Air compressor system

A compressor system is disclosed that includes a base structure having a first portion engageable with a support surface and a second portion cantilevered from the first portion. A compressor can be positioned on the first portion of the base structure and an intercooler in fluid communication with the compressor is supported by the second cantilevered portion. At least one attachment mount with a hook member connected to the intercooler is slidingly engageable with the second portion of the base structure.

TECHNICAL FIELD

The present invention generally relates to industrial air compressor systems and more particularly, but not exclusively, to assembly and connection of one or more intercoolers with the compressor systems.

BACKGROUND

Large industrial compressor systems typically have complex design and assembly procedures, and are difficult to move due to the large size and weight. Reducing system complexity can reduce costs related to manufacturing and assembly as well as to increase durability of the system. Some existing systems have various shortcomings relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.

SUMMARY

One embodiment of the present invention is a unique compressor system. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for compressor systems with an intercoler suspended from a base support. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Industrial compressor systems that use external fluid to fluid heat exchangers such as intercoolers are heavy weight packages. Heat exchangers as defined herein can be of any type commonly utilized in industrial applications. It should be noted that terms such as intercooler, cooler, inter-stage cooler, aftercooler or the like can be interchanged or substituted and still fall within the broad definition of a heat exchanger as defined by the present disclosure. Present compressor systems include intercoolers and a main base to support airend components and a motor with integral oil reservoir. Typically because each of the size and weight of industrial components each of the components are transported separately and assembled on site.

The compressor system packaging concept of the present disclosure eliminates the need for a large base structure and enables the transportation of the package in a single unit so as to avoid site assembly work during installation. This concept is scalable and can be applied to the entire range of compressors.

An aspect of assembling heavy weight intercoolers is disclosed in the present application. The intercoolers can be hung from a central base structure and then optionally clamped by bolted joints. The intercoolers can include an attachment such as a hanger bracket that enables mounting of the intercoolers to the base structure. The structural design of the intercooler shell and hanger bracket allows for free thermal expansion of cooler shell during all system operating conditions and also allows lifting of heavy coolers along with the base structure without permanent deforming or damaging the cooler shell.

An intercooler of the present application may promote a modular design concept; may promote standardization of structures and components across an entire range and size of centrifugal compressors with external coolers; may reduce overall footprint size; may promotes cost reduction and component quality improvement due to modular design; may Isolates thermal stress and deflection of coolers from base structure; and/or may ease assembly and serviceability of coolers and other subsystems.

Referring now toFIG. 1, a compressor system10is shown therein. The compressor system included a primary motive source30such as an electric motor, an internal combustion engine or a fluid-driven turbine and the like. The compressor30can include multi-stage compression and in the exemplary embodiment includes a first stage compressor32, a second stage compressor34, and a third stage compressor36. In other embodiments a different number of stages may be employed. The primary motive source20is operable for driving a compressor30via a drive shaft22to compress fluids such as air or the like. A structural base12is configured to support at least portions of the compressor system10on a support surface13such as a floor or ground and the like. One or more cantilevered extensions or arms14can extend from the base12and is configured to hold portions of the compressor system10suspended above the support surface13as will be described in more detail below. Portions of the compressed air discharged from the compressor30can be transported through more one or more conduits40,50,60,70and80to one or more intercoolers100and/or to another compressor stage. An inlet fluid manifold90and an outlet fluid manifold92can be fluidly connected to the intercoolers100to provide cooling fluid such as water or other liquid coolant to cool the compressed air after discharge from one or more of the compressor stages of the compressor30. The compressor system10can also include a controller110operable for controlling the primary motive power source and various valving and fluid control mechanisms (not shown) between the compressor30and intercoolers100.

Referring now toFIG. 2, each intercooler100can include an air inlet port200and an air outlet port210to transport relatively hot air into the intercooler and transport relatively cooler air out of the intercooler100. The intercooler100can also include a cooling fluid inlet port220and a cooling fluid outlet port230to transport the cooling medium such as water or the like into and out of the intercooler100. One or more freestanding support stands250can be connected to the intercooler100so that the intercooler100can be placed on a support surface while manufacturing, attaching or otherwise assembling the intercooler100with the compressor system10. It should be noted that during operation the support stands250do not contact the support base12or support surface13.

One or more attachment mounts or hanging brackets300can be attached to an outershell102of the intercooler100. The hanging brackets300can be attached to the outershell102by any means desired, however, in an illustrative embodiment the hanging brackets can be welded to the outer shell102. Other attachment means can include the use of threaded fasteners and/or locking connections such as dovetail joints, pressfit configurations and other mechanical fastening means as would be known by those skilled in the art. Each hanging bracket300can include an attachment portion302that can conform with a portion of the surface of the outer shell102. In the illustrative embodiment the outer shell102is substantially round and forms a cylinder shape wherein the attachment portion302is formed with a complimentary surface to that of the outer shell102. It should be understood that the illustrative shape is but one example and that other forms and shapes are contemplated herein. Each hanging bracket300can include a substantially flat vertical face304that transitions into a hook portion306having a top portion308that extends from the vertical face304to a front ledge310. The front ledge310extends downward in substantially parallel orientation as the flat vertical face304. It should be understood that the terms vertical and parallel do not need to be exact and that various differing angles and curved portions may be employed in certain embodiments. A space or groove312is formed between the front ledge310and the vertical face304so as to provide means for hanging the intercooler100onto a portion of the base12of the compressor system10as will be described in detail below.

Referring now toFIG. 3, a pair of intercooler heat exchangers100are shown coupled to an extension from the base12. A portion of the compressor system10can be mounted onto the base12that is engaged with a support surface such as a platform or the ground. The base12can include a cantilevered portion such as an arm that can be partially viewed inFIG. 1, but more clearly seen inFIG. 3. The cantilevered arm14can include a cross member400that extends between the pair of intercoolers100. The cross member400can include one or more eyelets410configured to permit an attachment mechanism such as a hoist, chain, rope, cable or other lifting member (not shown) to attach thereto or lift and help position the entire compressor system10. The cantilevered arm14can include first second walls450,460that are substantially parallel to one another and oriented in a substantially vertical direction. As explained above the terms parallel and vertical are not meant to rigidly define and variation to the extent that the system can be assembled and operated according to the principles herein is contemplated. The walls450,460extend in cantilever fashion away from the base12above the support surface13under the base12. A top wall470can extend between the first wall450and second wall460to define a width of the cantilevered arm14. Both the first wall450and the second wall460can include a top portion452,462, respectively for the hanging brackets300to slidingly engage over the top thereof. The hanging brackets300permit each intercooler100to be supported by the cantilevered arm14above a support surface13and also permits the intercoolers300assembly to slide along the top portions452,462of the cantilevered arm14in response to forces such as thermal expansion of various components and/or to properly position the intercooler100for assembly with the compressor system10. In one form one or more of the hanging brackets300can be releasably locked to the cantilevered arm via a threaded fastener301or the like after installation. The hanging brackets300permit the intercooler to expand and contract under variable thermal loads when one or more brackets are bolted or when all are free from mechanical fastening. A forward wall480connected to the side walls450and460provides structural stability and an abutment portion472to prevent the hanging brackets300from inadvertently sliding past the forward edge of the cantilevered arm14.

Referring now toFIG. 4, an enlarged perspective view of a portion of the intercooler assembly is shown to provide a close up view of the attachment portion of the hanging brackets300. The hook portions306of the hanging brackets300can be hung over the top edge of the top portion452of the first wall450and the top portion462of the second wall460. The hook portion306of each of the hanger brackets300can slide back and forth along the direction illustrated by the double arrow line500so as to limit binding caused by from thermal expansion as well as to ease the assembly procedures and improve structural integrity during operation of the compressor system10. It should be understood that while the cantilevered arm14is illustrated as having an intercooler300attached to either side, that in alternate embodiments only one intercooler300may be attached to a cantilever arm14.

In operation the compressor system is configured to provide compressed air at a desired temperature and pressure to external systems. The compressor systems can be used in any industrial application including but not limited to automobile manufacturing, textile manufacturing, process industries, refineries, power plants, mining, material handling, etc. The controller permits user input to define parameters such as pressure, temperature and mass flow rate. The controller will send command signals to the motor to rotate at a desired operating speed in order to drive the one or more compressors and control various valving to control airflow rate and coolant flow rate. In the illustrative example, the compressor system includes a three-stage centrifugal compressor system, however, the system can operate with other types of compressors and/or with more or less stages of compressors. One or more intercoolers can be fluidly coupled to each compressor stage such that after air is compressed through the first stage the air can be transported through a first intercooler and can be cooled to a desired temperature via a heat transfer mechanism such as conduction and convection in tube type heat exchangers. The compressed air can then be transported into a second stage compressor where the air further compressed and necessarily heated to a higher temperature through a thermodynamic process. The second stage compressed air can then be routed through a second intercooler to cool the air to desired temperature while remaining at or close to the compressor outlet pressure of the second stage compressor. The cooled compressed air exiting from the second intercooler can then be transported to a third stage compressor where it is compressed to a final desired pressure and then subsequently routed to a third stage intercooler to bring the temperature of the final discharged air pressure to the desired temperature for delivery to a final subsystem. In one form the compressors can be centrifugal compressors, however, other forms of compression can include axial flow compressors, piston compressors or other positive displacement compressors can be used under the teachings of the present disclosure. The intercoolers are designed and assembled in such a manner as to permit thermal expansion relative to the other components of the compressor system including the base support and the cantilevered portions extending from the base support. In this manner the intercoolers can remain structurally sound and minimize potential mechanical failure such as cracks generated by loads caused by mechanical constraints that limit material expansion during conditions of high temperature gradients across the system. Material selection for the intercoolers, the base support structure and other components can include various forms of metal, composites or metal alloys as desired. Metals can include but are not limited to aluminum, steel, iron, and/or super alloys. The metal material may further be formed from cast, wrought, or sheet configuration.