br />
Razvoj matematskih modela i unapre|enja u oblasti ra~unarske simulacije kombinovani sa rezulatima<br />
eksperimentalnih istra`ivanja ~ine sna`an sistem za analizu procesa i optimizaciju <strong>konstrukcije</strong> vij~anog<br />
<strong>kompresora</strong>. Kao rezultat, u nekoliko zadnjih godina profil zuba rotora vij~anog <strong>kompresora</strong> zna~ajno<br />
je evoluirao i na taj na~in su pobolj{ane performanse ma{ine. Iako efikasnost rada vij~anog <strong>kompresora</strong><br />
najvi{e zavisi od profila zuba rotora kao i distribucije zazora izme|u rotora i izme|u rotora i<br />
ku}i{ta <strong>kompresora</strong>, ostale komponente, kao {to su otvori na ku}i{tu, le`ajevi, zaptivke i sistem za<br />
podmazivanje, moraju biti tako projektovani da se u potpunosti iskoristi potencijal ostvaren <strong>razvoj</strong>em<br />
profila rotora.<br />
Klju~ne rije~i: vij~ani kompresori, konstrukcija, proizvodnja<br />
RECENT DEVELOPMENTS IN SCREW COMPRESSORS<br />
Nikola Sto{i}, Ph.D. and Ahmed Kova~evi}, Ms.C., Centre for Positive<br />
Displacement Compressor Technology, City University, London EC1V OHB, U.K.<br />
SUMMARY<br />
SUBJECT REVIEW<br />
Screw compressor dominate today compression of air, process gas and refrigerants. The recent<br />
advances in mathematical modelling and computer simulation combined with experimental test data<br />
form a powerful tool for process analysis and design optimisation. As a result, the screw rotors lobe<br />
profiles have evolved over the past few years enhancing machine performance. Although an efficient<br />
operation of screw compressors is mainly dependent on a rotor profile and clearance distribution,<br />
other components, like housing, ports, bearings, seals and lubrication system sholud be designed to<br />
take advantage of their potential if the full performance gains are to be achieved.<br />
Key words: screw compressors, construction, manufacturing<br />
1 UVOD<br />
Vij~ani kompresori su rotacione volumetrijske ma{ine<br />
jednostavne <strong>konstrukcije</strong> koje mogu raditi na vrlo<br />
visokim brojevima obrtaja u {irokom dijapazonu radnih<br />
pritisaka i protoka ostvaruju}i visok stepen iskori{tenja.<br />
Oni su kompaktni i pouzdani tako da su danas na<br />
trzi{tu zastupljeni u vi{e od 80% slu~ajeva dok se u<br />
pogonu ve} nalazi oko 50% vij~anih <strong>kompresora</strong> u<br />
odnosu na ukupan broj industrijskih <strong>kompresora</strong>.<br />
Osnovni razlog za ovako zna~ajan uspjeh vij~anih<br />
<strong>kompresora</strong> na tr`i{tu valja tra`iti u savremenom <strong>razvoj</strong>u<br />
proizvodne tehnike koja je omogu}ila da se linearne<br />
tolerancije pri proizvodnji rotora preciznim profilnim<br />
glodanjem ili bru{enjem svedu na vrijednost ni`u<br />
1 INTRODUCTION<br />
Screw compressors are rotary positive displacement<br />
machines of simple design with the moving<br />
parts comprising only two rotors rotating in four<br />
to six bearings. They are capable of efficient<br />
operation at high speeds over a wide range of<br />
operating pressures and flow rates. They are<br />
therefore both reliable and compact and consequently<br />
they comprise 80% of all positive displacement<br />
compressors now sold and 50% of<br />
those currently in operation. Their remarkable success<br />
is mainly due to improvements in high accuracy<br />
profile milling and grinding which now make<br />
it possible to reduce linear tolerances to below<br />
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Ma{instvo 2(3), 63 - 78, (1999)<br />
N.Sto{i},...: SAVREMENI RAZVOJ KONSTRUKCIJE...<br />
od 10 µm. Na taj na~in se ostvaruje ekonomi~na<br />
proizvodnja rotora sa me|usobnim zazorima u granicama<br />
od 35-50 µm. Unutra{nje curenje se time svodi<br />
na mali dio vrijednosti ostvarenih u prija{njim konstrukcijama<br />
vij~anih <strong>kompresora</strong>. Kao rezultat se dobiva<br />
manji vij~ani kompresor sa ve}im stepenom iskori{tenja<br />
u pore|enju sa ostalim tipovima <strong>kompresora</strong>.<br />
Vij~ane ma{ine se danas upotrebljavaju kao kompresori<br />
ili kao ekspanderi i imaju najraznovrsnije namjene.<br />
Oni rade sa razli~itim vrstama radnih fluida koji mogu<br />
biti gasovi, pare ili vi{efazne mje{avine sa promjenom<br />
faze unutar ma{ine. Mogu raditi bez unutra{njeg podmazivanja,<br />
ili kao uljno podmazivani, ili sa drugim fluidom<br />
koji se ubrizgava u radni prostor za vrijeme<br />
procesa kompresije ili ekspanzije ili prije ili poslije njih.<br />
Da bi se postigle optimalne karakteristike <strong>kompresora</strong>,<br />
razli~ite aplikacije vij~anog <strong>kompresora</strong> zahtijevaju<br />
razli~itu konstrukciju i druk~iji na~in rada. Zbog toga<br />
nije mogu}e upotrebljavati univerzalne rotore ili izabrati<br />
univerzalne radne parametre koji }e dati optimalnu<br />
efikasnost ~ak unutar vrlo uskog dijapazona rada<br />
ma{ine. Detaljna termodinamska analiza i poznavanje<br />
uticaja razli~itih konstruktivnih parametara na karakteristike<br />
vij~ane ma{ine su, zbog raznolikosti primjene i<br />
geometrijske kompleksnosti ma{ine, sigurno mnogo<br />
zna~ajniji i slo`eniji nego u slu~aju drugih sli~nih<br />
ma{ina. Odavde slijedi da je za optimalne performanse<br />
ma{ine za odre|enu primjenu neophodno dobro<br />
postaviti optimizacione kriterije. Ovakav pristup je, isto<br />
tako, od velikog zna~aja za eventualna unapre|enja<br />
postoje}ih konstrukcija vij~anih ma{ina i za pro{irenje<br />
domena njihove primjene.<br />
10 µm. This permits rotors to be manufactured<br />
with interlobe clearances of 30-50 µm at an economic<br />
cost. Internal leakages are thus far less<br />
than in earlier machines of this type and as a<br />
result, twin screw compressors are more efficient<br />
than other types.<br />
Screw machines are used today for different applications<br />
both as compressors and expanders. They<br />
operate on a variety of working fluids which may<br />
be gases, dry vapours or multi-phase mixtures<br />
with phase changes taking place within the<br />
machine. They may operate with oil flooding, with<br />
other fluids injected during the compression or<br />
expansion process, or without any form of internal<br />
lubrication. Their geometry may vary depending<br />
on the number of lobes in each rotor, the<br />
basic rotor profile and the relative proportions of<br />
each rotor lobe segment. It follows that there is<br />
no universal configuration which would be the<br />
best for all applications. Hence, detailed thermodynamic<br />
analysis of the compression process<br />
and evaluation of the influence of the various<br />
design parameters on performance is more important<br />
to obtain the best results from these<br />
machines than from other types which could be<br />
used for the same application. It follows that a<br />
set of well defined criteria governed by an optimisation<br />
procedure is a prerequisite for achieving<br />
the best design for each application. Such guidelines<br />
are also essential for the further improvement<br />
of existing screw machine designs and<br />
broadening their range of uses.<br />
Industrijski kompresori komprimiraju zrak, rashladne<br />
fluide ili procesne plinove. Za svaku od ovih namjena<br />
konstrukcija ma{ine se mora razlikovati kako<br />
bi se postigli o~ekivani rezultati. U rashladnim<br />
ma{inama i kod kompresije procesnih plinova, gdje<br />
je vrijeme rada <strong>kompresora</strong> zna~ajno du`e od vremena<br />
stajanja, obi~no se kao osnovni preduslov<br />
postavlja visok stepen iskori{tenja <strong>kompresora</strong>. Za<br />
zra~ne kompresore, posebno u mobilnim agregatima,<br />
efikasnost mo`e biti ni`a i obi~no je manje zna`ajna<br />
od veli~ine <strong>kompresora</strong> i njegove cijene.<br />
Oblast kompresije zraka je, kako u slu`aju suhoradnih<br />
tako i u slu~aju uljno podmazivanih <strong>kompresora</strong>, gotovo<br />
isklju~ivo pokrivena vij~anim kompresorima. Situacija<br />
je vrlo sli~na i u procesnoj industriji, dok se u rashladnoj<br />
tehnici klipni i lamelni kompresori sve vi{e<br />
zamjenjuju vij~anim kompresorima, tako da se u narednim<br />
godinama mo`e o~ekivati dramati~no pove}anje<br />
zahtjeva za vij~anim rashladnim kompresorima.<br />
Veli~ina vij~anih <strong>kompresora</strong> koji se danas koriste u<br />
komercijalne svrhe je izmedju 75 i 620 mm u<br />
Typically, refrigeration and process gas compressors,<br />
which operate for long periods, must be<br />
designed to have a high efficiency. In the case of<br />
air compressors, especially for mobile applications,<br />
efficiency may be less important than size and<br />
cost.<br />
For both dry and oil free air compression, screw<br />
compressors are used almost exclusively. This is<br />
also gradually becoming the case for process gas<br />
compression. In the field of refrigeration, the use<br />
of reciprocating and vane compressors is<br />
decreasing and a dramatic increase in favour of<br />
screw machines is expected in the next few<br />
years.<br />
Screw compressors in normal commercial usage<br />
today have main rotors whose outer diameters vary<br />
between 75 mm and 620 mm. These deliver<br />
between 0.6 m3/min and 600 m 3 /min of compressed<br />
gas. The normal pressure ratios attained in a single<br />
- 64 -
Ma{instvo 2(3), 63 - 78, (1999)<br />
N.Sto{i},..: SAVREMENI RAZVOJ KONSTRUKCIJE...<br />
pre~niku vode}eg rotora. Dobava tih <strong>kompresora</strong> je<br />
izmedju 0,6 i 600 m 3 /min gasa na uslovima usisa.<br />
Odnos pritisaka je oko 3.5 za suhoradne kompresore<br />
dok se za uljnopodmazivane kre}e do 15.<br />
Uobi~ajena razlika pritisaka je do 15 bara ali se u<br />
nekim slu~ajevima de{ava da ona prelazi 40 bara.<br />
Volumetrijsko iskori{tenje uljno podmazivanih vij~anih<br />
<strong>kompresora</strong> obi~no je preko 90%, tako da je danas<br />
specifi~na snaga vij~anih <strong>kompresora</strong> svedena na<br />
vrijednosti koje su se prije samo nekoliko godina<br />
smatrale nemogu}ima.<br />
stage are 3.5:1 for dry compressors and up to 15:1<br />
for oil flooded machines. Normal stage pressure<br />
differences are up to 15 bars, but maximum values<br />
sometimes exceed 40 bars. Typically, for oil flooded<br />
air compression applications, the volumetric efficiency<br />
of these machines now exceeds 90 % while<br />
specific power inputs, which are both size and performance<br />
dependent, have been reduced to values<br />
which were regarded as unattainable only a few<br />
years ago.<br />
2 SKRIVENI DETALJI<br />
2 SCREW COMPRESSOR PRACTICE<br />
[vedska kompanija SRM je pionir u <strong>razvoj</strong>u i primjeni<br />
vij~anih <strong>kompresora</strong>. I drugi proizvo|a}i, kao<br />
{to su Compair u Velikoj Britaniji, Atlas-Copco u<br />
Belgiji, Ingersol-Rand i Denver Gardner u Americi,<br />
GHH u Njema~koj, nalaze se neposredno do njih.<br />
York, Trane, Carrier i Bitzer su vode}e kompanije<br />
koje vij~ane kompresore koriste u rashladnoj tehnici<br />
i klimatizaciji. Japanski proizvo|a}i vij~anih <strong>kompresora</strong>,<br />
kao {to su Hitachi, Mycom i Kobe-Steel su<br />
tako|er vrlo dobro poznati. U zadnje vrijeme se na<br />
Srednjem i Dalekom Istoku pojavljuje veliki broj kompanija<br />
koje se se bave vij~anim kompresorima.<br />
Otvaranjem novih tr`i{ta, u Kini i Indiji, a i u drugim<br />
zemljama u <strong>razvoj</strong>u dolazi do otvaranja fabrika<br />
vij~anih <strong>kompresora</strong>. Iako se ne bavi proizvodnjom<br />
vij~anih <strong>kompresora</strong>, Britanska kompanija Holroyd je<br />
najve}i proizvo|a} rotora za vij~ane kompresore i<br />
vode}i konstruktor i proizvo|a} alata i ma{ina za<br />
proizvodnju rotora vij~anih <strong>kompresora</strong>.<br />
Iako popularnost vij~anog <strong>kompresora</strong> raste iz dana<br />
u dan, otvorena literatura je u toj oblasti jo{ uvijek<br />
ograni~ena. Tri klasi~ne knjige o vij~anim kompresorima<br />
su publikovane na ruskom jeziku u ranim<br />
{ezdesetim godinama. [40] 1960, daje potpuni pregled<br />
na~ina generisanja kru`nog, elipti~nog i cikloidnog<br />
profila i u detalje izvodi ruski asimetri~ni<br />
profil kasnije nazvan SKBK. Na~in generisanja profila<br />
opisan u toj knjizi bazira se na takozvanom metodu<br />
obvojnice. [2] 1961. ponavlja teoriju generacije<br />
profila time daju}i svoj doprinos oblasti profilisanja<br />
alata za proizvodnju rotora. [15] je knjiga sa generalnom<br />
kompresorskom tematikom, ali je dio o<br />
vij~anim kompresorima vrlo interesantan i informativan.<br />
Priru~nik [1] na ruskom jeziku iz 1977 godine<br />
daje potpuno reproducibilan prikaz asimetri~nog<br />
SRM profila 5 godina nakon {to je ovaj patentiran<br />
skupa sa Lysholmovim profilom. Dvije knjige su publikovane<br />
na njema~kom jeziku [35] 1979, prezentira<br />
metod generacije profila baziran na teoriji zup~anika<br />
Svenska Rotor Maskiner (SRM), a Swedish company,<br />
was the pioneer and are still leaders in the field<br />
of screw compressor design and development practice.<br />
Other companies, such as Compair in the U.K,<br />
Atlas-Copco in Belgium, Ingersoll-Rand and Denver<br />
Gardner in the USA and GHH in Germany are the<br />
main air compressor manufacturers. York, Trane and<br />
Carrier in the USA lead in refrigeration and air conditioning<br />
applications. Japanese screw compressor<br />
manufacturers, such as Hitachi, Mycom and Kobe-<br />
Steel are also well known. In recent years there<br />
have been a number of mergers and buy outs of<br />
smaller companies by these larger ones. New markets<br />
in China, India and other developing countries<br />
in the Middle and Far East have led to new screw<br />
compressor companies being founded there as well<br />
as factories being built there by the major manufacturers.<br />
Although they do not manufacture compressors,<br />
Holroyd, a British company is the world's<br />
largest screw rotor manufacturer. They are also<br />
world leaders in tool design and machine tool production<br />
for the manufacture of screw compressor<br />
rotors.<br />
Despite the rapid growth in screw compressor<br />
usage, public knowledge of the scientific basis of<br />
their design is still limited. Three classical screw<br />
compressor textbooks were published in Russia in<br />
the early nineteen sixties. [40] 1960 gives a full<br />
analysis on how to generate circular, elliptic and<br />
cycloidal rotor profiles as well as a russian asymmetric<br />
profile later named SKBK. The method of profile<br />
generation in this book was based on an envelope<br />
approach. [2], 1961 demonstrates this theory<br />
and, in addition, makes a contribution to the field<br />
of rotor tool profile generation. [15], 1964, is a more<br />
general textbook but its section on screw compressors<br />
is very interesting and informative. A Russian<br />
handbook, [1], published in 1977, gives a reproducible<br />
presentation of how to generate the SRM<br />
- 65 -
Ma{instvo 2(3), 63 - 78, (1999)<br />
N.Sto{i},...: SAVREMENI RAZVOJ KONSTRUKCIJE...<br />
kako bi rekonstruisao SRM asimetri~ni profil 7 godina<br />
nakon {to je patentiran, a [23] 1988, publikuje<br />
neke in`enjerske aspekte vij~anih <strong>kompresora</strong>.<br />
Mali je broj knjiga koje se bave vij~anim kompresorima<br />
objavljen na engleskom jeziku: [32] 1993, o<br />
industrijskim kompresorima i [3] 1994 o rotacionim<br />
kompresorima sa dva vratila. Me|utim, sve one su<br />
suvi{e generalne da bi bile razmatrane kao referentna<br />
literatura o vij~anim kompresorima.<br />
Nekoliko priru~nika o vij~anim kompresorima su<br />
objavili proizvo|a}i vij~anih <strong>kompresora</strong>, isto kao i<br />
odre|eni broj bro{ura koje daju korisne informacije,<br />
ali su one ili povjerljive ili su nedostupne i daleko<br />
od javnosti. Neke od njih, kao {to je, na primjer,<br />
SRM Data Book, ina~e dobro ~uvane i dostupne<br />
samo licensorima, ~esto su citirane kao literatura iz<br />
oblasti vij~anih <strong>kompresora</strong>.<br />
Me|utim, broj patenata koji su se pojavili u zadnjih<br />
trideset godina je neproporcionalno velik, mo`e se<br />
re~i da je patenata objavljeno na hiljade. Samo je<br />
SRM objavio 750 patenata. Svi se patenti bave<br />
razli~itim aspektima vij~anih <strong>kompresora</strong> a njihov<br />
najve}i broj profilima rotora. SRM je objavio patente<br />
[33] 1946 simetri~nog, [41] 1973 za asimetri~ni i [4]<br />
1982 za "D" profil. Oni su klasi~na referentna literatura<br />
koja prikazuje vje{tinu profilisanja rotora<br />
vij~anog <strong>kompresora</strong>. Jo{ neki patenti mogu se<br />
spomenuti kao primjer uspje{nog na~ina generacije<br />
profila: Atlas-Copco, Compair [19], Denver Gardner<br />
[9], Hitachi [20], Ingersol-Rand. U posljednjih je<br />
nekoliko godina jedan broj relativno malih kompanija<br />
objavio vi{e izuzetno uspje{nih patenata, kao {to<br />
su, na primjer, [24] i [8]. Potpuno novi pristup generaciji<br />
profila po kojem se polazne krive zadaju na<br />
zup~astom stapu objavljen je u [37] i u [50].<br />
Svi patentirani profili su generisani na osnovu neke<br />
valjane metode, ali su korisne informacije o<br />
kori{tenim metodama pa`ljivo uklonjene iz patenta ili<br />
iz prate}ih publikovanih radova. Informacije u patentima<br />
su ili sakrivene ili je iz njih gotovo nemogu}e<br />
direktno dobiti profil. Ova se ~injenica mo`e ilustrovati<br />
kroz tri primjera. U radu [29] 1978 objavljuje<br />
se izvodjenje simetri~nog kru`nog profila koji je<br />
patentiran 32 godine prije toga. U [35] se koristi<br />
klasi~nim uslovima sprezanja konjugovanih zup~anika<br />
da bi reprodukovao asimetri~ni SRM profil 9 godina<br />
nakon {to se patent pojavio. Kao kuriozitet mo`e se<br />
pomenuti da je jedan SRM-ov licencor, nakon 13<br />
godina <strong>proizvodnje</strong> <strong>kompresora</strong>, iskoristio sav<br />
akademski potencijal kako bi analiti~ki reprodukovao<br />
SRM "D" profil.<br />
asymmetric profile only 5 years after it was patented<br />
as well as the classical Lysholm profile. There<br />
are two German textbooks. [35], 1979, used a profile<br />
generation method based on gear theory to<br />
reconstruct the SRM asymmetric profile 7 years after<br />
it was patented. [23], 1988, published some engineering<br />
aspects of screw compressors.<br />
Only recently have any textbooks on screw compressors<br />
been published in English. [32], 1993, was<br />
on industrial compressors and [3], 1994, was on<br />
rotary twin shaft compressors. However, these are<br />
too general to be useful as detailed reference literature.<br />
A few compressor manufacturers' handbooks on<br />
screw compressors and a number of brochures give<br />
useful information, but they are either classified or<br />
of very limited accessibility. Some, like the SRM<br />
Data Book, although cited in screw compressor literature,<br />
are available only to SRM licencees.<br />
Literally thousands of patents have been awarded<br />
on screw compressors in the past thirty years and<br />
SRM alone has 750. They cover various aspects of<br />
screw compressor design but are mainly for rotor<br />
profiles. SRM patents [33], 1946, for symmetric,<br />
[41], 1973, for asymmetric and [4], 1982, for the<br />
"D" profiles are classical examples of state of the<br />
art screw compressor profile generation. Other<br />
succesful profiling patents are those of Atlas-Copco,<br />
Compair [19], Denver Gardner [9], Hitachi [20] and<br />
Ingersoll-Rand [6]. In recent years, several highly<br />
successful patents such as [24] and [8] have been<br />
granted to relatively small companies. A fresh<br />
approach to profile generation based on the use of<br />
a rack for the primary curves was published in [37]<br />
and [50].<br />
Although all patented profiles were generated by<br />
well defined procedures, so little of the methods on<br />
which they were based was published that it was<br />
very difficult to reproduce them. Thus details of how<br />
to derive the circular symmetric profile, [29], were<br />
not published until 1978, 32 years after it was<br />
patented. Similarly, a derivation of the SRM asymmetric<br />
profile based on classical gear conjugacy criteria,<br />
[35], was not published until 9 years after the<br />
patent appeared. It is even more interesting to note<br />
that one SRM licencee funded a university research<br />
programme to obtain an analytical derivation of the<br />
SRM "D" profile in 1995, after 13 years of manufacturing<br />
it.<br />
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Ma{instvo 2(3), 63 - 78, (1999)<br />
N.Sto{i},..: SAVREMENI RAZVOJ KONSTRUKCIJE...<br />
Me|u patentima iz podru~ja vij~anih <strong>kompresora</strong> mogu<br />
se na}i i oni koji se bave drugim aspektima ove<br />
oblasti. Uglavnom su patentirane sve dobro poznate<br />
karakteristike vij~anih <strong>kompresora</strong>, kao {to je ubrizgavanje<br />
ulja, usisni i tla~ni otvori koji prate helikoidu<br />
rotora, kompenzacija aksijalnih sila, rastere~enje <strong>kompresora</strong>,<br />
usisni klip, ekonomajzerski otvor, uglavnom od<br />
strane SRM-a, ali i neke druge kompanije tako|er vrlo<br />
revnosno objavljuju patente. Izgleda da patentni<br />
stru~njaci za vij~ane kompresore imaju isti ili sli~an<br />
zna~aj kao i in`enjeri koji se bave njihovim <strong>razvoj</strong>em.<br />
Iako su ~lanci o vij~anim kompresorima rijetkost u<br />
~asopisima, oni su izuzetno korisna literatura o kompresorima<br />
mada ne odaju mogo detalja o profilisanju<br />
vij~anih <strong>kompresora</strong>. Tako Lysholmovi klasi~ni ~lanci<br />
[26] iz 1942 i [27] iz 1966 ne spomenju ni jedan detalj<br />
o profilisanju koje je autor koristio u svojoj uspje{noj<br />
praksi da bi pobolj{ao zaptivenost <strong>kompresora</strong>. ^lanci<br />
[45] i [46] se mogu vi{e smatrati izuzetkom nego praksom.<br />
U posljednje vrijeme je objavljivano ne{to vi{e<br />
materijala o vij~anim komopresorima u ~asopisima, {to<br />
je podstaknuto od strane nekoliko institucija, kao {to<br />
su International Institution of Refrigeration [15] i [48],<br />
IMechEng [44], [12], [13], [55] i [57] i ASME [16] i [51].<br />
Ovakvom aktivno{}u je u nekoliko zadnjih godina u<br />
~asopisima distribuirano vi{e informacija o vij~anim<br />
kompresorima nego {to je objavljeno tokom svih<br />
prethodnih godina zajedno. [52] je primjer ~lanka koji<br />
je objavljen u skladu sa najmodernijim trendovima vremenski<br />
dobro izabranog trenutka za publikovanje.<br />
Tri kompresorske konferencije su u potpunosti ili djelomi~no<br />
orjentisane na vij~ane kompresore: Purdue<br />
Compressor Technology Conference u Lafayette, SAD,<br />
IMechEng konferencija o industrijskim kompresorima u<br />
Londonu, Engleska i "VDI Schraubenkompressoren<br />
Tagung" u Dortmundu, Njema~ka. Usprkos obilju<br />
~lanaka o vij~anim kompresorima, samo mali broj<br />
~lanaka sa konferencija daje korisne informacije o profilisanju<br />
rotora vij~anog <strong>kompresora</strong> i o konstrukcijama<br />
<strong>kompresora</strong>. Svi ~lanci sa konferencija daju valjan<br />
prikaz obavljenih istra`ivanja ali skoro ni jedan od njih<br />
ne daje reproducibilne informacije koje se odnose na<br />
kori{tene metode profilisanja. ^lanci kakakteristi~ni za<br />
Purdue konferenciju su oni koji se vrlo ~esto citiraju,<br />
ali iz kojih ~italac mo`e saznati vrlo malo o generaciji<br />
profila, kao {to su: [11], [47] i [49], a tako|er i [42],<br />
[43], [53] i [56]. ^lanci [34], [58], [59] i [60] ukazuju na to<br />
da je teorija obvojnice naj~e{}e kori{tena metoda za<br />
izra~unavanje geometrijskih karakteristika rotora. U<br />
zbornik radova sa Dortmundske konferencije nalazi se<br />
odre|eni broj vrlo interesantnih ~lanaka o vij~anim<br />
kompresorima. [36] iz 1984 prezentira na~in generisanja<br />
profila na bazi zup~astog {tapa pri ~emu daje<br />
potpuno reproducibilan patent [37] baziran na klasi~noj<br />
Most of the well known characteristics of screw<br />
compressors, such as oil flooding, making the suction<br />
and discharge ports follow the rotor tip helices,<br />
axial force compensation, unloading, the slide valve<br />
and the economizer port, were also patented, mainly<br />
by SRM. However other companies were equally<br />
keen to file patents. It appears that, in the field<br />
of screw compressors, patent experts are as important<br />
as engineers.<br />
There are surprisingly few journal publications on<br />
screw compressors in the technical literature.<br />
Notable exceptions are Lysholm's [26-27] classical<br />
papers of 1942 and 1966. However neither of<br />
these described any of the profiling details which<br />
he developed successfully in order to reduce the<br />
blow-hole area. Other exceptions are [45] and<br />
[46]. In recent years, journal publication of screw<br />
compressor material has been encouraged by the<br />
International Institution of Refrigeration [15] and<br />
[48], the IMechE [44], [12], [13], [55] and [57] and<br />
ASME [16] and [51]. This led to more information<br />
on screw compressors in journals during<br />
recent years than in all previous years together.<br />
[52] is an example of the modern practice of more<br />
timely publishing.<br />
There are three compressor conferences which deal<br />
exclusively or partly with screw compressors. These<br />
are: the Purdue University compressor technology<br />
conferences in the U.S.A, the ImechE conferences<br />
on industrial compressors in England and the "VDI<br />
Schraubenkompressoren Tagung" in Germany.<br />
Despite the wealth of screw compressor papers<br />
which these contain, very few give useful information<br />
on rotor profiling procedures and compressor<br />
design.<br />
Typical Purdue papers, frequently cited, from which<br />
a reader will gain a little on profile generation are:<br />
[11], [47] and [49] , also [42], [43], [53], [56]. Refs<br />
[34], [58], [59], and [60] indicate that envelope theory<br />
was used to calculate some geometric features<br />
of their rotors.<br />
The "VDI Schraubenkompressoren Tagung" proceedings<br />
contain some interesting screw compressor<br />
papers. [36] 1984 presents a rack method<br />
of rotor profile generation, based on classical<br />
gearing theory, which is fully reproducible.<br />
Unfortunately, although soundly conceived, profiles<br />
produced by this method were not commercially<br />
successfull because of their poor tightness. [16]<br />
and [18] give some more details on profiling and<br />
manufacturing control. [21], [22] and [54] are typi-<br />
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teoriji zup~anika. Me|utim, na`alost, na prikazani na~in<br />
dobiveni profil, iako baziran na odli~nim osnovama<br />
nema velik komercijalni zna~aj zbog vrlo slabog zaptivanja.<br />
[16] i [18] daju ne{to vi{e detalja o profilisanju<br />
i kontroli <strong>proizvodnje</strong>. [21], [22] i [54] su tipi~ni primjeri<br />
uspje{nog akademskog istra`ivanja primjenjenog na<br />
stvarno in`enjerstvo. [38] i [39] se mogu nazvati primjerom<br />
prakti~ne primjene preciznog in`enjerskog<br />
rada. Londonska kompresorska konferencija, iako ne<br />
tako u~estala, dala je nekoliko vrlo interesantnih ~lanaka<br />
kao {to je, na primjer [10].<br />
Mnoge referentne knjige o zup~anicima su korisna<br />
polazna osnova za profilisanje rotora vij~anog <strong>kompresora</strong>,<br />
ali je ve~ina od njih ograni~ena na klasi~e<br />
uslove sprezanja zup~anika. Kao primjer se mo`e<br />
ista}i klasi~na knjiga [7]. Knjiga [25] se mo`e smatrati<br />
izuzetkom od ovog pravila jer daje teoriju<br />
sprezanja zup~anika koja se direktno mo`e primijeniti<br />
i na profilisanje rotora vij~anog <strong>kompresora</strong>.<br />
3 SAVREMENI RAZVOJ VIJ^ANOG<br />
KOMPRESORA<br />
Efikasan rad vij~anog <strong>kompresora</strong> uglavnom zavisi<br />
od pravilne <strong>konstrukcije</strong> njegovih rotora. Dodatno se<br />
kao uslov za uspje{nu konstrukciju razli~itih vrsta<br />
<strong>kompresora</strong> postavlja i sposobnost da se radne<br />
karakteristike mogu precizno predvidjeti u slu~aju da<br />
se promijeni bilo koji parametar kao {to je na primjer<br />
zazor, oblik profila rotora, pozicija i koli~ina<br />
ubrizganog ulja ili nekog drugog fluida u radni prostor,<br />
pre~nik i proporcija rotora i brzina obrtanja.<br />
Danas, kad su zazori u kompresoru mali, unutra{nje<br />
curenje koje ima veliki uticaj na efikasnost sve vi{e<br />
zavisi od du`ine linije dodira rotora, tako da kao<br />
mogu}nost za pobolj{anje <strong>kompresora</strong> ostaje jo{<br />
samo bolje profilisanje rotora. Tako se posebna<br />
pa`nja posve}uje unapredjenju karakteristika rotora<br />
da se, {to je god vi{e mogu}e, pove}a unutra{nji<br />
protok <strong>kompresora</strong> a da se linija dodira izmedju<br />
rotora smanji, te da se istovremeno unutra{nje trenje<br />
usljed relativnog klizanja dodirnih povr{ina rotora<br />
u~ini {to je mogu}e manjim.<br />
Mada na prvi pogled izgleda da je u profilisanju rotora<br />
dosad u~injeno sve {to je bilo mogu}e, to je<br />
daleko od istine. U stvari, ima jo{ mnogo prostora za<br />
zna~ajna pobolj{anja. ^ini se da na~in profilisanja koji<br />
kao polaznu osnovu uzima zup~asti {tap, ima najvi{e<br />
izgleda da postigne najbolje rezultate jer se njime<br />
mogu dobiti ja~i i lak{i rotori sa ve}om dobavom i<br />
manjim kontaktnim naponima. Ovo posljednje<br />
omogu}ava da se u radni prostor kompreora ubrizgava<br />
fluid ni`e viskoznosti.<br />
Kori{tenjem metoda vi{eparametarske optimizacije<br />
dobivaju se sve bolje oblikovani otvori na ku~i{tu<br />
vij~anog <strong>kompresora</strong>. Time se smanjuju gubici na<br />
cal examples of successful university research<br />
applied to solve real engineering problems. [38]<br />
and [39] may be regarded as examples of fine<br />
engineering work.<br />
Although relatively infrequent, the London compressor<br />
conferences included some interesting papers,<br />
such as [10].<br />
Many reference textbooks on gears give a useful<br />
background to screw rotor profiling. However all of<br />
them are limited to the classical gear conjugate<br />
action condition. One example of this is [7]. [25] is<br />
an exception to this practice which contains gear<br />
theory directly applicable to screw compressor profiling.<br />
3 RECENT DEVELOPMENTS<br />
The efficient operation of screw compressors is<br />
mainly dependent on proper rotor design. An additional<br />
and important requirement for the successful<br />
design of all types of compressor is the ability to<br />
predict accurately the effects on performance of<br />
the change in any design parameter such as clearance,<br />
rotor profile shape, oil or fluid injection position<br />
and rate, rotor diameter and proportions and<br />
speed.<br />
Now that tight clearances are achievable, internal<br />
compressor leakage rates become small. Hence, further<br />
improvements are only possible by the introduction<br />
of more refined design principles. The main<br />
requirement is to improve the rotor profiles so that<br />
the internal flow area through the compressor is maximised<br />
while the leakage path is minimised and internal<br />
friction due to relative motion between the contacting<br />
rotor surfaces is made as small as possible.<br />
Although rotor profiling procedures may appear to be<br />
fully defined, substantial improvements are still possible.<br />
The most promising approach for this seems<br />
to be through rack profile generation which gives<br />
stronger but lighter rotors with higher throughput and<br />
lower contact stress. The latter enables fluids with<br />
lower viscosity than oil to be used for lubrication.<br />
Rotor housings with better shaped ports can be<br />
designed using multivariable optimization techniques.<br />
Flow losses may thereby be reduced permitting<br />
higher rotor speeds and hence more effective compressors.<br />
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usisu i na izlazu {to omogu}ava pove}anje broja<br />
obrtaja <strong>kompresora</strong>, a time se direktno pove~ava i<br />
njegova efektivnost.<br />
Zna~ajni uspjesi su u nekoliko zadnjih godina postignuti<br />
i u <strong>razvoj</strong>u le`ajeva za kompresore, ~ime je omogu}eno<br />
podmazivanje <strong>kompresora</strong> fluidom viskoznosti<br />
manje nego kod obi~no kori{tenih ulja. Zaptiva~i su,<br />
takodjer, mnogo efikasniji nego ranije. Sve ovo je dalo<br />
dobru osnovu za efikasniji rad <strong>kompresora</strong>.<br />
3.1 Profili rotora<br />
Naj~e{}e kori{ten metod generacije profila rotora<br />
vij~anog <strong>kompresora</strong> je da se defini{e primarni profil<br />
na jednom od rotora a da se nakon toga tra`e<br />
odgovaraju}e krive na drugom rotoru primjenom<br />
razli~itih uslova sprezanja. Na osnovnom rotoru je<br />
mogu}e definisati bilo koju krivu liniju ali je tradicionalno<br />
naj~e{}e kori{tena kriva upravo kru`nica.<br />
Bilo koja kru`nica sa centrom na podionom krugu<br />
generisa}e sli~nu kru`nicu na drugom rotoru. Ista<br />
situacija se dobije ako je centar kru`nice u osi rotora.<br />
Kru`nice sa centrom van podionog kruga na isti<br />
na~in kao i ostale krive: elipsa, parabola ili hiperbola<br />
proizve{}e na drugom rotoru neku generisanu<br />
krivu, koja se naziva trohoida. Sli~no tome, ta~ka<br />
koja je fiksirana na jednom rotoru generisa}e epi- ili<br />
hipocikloidu na drugom rotoru. Sva vje{tina profilisanja<br />
rotora se decenijama svodila na pravilan izbor<br />
primarnih krivih na jednom rotoru koje }e omogu}iti<br />
izvo|enje odgovaraju}eg profila na drugom rotoru.<br />
Kru`ni simetri~ni profil se sastoji samo od kru`nica,<br />
dok se Lysholmov profil, osim od kru`nica postavljenih<br />
u centar podionog kruga, sastoji od sistema<br />
cikloida na strani visokog pritiska ~ime je dobiven<br />
prvi asimetri~ni profil rotora vij~anog <strong>kompresora</strong>. Za<br />
asimetri~ni SRM profil je prvi put iskori{tena ekscentri~na<br />
kru`nica na strani niskog pritiska na<br />
vo|enom rotoru dok je na SKBK profilu isto ura|eno<br />
na vode}em rotoru. U oba slu~aja su izvedene krive<br />
analiti~ki definisane kao epi- ili hipocikloide. SRM<br />
"D" profil se sastoji samo od kru`nica od kojih su<br />
neke sasvim male, ali su sve ekscentri~no postavljene<br />
na vode}em ili vo|enom rotoru. Svi patenti koji<br />
slijede nakon toga baziraju se na definisanju jednog<br />
od rotora i izvo|enju drugog, i svi su, vjerovatno,<br />
bazirani na klasi~nom sprezanju zup~anika ili na<br />
nekim sli~nim uslovima. Tek u posljednje vrijeme<br />
kru`nice su postepeno zamjenjuju nekim drugim<br />
krivuljama kao {to su: elipsa kod FuSheng profila<br />
[24], parabola na Compair [19] i Hitachi profilima i<br />
hiperbola na "hyper" profilu [8]. ^ini se da je hiperbola<br />
na posljednjem profilu odgovaraju}a zamjena za<br />
ostale krive, jer daje najbolji odnos dobave rotora i<br />
du`ine linije zaptivanja.<br />
3.1 Rotor Profiles<br />
The normal procedure used to generate rotor profiles<br />
is to create primary profile curves on one rotor<br />
and, by use of an appropriate conjugate criterion,<br />
a corresponding secondary profile curve on the<br />
other. Any curve can be used as the primary one,<br />
but traditionally a circle is the most comon. All circles<br />
with their centres on the pitch circle generate<br />
a similar circle on the other rotor. This is also true<br />
if the circle centres are at the rotor axes. Circles<br />
with centres not on the pitch circle and other<br />
curves, like ellipses, parabolae and hyperbolae<br />
require more elaborate curves to be generated, on<br />
the other rotor which are described as trochoids.<br />
Similarly, points located on one rotor will cut epior<br />
hypocycloids on the other rotor. For decades,<br />
the skill required to produce rotors was limited to<br />
the ability to choose a primary arc which would<br />
permit the derivation of an appropriate secondary<br />
profile.<br />
The symmetric circular profile consist of circles only.<br />
Apart from the use of pitch circle centred circles,<br />
Lysholm introduced a set of cycloids on the high<br />
pressure side to form the first asymmetric screw<br />
rotor profile. Later the SKBK profile used the same<br />
curves. The SRM asymmetric profile employs an<br />
eccentric circle on the low pressure side of the<br />
gate rotor. In all these cases the curves evolved<br />
analytically from them were epi- or hypocycloids.<br />
The SRM "D" profile consists exclusively of circles,<br />
almost all of them eccentrically positioned on the<br />
main or gate rotor. All patents which followed, specify<br />
primary curves on one rotor and secondary generated<br />
curves on the other rotor. All are probably<br />
derived from classical gear contact theory or a similar<br />
alternative criterion. More recently, circles have<br />
gradually been replaced by other curves such as<br />
ellipsae in the FuSheng profiles [24], parabolae in<br />
the Compair [19] and Hitachi [20] profiles and hyperbolae<br />
in the 'Hyper' [8] profile. Replacing the circle<br />
by a hyperbola in the latest profile, seems to give<br />
the best ratio of rotor displacement to sealing line<br />
length.<br />
Another method of rotor profile generation is to<br />
consider imaginary, or 'nonphysical' rotors. Since<br />
all gearing equations are independent of the coordinate<br />
system in which they are expressed, it is<br />
possible to define primary arcs as given curves<br />
using a coordinate system which is independent of<br />
both rotors. By this means, in many cases the<br />
defining equations may be simplified. Also, the<br />
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Drugi na~in na koji je mogu}e definisati profil rotora<br />
je da se osnovne krive izaberu na nekom<br />
zami{ljenom, "nefizikalnom" rotoru. Po{to su sve<br />
jedna~ine zup~anika neovisne od koordinatnog sistema<br />
u kojem su izra`ene, primarni luk je mogu}e<br />
definisati i u nekom koordinatnom sistemu koji je ne<br />
ovisi ni o jednom rotoru. U ve~ini slu~ajeva se na<br />
taj na~in jedna~ine mogu pojednostaviti. Upotreba<br />
jednog koordinatnog sistema za definisanje svih krivih<br />
na rotoru tako|er mo`e pojednostaviti proces<br />
profilisanja. Tako se polazni profil u cijelosti mo`e<br />
definisati u koordinatnom sistemu koji ne zavisi od<br />
rotora, {to vrijedi i za rotor sa beskona~nim<br />
pre~nikom koji se naziva zup~asti {tap. Prvi ikada<br />
publikovani patent koji prikazuje ovakvu generaciji<br />
profila rotora [30] objavljen 1977, iako nije prakti~no<br />
primjenljiv, vje{to koristi pomenutu teoriju. [37] i kasnije<br />
[50] prvi daju dobru osnovu za generaciju profila<br />
vij~anog <strong>kompresora</strong>.<br />
Efikasan vij~ani kompresor mora imati rotore ~iji profil<br />
osigurava veliki proto~ni presjek, kratku liniju zaptivanja<br />
i mali nezaptiveni prostor na vrhu rotora. To<br />
zna~i, da je za ve}i proto~ni presjek i broj obrtaja<br />
<strong>kompresora</strong>, i dobava <strong>kompresora</strong> ve}a. Kra}e linije<br />
dodira i manji nezaptiveni prostor smanji}e unutra{nje<br />
curenje. Ve}a dobava i manje curenje }e pove}ati<br />
volumetrijski stepen iskori{tenja <strong>kompresora</strong>, koji je<br />
defini{an kao dobava podijeljena zbirom ukupnog<br />
protoka i curenja. Time se dalje pove}ava adijabatski<br />
stepen iskori{tenja, jer se za kompresiju gasa koji<br />
recirkuli{e unutar <strong>kompresora</strong> tro{i manje snage.<br />
Izbor odnosa veli~ine nezaptivenog prostora i broja<br />
radnih zapremina zavisi}e od namjene <strong>kompresora</strong>.<br />
Kako je za manje razlike pritisaka curenje proporcionalno<br />
manje, dobici postignuti velikim proto~nim<br />
presjekom mogu poni{titi ili smanjiti gubitke nastale<br />
usljed velikog nezaptivenog prostora. Na sli~an na~in<br />
se mo`e dobiti optimalni broj zuba vij~anog <strong>kompresora</strong>,<br />
po{to manji broj zuba daje ve}i proto~ni<br />
presjek ali i rezultira u ve}oj razlici pritiska izme|u<br />
radnih prostora.<br />
Sa smanjenjem zazora izmedju rotora, bez obzira na<br />
podmazivanje <strong>kompresora</strong> uljem, vjerovatno}a direktnog<br />
dodira me|u rotorima sa pove}ava. Dodir<br />
me|u rotorima dovodi do pove}anja kontaktnih sila i<br />
optere}enja rotora {to dalje uzrokuje deformaciju<br />
vo|enog rotora. Zbog toga, njegov profil mora biti<br />
konstruisan tako da se rizik od pucanja ili plasti~ne<br />
deformacije rotora smanji na najmanju mogu}u mjeru.<br />
Brzi <strong>razvoj</strong> metoda matematskog modeliranja i<br />
ra~unarske simulacije je, u posljednje vrijeme, podstakao<br />
i olak{ao istra`ivanje novih profila rotora.<br />
use of one coordinate system to define all the<br />
curves, simplifies the design process. Typically, the<br />
template is specified in a rotor independent coordinate<br />
system. This is valid for a rotor of infinite<br />
radius, which is a rack. From this, a secondary arc<br />
on some of the rotors is obtained by a procedure,<br />
which is called 'rack generation'. The first patent<br />
on rack generation published, [30], is based on<br />
this theory but lacks practicality. [37] and, more<br />
recently, [50] give a good basis for rotor profile<br />
generation.<br />
For a screw compressor to be efficient, the rotor<br />
profile must form a large flow cross section area, a<br />
short sealing line and a small blow-hole area. The<br />
larger the cross section area, the higher the flow<br />
rate for the same rotor sizes and speeds. Shorter<br />
sealing lines and a smaller blow-hole reduce leakages.<br />
Higher flow and smaller leakage rates both<br />
increase the compressor volumetric efficiency, which<br />
is the rate of flow delivered as a fraction of the<br />
sum of the flow plus leakages. This in turn increases<br />
the adiabatic efficiency because less power is<br />
wasted in the compression of gas which is recirculated<br />
internally.<br />
The optimum choice between blow hole and flow<br />
areas depends on the compressor duty since, for<br />
low pressure differences, the leakage rate will be<br />
relatively small and hence the gains achieved by<br />
a large cross section area may outweigh the losses<br />
associated with a larger blow-hole. Similar considerations<br />
determine the best choice for the number<br />
of lobes since fewer lobes imply greater flow<br />
area but increased pressure difference between<br />
them.<br />
As precise manufacture permits rotor clearances to<br />
be reduced, despite oil flooding, the likeliehood of<br />
direct rotor contact is increased. Hard rotor contact<br />
leads to deformation of the gate rotor, increased<br />
contact forces and ultimately rotor seizure. Hence<br />
the profile should be designed so that the risk of<br />
seizure is minimised.<br />
The search for new profiles has been both stimulated<br />
and facilitated by recent advances in mathematical<br />
modelling and computer simulation. These<br />
analytical methods may be combined to form a<br />
powerful tool for process analysis and optimisation<br />
and thereby eliminate the earlier approach of intuitive<br />
changes, verified by tedious trial and error testing.<br />
As a result, this approach to the optimum<br />
design of screw rotor lobe profiles has substantial-<br />
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Analiti~ke metode je mogu}e kombinovati na taj<br />
na~in da se dobije mo}no sredstvo za analizu i optimizaciju<br />
procesa vij~anog <strong>kompresora</strong>, ~ime se u<br />
potpunosti mo`e zaobi}i ranije kori{tena metoda intuitivne<br />
<strong>konstrukcije</strong> zasnovana na mukotrpnom metodu<br />
poku{aja i pogre{ke. Kao rezultat, ovaj pristup optimalnom<br />
konstruisanju rotora vij~anog <strong>kompresora</strong><br />
zna~ajno je evoluirao u nekoliko zadnjih godina sa<br />
velikim {ansama da se u narednim godinama<br />
postignu dalja pobolj{anja karakteristika ma{ine.<br />
Me|utim, i geometrija rotora, isto kao i radni proces<br />
u vij~anom kompresoru su toliko kompleksni da je<br />
potrebno uvesti niz aproksimacija kako bi modeliranje<br />
bilo ostvarivo. Kao posljedica, u otvorenoj literaturi<br />
se mogu na}i matematski modeli i numeri~ki<br />
kodovi sa vrlo {arolikim pristupom problemu i sa<br />
razli~itim matematskim nivoima modeliranja fenomena<br />
u vij~anom kompresoru. Nedostatak uporedivih<br />
eksperimentalnih rezultata jo{ uvijek onemogu}ava<br />
verifikaciju i svestranu ocjenu razli~itih koncepcija<br />
modeliranja. Uprkos tome, matematsko modeliranje i<br />
simulacija ra~unarom sve vi{e dobivaju na popularnosti<br />
i sve se vi{e koriste za unapre|enje konstruktivnih<br />
karakteristika vij~anog <strong>kompresora</strong>.<br />
Na slici 1. prikazan je niz rotora vij~anog <strong>kompresora</strong><br />
tako da se oni mogu me|usobno usporediti.<br />
Profili su ozna~eni brojevima u zagradama, koji u<br />
popisu literature ukazuju na patente za te rotore.<br />
U prvu prikazanu grupu spadaju rotori sa 4 zuba na<br />
vode}em i 6 zubi na vo|enom rotoru. Ovakva konfiguracija<br />
rotora je kori{tena skoro za svaku aplikaciju.<br />
Asimetri~ni SRM profil [41], koji se mo`e smatrati<br />
do sada najuspje{nijim profilom rotora vij~anog<br />
<strong>kompresora</strong>, nalazi se na po~etku. Slijede}i je SRM<br />
"D" profil [4]. Na kraju je prikazan profil generisan<br />
na osnovu zup~astog {tapa - rack generisan profil<br />
[50]. Izbor i raspored osnovnih krivih na zup~astom<br />
{tapu pomo}u kojih su generisani ovi rotori daje<br />
ve}i popre~ni presjek me|uzublja i ja~i zub vo|enog<br />
rotora u odnosu bilo koji drugi poznati profil rotora<br />
vij~anog <strong>kompresora</strong> ove konfiguracije.<br />
Konfiguracija vij~anog <strong>kompresora</strong> sa 5 zubi vode}eg<br />
i 6 zubi vo|enog rotora postaje sve popularnija, jer<br />
se njome postize kompromis izmedju velike dobave i<br />
velikog tla~nog otvora sa skoro nenadma{nim strujnim<br />
karakteristikama za manji pre~nik rotora.<br />
Kompresori sa ovakvom konfiguracijom rotora su jednako<br />
pogodni za kompresiju zraka kao i za rashladnu<br />
tehniku ili za klimatizaciju. U nastavku je, radi<br />
upore|enja, data ve}a skupina ovih rotora koja<br />
po~inje sa SRM "D" profilom [4], nakon toga slijede<br />
"Sigma" profil [5], FuSheng [24] i "Hyper" profil [8].<br />
Svi ovi profili su 'rotor generisani' profili a osnovna<br />
ly evolved over the past few years and is likely to<br />
lead to further improvements in machine performance<br />
in the near future.<br />
A comparison of several pairs of screw compressor<br />
rotors is shown in Fig. 1. Each pair is labeled by<br />
a number in brackets which denotes its patent.<br />
The first group gives rotors with 4 lobes on the<br />
main and 6 lobes on the gate rotor. This rotor configuration<br />
is the most universally accepted for almost<br />
any application. The SRM asymmetric profile [41],<br />
which historically was the most successful, is on the<br />
top. The next one is the SRM "D" profile [4]. The<br />
Ingersol-Rand profile, [6], shows how attempts were<br />
made to produce more displacement from the same<br />
compresor size. Finally, rack generated rotors [50]<br />
are presented.<br />
The second group shown are 4/5 rotors which is<br />
becoming a very popular combination for oil-flooded<br />
air compressors. The first pair, SRM "D" [4]<br />
rotors are applied in "Tamrotor" compressors which<br />
are regarded as best compressors in their class.<br />
They are followed by "Cyclon" [19] rotors. The last<br />
in this group are 'rack-generated' rotors [50]. The<br />
selection and distribution of primary curves on the<br />
rack which was used to create these rotors, gives<br />
a larger cross section area with stronger gate rotor<br />
lobes than any other known screw compressor<br />
rotor pair.<br />
The largest group of rotors presented has a 5/6<br />
configuration. This is becoming the most popular<br />
rotor combination because it permits a good compromise<br />
between large displacement and large discharge<br />
ports with favourable load characteristics in<br />
small rotor sizes. These rotors are equally successful<br />
for air compression and refrigeration and air-conditioning<br />
applications. The group starts with the SRM<br />
"D" profile, [4], followed by the "Sigma", [5],<br />
FuSheng, [24] and "Hyper" [8] profiles. All are 'rotorgenerated'<br />
profiles and the main diference between<br />
them is in the leading lobe which is mainly an<br />
eccentric circle followed by a line, ellipse and<br />
hyperbola respectively. The hyperbola appeared to<br />
be the best possible geometrical solution for that<br />
purpose. However at the end of the group are two<br />
rack-generated profiles, [37] and [50]. The last of<br />
these shows the best delivery for its size. it also<br />
has two additional features. Firstly, the rotors retain<br />
a seal over the entire contact length while maintaining<br />
a small blow-hole, which was not the case<br />
in [37]. Secondly, two contact bands in the prox-<br />
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Slika 1. Upore|enje nekih rotora vij~anih <strong>kompresora</strong><br />
Figure 1. A comparison of several pairs of screw compresor rotors<br />
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razlika izme|u njih se uo~ava na vode}em rotoru koji<br />
po~inje sa ekscentri~nom kru`nicom a nastavlja se<br />
linijom, elipsom ili hiperbolom respektivno. Pokazuje<br />
se da je hiperbola najbolje mogu}e primjenjivo<br />
geometrijsko rje{enje. Na kraju grupe se nalaze dva<br />
'rack generisana' profila [37] i [50]. Mo`e se vidjeti da<br />
posljednji profil ima najve}u dobavu. Tako|er, mogu<br />
se uo~iti jo{ dvije osobine koje karakteri{u te rotore<br />
i favorizuju ih u odnosu na ostale. Postignuto je zaptivanje<br />
du` cijele linije dodira i time manji nezaptiveni<br />
prostor, {to nije slu~aj kod profila [37]. Dodatno, kontaktne<br />
povr{ine sa jedne i druge strane profila u blizini<br />
podionog kruga su ravne linije na zup~astom {tapu<br />
tako da formiraju evolventu na rotorima. Zbog toga<br />
{to je relativno kretanje jednog rotora u odnosu na<br />
drugi gotovo ~isto kotrljanje, to je najbolji dodir {to<br />
ga je mogu}e posti}i izme|u rotora. Rack generisani<br />
rotori konfiguracije 5/6 su prikazani na slici 2.<br />
Posljednja grupa rotora sa 4 i 5 rotora u vode}em<br />
i vo|enom vijku respektivno, postaje sve vi{e popularna<br />
za uljnopodmazivane zra~ne kompresore. Prvi<br />
par rotora su "Cyclon" rotori [19]. Iza njih su SRM<br />
"D" rotori [4] i na kraju grupe rotori generisani<br />
pomo}u zup~astog {tapa [50].<br />
3.2 Konstrukcija <strong>kompresora</strong><br />
Iako je moderan profil rotora neophodan uslov da<br />
bi vij~ani kompresor bio efikasan, sve ostale komponente<br />
tako|er moraju biti konstruisane tako da se<br />
na najbolji na~in iskoristi potencijal rotora i ostvare<br />
najbolje mogu}e performanse <strong>kompresora</strong>. Zbog<br />
toga je vrlo va`no pravilno odabrati zazor izme|u<br />
ku}i{ta i rotora, posebno na strani visokog pritiska.<br />
To, povratno, zahtijeva ili skuplje le`ajeve sa manjim<br />
zazorima ili jeftinije le`ajeve kod kojih su prednaprezanjem<br />
zazori svedeni na prihvatljivu veli~inu.<br />
Vij~ani kompresor je op}enito, a slu~aju uljnopodmazivanog<br />
<strong>kompresora</strong>, kada radi sa velikom razlikom<br />
pritisaka, posebno optere}en aksijalnim i radijalnim<br />
silama koje se na ku}i{te prenose preko<br />
le`ajeva. Za vij~ane kompresore malog i srednjeg<br />
kapaciteta obi~no se koriste kotrljaju}i le`ajevi, koji<br />
u tom slu~aju moraju biti tako dobro odabrani da<br />
zadovolje sve zadane uslove rada. Obi~no se koriste<br />
dva le`aja na tla~noj strani vratila rotora kako bi se<br />
aksijalne i radijalne sile na ku}i{te prenijele odvojeno.<br />
Tako|er je bitno je da je me|uosno rastojanje<br />
djelimi~no odre|eno i veli~inom le`ajeva i njihovim<br />
unutra{njim zazorima.<br />
Kontaktne sile, koje su definisane obrtnim momentom<br />
koji se prenosi izme|u rotora, igraju klju~nu ulogu<br />
kod <strong>kompresora</strong> sa direktnim dodirom rotora. Ove su<br />
sile relativno male u slu~aju pogona preko vode}eg<br />
imity of the pitch circles are straight lines on the<br />
rack which form involutes on the rotors. Hence the<br />
relative motion between the rotors is close to pure<br />
rolling which is the best possible.<br />
3.2 Compressor Design<br />
Screw compressor design has gradually evolved and<br />
the trend is to get as small as possible a machine<br />
to meet the required performance. This means that<br />
rotor tip speeds are as high as possible within the<br />
limits imposed by efficiency requirements. Normal<br />
practice is to use rolling element bearings wherever<br />
possible because these permit smaller clearances<br />
than journal bearings. Similarly, the ports are made<br />
as large as possible to minimize suction and discharge<br />
gas speeds. These features lead to great<br />
similarity in all designs for any specified application.<br />
Although advanced rotor profiles are a necessary<br />
condition for a screw compressor to be efficient, all<br />
other components must be designed to minimise<br />
losses if maximum improvements are to be<br />
achieved. Thus the rotor to housing clearances must<br />
be properly selected, especially at the high pressure<br />
end. This in turn requires either expensive<br />
bearings with small clearances or cheaper bearings<br />
with their clearances reduced to an acceptable<br />
value by preloading.<br />
A screw compressor, especially of the oil flooded<br />
type, operates with high pressure differences.<br />
These create large axial and radial bearing forces.<br />
Rolling element bearings are normally chosen for<br />
small and medium screw compressors and these<br />
must be carefully selected to obtain a satisfactory<br />
design since, inter alia, the distance between the<br />
rotor centre lines is in part determined by them. It<br />
must be added that recent advances in the development<br />
of advanced low friction rolling element<br />
bearings greatly contributes to this choice [31].<br />
Usually two bearings are fitted at the high pressure<br />
end of the rotor shafts in order to absorb the radial<br />
and axial loads separately.<br />
The contact force between the rotors is determined<br />
by the torque transferred between them and is very<br />
significant when they make direct contact. It is relatively<br />
small when the compressor drive is through<br />
the main rotor. However, when the drive is through<br />
the gate rotor, the contact force is substantially larger<br />
and, as far as possible, this arrangement should<br />
be avoided.<br />
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Slika 2. Rack generisani rotori vij~anog <strong>kompresora</strong> konfiguracije 5/6<br />
Figure 2. A pair of 5/6 rack generated screw compressor rotors<br />
rotora. Pogon preko vo|enog rotora uzrokuje<br />
zna~ajno pove}anje kontaktnih sila tako da se ovaj<br />
slu~aj mora isklju~iti iz bilo kakvog ozbiljnijeg razmatranja.<br />
Ulje koje se u vij~anom kompresoru ubrizgava izme|u<br />
rotora za podmazivanje, hladjenje i zaptivanje, koristi<br />
se i za podmazivanje le`ajeva. Pri tom je vrlo va`no<br />
uspostaviti odvojen sistem snabdijevanja le`ajeva<br />
uljem i sistem za evakuaciju ulja iz le`ajeva da bi se<br />
gubici usljed trenja smanjili. Ulje se u radni prostor<br />
<strong>kompresora</strong> ubrizgava na onom mjestu na kojem se,<br />
prema termodinamskim prora~unima, temperature<br />
radnog fluida i ulja podudaraju. Polo`aj otvora za<br />
ubrizgavanje ulja je definisan uglom na helikoidi rotora<br />
ali se obi~no postavlja tako da ulje tangencijalno<br />
ulazi u radni prostor kako bi se iskoristilo {to je god<br />
mogu}e vi{e njegove kineti~ke energije.<br />
Kompresor moderne <strong>konstrukcije</strong> treba imati male<br />
gubitke na usisu i potisu. Zato se usisni otvor unutar<br />
ku}i{ta <strong>kompresora</strong> postavlja tako da usisani gas na<br />
svom putu {to manje mijenja smijer kretanja te da<br />
bi imao malu brzinu strujanja. To se posti`e<br />
pove}anjem zapremine usisnog otvora. Veli~ina i<br />
oblik tla~nog otvora definisani su ugra|enim odnosom<br />
pritiska koji }e dati optimalne termodinamske<br />
performanse <strong>kompresora</strong>. Nakon toga se popre~ni<br />
presjek izlaznog toka dodatno pove}ava da bi se<br />
smanjila brzina toka na izlazu i time postigla minimizacija<br />
gubitaka u unutra{njem i izlaznom toku.<br />
Ku}i{te treba da bude pa`ljivo dimenzionisano kako<br />
bi se smanjila te`ina <strong>kompresora</strong> a jedan od na~ina<br />
da se to postigne je ugradnja pre~ke u usisnom<br />
otvoru u cilju pove}anja ~vrsto}a <strong>kompresora</strong> na<br />
vi{im pritiscima.<br />
Vij~ani kompresor je vrlo jednostavna toplotna ma{ina<br />
The oil which is injected into the compressor for<br />
flooding is also used for bearing lubrication but, to<br />
minimise friction losses, the bearing feed and return<br />
system is separate. The position in the compressor<br />
chamber where the oil is injected is set at the<br />
point where thermodynamic calculations show the<br />
gas and oil inlet temperatures to coincide. It is<br />
defined on the rotor helix with the injection hole<br />
located so that the oil enters tangentially in line with<br />
the gate rotor tip in order to recover as much as<br />
possible of the oil kinetic energy.<br />
To minimise flow losses in the suction and discharge<br />
ports, the following features must be included.<br />
The suction port should be positioned in the<br />
housing to let the gas enter with the fewest possible<br />
bends and the gas approach velocity kept low<br />
by making the flow area as large as possible. The<br />
discharge port size is first determined by estimating<br />
the built-in-volume ratio required for optimum thermodynamic<br />
performance. It is then increased in<br />
order to reduce the exit gas velocity and hence<br />
obtain the minimum combination of internal and discharge<br />
flow losses.<br />
The casing should be carefully dimensioned to minimize<br />
its weight and contain reinforcing bars across<br />
the suction port to improve its rigidity at higher<br />
pressures.<br />
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sa samo nekoliko pokretnih dijelova: dva rotora i<br />
obi~no ~etiri ili {est le`ajeva. Tokom njegovog <strong>razvoj</strong>a<br />
do{lo se do vrlo tipi~nog oblika po ~emu postaje<br />
vrlo prepoznatljiv. Tendencija je da se dobije {to<br />
je god mogu}e manja ma{ina koja }e jo{ uvijek dati<br />
zadovoljavaju}e performanse. To zna~i da se brzina<br />
vrha zuba mora {to je mogu}e vi{e pove}ati, ali je<br />
treba jo{ uvijek dr`ati u granicama koje daju prihvatljive<br />
mehani~ke gubitke. Upotreba kotrljaju~ih<br />
umjesto kliznih le`ajeva skoro da se mo`e postaviti<br />
kao pravilo koje treba uvijek po{tovati, jer su zazori<br />
na kotrljaju~im le`ajevima, a i gubici zna~ajno manji.<br />
Otvori za komunikaciju radnog fluida moraju biti {to<br />
je god mogu}e otvoreniji da bi se smanjile brzine<br />
gasa na usisu i izlazu. Sve ovo dovodi do vrlo sli~nih<br />
konstrukcija <strong>kompresora</strong> tako da su izuzetci vrlo rijetki<br />
i skoro zanemarivi. Primjer savremene <strong>konstrukcije</strong><br />
uljnopodmazivanog vij~anog <strong>kompresora</strong> sa reduktorom<br />
dat je na slici 3.<br />
Valja tako|er napomenuti da je u zadnje vrijeme<br />
dosta uradjeno na <strong>razvoj</strong>u kotrljaju~ih le`ajeva sa<br />
vrlo niskim trenjem [31], {to }e zna~ajno doprinijeti<br />
pobolj{anju performansi <strong>kompresora</strong>.<br />
Na slici 4. prikazuju se svi vitalni dijelovi modernog<br />
uljnopodmazivanog vij~anog <strong>kompresora</strong>.<br />
4. CONCLUSIONS<br />
At the onset of the millenium, the twin screw compressor<br />
has become a mature product. As a result<br />
of orchestrated efforts by a large number of companies,<br />
driven by market forces, it has become a<br />
compact, efficient and reliable machine. Every detail<br />
counts today. Even small advances in any feature<br />
will give distinctive improvements which may be<br />
used to gain commercial advantage. Hence,<br />
despite its now established role in industry, efforts<br />
continue to make advances in every aspect of its<br />
design, manufacture and mode of operation.<br />
Although improvements so gained are most likely to<br />
be evolutionary, there is still scope for revolutionary<br />
methods or procedures to achieve a better product.<br />
The most promising development appears to be<br />
rack profile generation to produce stronger but<br />
lighter rotors with higher displacement<br />
and lower contact stress.<br />
4 ZAKLJU^AK<br />
Vij~ani kompresor je proizvod koji je dorastao<br />
trenutku smjene vijekova. Pa`ljivo usmjereni napori<br />
velikog broja kompanija dirigovani zahtjevima tr`i{ta<br />
rezultirali su kompaktnom i efikasnom vij~anom<br />
ma{inom. U <strong>razvoj</strong>u vij~anih <strong>kompresora</strong> do{lo se u<br />
fazu kad se unapre|enja razmatraju do najsitnijih<br />
detalja. Male razlike dovode do malih ali zna~ajnih<br />
pomaka koji ~ine individualne prednosti svakog od<br />
<strong>kompresora</strong>.<br />
Iako se ~ini da se samo kontinualnim <strong>razvoj</strong>em<br />
vij~ani kompresori mogu promijeniti na bolje, jo{ uvijek<br />
ima dosta mjesta za primjenu manje ili vi{e revolucionarnih<br />
metoda ili procedura koje }e rezultirati<br />
boljim proizvodom. ^ini se da je najperspektivniji<br />
metod generacije profila pomo}u zup~astog {tapa<br />
koji daje ja~e, ali i lak{e rotore sa ve}om dobavom<br />
i manjim kontaktnim naponima me|u rotorima.<br />
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Slika 3. Konstrukcija vij~anog <strong>kompresora</strong> sa reduktorom<br />
Figure 3. A screw compressor with a gearbox design<br />
Slika 4. Sastavni dijelovi modernog uljnopodmazivanog vij~anog <strong>kompresora</strong><br />
Figure 4. A modern oil floded screw compressor parts<br />
LITERATURA - REFERENCES<br />
[1] Amosov P.E et al, 1977: Vintovie kompresornie<br />
mashinii - Spravochnik (Screw Compression<br />
Machines - Handbook), Mashinstroienie, Leningrad<br />
[2] Andreev P.A, 1961: Vintovie kompressornie<br />
mashinii (Screw Compression Machines), SUDPROM<br />
Leninngrad<br />
[3] Arbon I.M, 1994: The Design and Application of<br />
Rotary Twin-shaft Compressors in the Oil and Gas<br />
Process Industry, MEP London<br />
[4] Astberg A, 1982: Patent GB 2092676B<br />
[5] Bammert K, 1979: Patent Application FRG<br />
2911415<br />
[6] Bowman J.L, 1983: US Patent 4,412,796<br />
[7] Buckingham E, 1963: Analytical Mechanics of<br />
Gears, Dover Publ, N.York<br />
[8] Chia-Hsing C, 1995: US Patent 5,454,701<br />
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[9] Edstrom S.E, 1974: US Patent 3,787,154<br />
[10] Edstrom S.E, 1989: Quality Classes for screw<br />
Compressor Rotors, Proc IMechE Conference<br />
Development in Industrial Compressors, 83<br />
[11] Edstrom S.E, 1992: A Modern Way to Good<br />
Screw Compressors, International Compressor<br />
Engineering Conference At Purdue, 18<br />
[12] Fleming J.S, Tang Y, 1994: The Analysis of<br />
Leakage in a Twin Screw Compressor and its<br />
Application to Performance Improvement, Proc<br />
IMechE, Journal of Process Mechanical Engineering,<br />
Vol 209, 125<br />
[13] Fleming J.S, Tang Y, Cook G, 1998: The Twin<br />
Helical Screw Compressor, Part 1: Development,<br />
Applications and Competetive Position, P. 2:A<br />
Mathematical Model of the Working process, Proc<br />
IMechE, Journal of Mechanical Engineering Science,<br />
Vol 212, p369<br />
[14] Fujiwara M, Osada Y, 1995: Performance<br />
Analysis of Oil Injected Screw Compressors and their<br />
Application, Int J Refrig Vol 18, 4<br />
[15] Golovintsov A. G et al, 1964: Rotatsionii kompresorii<br />
(Rotary Compressors), Mashinostroenie,<br />
Moscow<br />
[16] Hanjali} K, Sto{i} N, 1994: Application of mathematical<br />
modeling of screw engines to the optimization<br />
of lobe profiles, Proc. VDI Tagung<br />
"Schraubenmaschinen 94" Dortmund VDI Berichte<br />
1135<br />
[17] Hanjali} K, Sto{i} N, 1997: Development and<br />
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