Abstract:
A method for regulating a fan in a compressor unit which having at least one compressor element, a motor connected to the compressor element, and a cooler including at least one radiator and a fan cooperating therewith; driven by a motor. The motor of the compressor element is driven at a speed varying as a function of it&#39;s a load and the number of revolutions of the motor of the fan is regulated as a function of a selected lever of cooling, thereby mitigating condensation of moisture by excessive cooling. The unit includes a speed regulation device connected to the motor of the compressor element.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a method for regulating a fan in a compressor unit which comprises at least one compressor element, at least one motor with electronically adjustable speed driving this compressor element, and at least one cooler comprising at least one radiator and at least one fan cooperating therewith, driven by an electric motor, whereby the motor of the compressor element is driven at a speed varying in function of its load. 
     2. Discussion of the Related Art 
     In an air-cooled air compressor with oil lubrication, such cooler can be provided in the outlet of the compressor element, before or after the oil separator or the pressure vessel. 
     In this application, oil must be comprehended in a broad sense. By oil, not only mineral oil must be understood, but also any viscous agent which can be used for lubricating and cooling rotors, gear wheels or bearings and which is hydrophobic or incompatible with water. 
     In a multistage-compressor, the cooler can be mounted in between the stages. 
     In the known compressor units, the fan, during cooling, always is driven at a constant number of revolutions, to wit a number of revolutions whereby it still can cool sufficiently in the worst working circumstances of the compressor element, this is with the highest working pressure, at maximum load, and with the highest air humidity and air temperature. 
     In consideration of the fact that the load of the motor of the compressor element and, therefore, also its number of revolutions, varies, a constant speed of the fan at a low load results in too large a cooling. 
     In the first place, this is disadvantageous for the energy consumption. If the fan motor at its set number of revolutions consumes, for example, 5 kW of power, this will be only 0.2 kW with the minimum number of revolutions. 
     In the second place, this constant number of revolutions brings along that the cooling may be too large, which can result in a condensation of moisture originating from the suctioned and compressed air. 
     If the compressor is a compressor cooled by means of oil, then the condensed water in the oil is strongly disadvantageous for the working of the compressor element. 
     If the same oil also is used for lubricating the bearings, then the water in the oil is very bad for the service life of this latter. 
     In such oil-cooled compressor, the oil, after the compressor element, is separated in an oil separator and returned to the compressor element. 
     It is known to place the cooler into the return conduit for the oil and to place a thermostatic valve in this return conduit, which valve, when the temperature of the oil drops below a certain border value, redirects the oil to the compressor element via a bypass of the cooler. 
     The oil which is injected into the compressor element therefore does not cool off further, as a result of which the compressed air getting into the oil separator can be sufficiently warm, as no moisture should condensate there. 
     As the fan further revolves at full speed, whereas the oil is flowing through the bypass, this fan further cools down the radiator. When then the oil is sufficiently warm because the thermostatic valve again shall alter its position, warm oil gets into this radiator, which brings along large thermic shocks. 
     The further revolving fan also cools down other parts of the compressor, such that, even if the oil is not directed through the cooler, this can be cooled somewhat and the formation of condensation in the oil separator still is not excluded. 
     In multistage-compressor units, an intermediate cooler cooled by a fan driven at a constant number of revolutions at low load also may cool too much, which also may lead to the formation of condensation. 
     Even in the case of an oil-free multistage-compressor unit, water drops which, with the air at high speed, are carried along in the high-pressure stage, may cause damages there. 
     SUMMARY OF THE INVENTION 
     The invention aims at a method for controlling a fan in a compressor unit which remedies said disadvantages and, in the first place, allows to avoid condensation problems and further has a better energetic efficiency, reduces or prevents thermic tensions in the coolers and can reduce the noise level. 
     According to the invention, this aim is achieved in that the number of revolutions of the motor of the fan is regulated in function of the required cooling, however, such that condensation of moisture due to exaggerated cooling is avoided. 
     FURTHER PRIOR ART 
     U.S. Pat. No. 5,910,161 describes a method whereby the motor of fans of a compressor unit is regulated, however, the compressor unit forms part of a cooling device, and the fans cool the condensers in the cooling circuit, and this such that in these condensers, the cooling medium is condensed completely. 
     Also U.S. Pat. No. 5,873,257 relates to a cooling device whereby also the condenser is cooled by a fan of which the speed of the motor is regulated in this manner. Of course, in the condenser a condensation of the cooling medium is taking place. Also opposite to the evaporator, a fan with controlled motor is installed, however, this evaporator is no cooler. 
     FURTHER SUMMARY OF THE INVENTION 
     According to the invention, preferably the speed of the motor of the fan is regulated in function of the speed of the motor of the compressor element. 
     The speed of the motor of the fan can be regulated in function of the speed of the motor driving the compressor element, such that the ratio of the speeds of both motors takes a course according to an empirically determined curve. 
     The invention also relates to a compressor installation with a fan which is regulated according to the method according to the invention, described in the aforegoing. 
     Thus, the invention relates to a compressor unit comprising at least one compressor element, at least one motor with electronically adjustable speed which drives this compressor element at a speed varying in function of its load, and at least one cooler which comprises at least one radiator and at least one fan cooperating therewith, driven by an electric motor, whereby the characterizing feature consists in that the motor of the fan is a motor with electronically adjustable speed and is coupled to means for regulating its speed in function of the required cooling, such that its speed varies in function of the required cooling, whereas condensation of moisture due to exaggerated cooling is avoided. 
     The speed regulating device or otherwise means for regulating the speed of the motor of the fan preferably are coupled to the seed regulating device or otherwise means for regulating the speed of the motor driving a compressor element. 
     Thereby, the means for regulating the speed of the motor of the fan can be coupled such to the means for regulating the speed of the motor driving a compressor element that the ratio of the speeds of both motors takes a course according to an empirically determined curve. 
     In a practical embodiment, the compressor unit comprises an oil-cooled compressor element to which a pressure conduit connects in which an oil separator is mounted, whereby this oil separator is connected to the compressor element by means of a return conduit for oil in which the radiator of an oil cooler with a fan is mounted and this fan is the fan which is coupled to said means for regulating its speed. 
     In another embodiment, the compressor unit comprises several stages and thus at least a low-pressure compressor element and a high-pressure compressor element and, in the intermediate conduit connecting the two compressor elements to each other, the radiator of an intermediate cooler with a fan is mounted and is this fan the fan which is coupled to said means for regulating its speed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     With the intention of better showing the characteristics of the invention, hereafter, as an example without any limitative character, several preferred forms of embodiments of a method for regulating a fan in a compressor unit and of a compressor unit provided with a fan regulated in this manner, according to the invention are described, with reference to the accompanying drawings, wherein: 
     FIG. 1 schematically represents a compressor unit according to the invention; 
     FIG. 2 represents a graphic chart of the temperature in the oil separator, whereby just no condensation occurs, in function of the environmental temperature; 
     FIG. 3 represents a graphic chart of the speed of the motor of the fan in function of the speed of the motor of the compressor element; 
     FIG. 4 schematically represents a compressor unit analogous to that of FIG. 1, however, in relation to another form of embodiment; 
     FIG. 5 represents a graphic chart analogous to that of FIG. 3, however, for the compressor unit of FIG. 4; 
     FIG. 6 schematically represents a compressor unit analogous to that of FIGS. 1 and 4, however, in relation to still another form of embodiment. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     The compressor unit for compressing air from the environment, represented in FIG. 1, comprises an oil-cooled compressor element  1  driven by means of an electric motor  2  with electronically adjustable speed. 
     In the represented example, the compressor element  1  is a screw-type compressor element with two screw-shaped rotors  3  which are beared in a housing  4 . 
     The interior space of the housing  4  or rotor chamber connects to an air-suctioning conduit  5 , whereas, by means of a return valve  6 , gives out into a pressure conduit  7  for the compressed air. 
     In this pressure conduit  7 , an oil separator  8  is provided which also forms a pressure vessel. 
     This oil separator  8  consists of a vessel  9  in which at the top, a filter  10  is mounted which is surrounded by a screen  10 A. 
     The pressure conduit  7  gives out in the vessel  9 , opposite to the screen  10 A, and a part of the oil in the compressed air is mechanically separated by this screen  10 A and flows downward along this screen  10 A. 
     The remainder of the oil is kept back by the filter  10  which is situated opposite to the exit  11  of the vessel  9 . This exit  11  can be closed off by a return valve  12 . 
     Further, the radiator  13  of an air cooler  14  is mounted in the pressure conduit  7 . 
     To the underside of the vessel  9 , a return conduit  15  for the collected oil connects, which, by means of a spray head, connects to the interior side of the housing  4 . 
     In this return conduit  15 , the radiator  16  of an oil cooler  17  is mounted. 
     The air cooler  14  and the oil cooler  17  have a common fan  18  which is driven by an electric motor  19  with electronically adjustable speed and which, thus, is mounted opposite to the two radiators  13  and  16 . 
     The number of revolutions of the motor  19  of the fan  18  is variable in function of the number of revolutions of the motor  2  which drives the oil-injected compressor element  1 . 
     Both motors  2  and  19 , for example, are induction motors, the speed of which depends on the frequency of the power supply, and are controlled by the intermediary of a frequency transformer  20 ,  21 , respectively, by means of the same control system  22 , in the manner described in the following. 
     The frequency transformer  20 , together with the control system  22 , forms a speed regulation device or otherwise means for regulating the speed of the compressor element  1  in function of the load, such in order to be able to deliver the required flow rate at a constant pressure, to wit the working pressure normally set by the user. 
     The means for regulating the speed of the fan  18  and thus for regulating the cooling capacity or thus the cooling of the oil flowing through the radiator  16 , consist of the frequency transformer  21  which, as will be explained in the following, in its turn is controlled by the frequency transformer  20 , directly or by means of the control system  22 . 
     In order to avoid the condensation of moisture from the suctioned air in the oil separator  8 , the temperature in the oil separator  8  always must remain above the condensation temperature, in order to avoid that water can be formed which exerts a disadvantageous influence on the working of the compressor element. 
     The condensation temperature in the oil separator  8  depends on the conditions of the environment, in particular the moisture content of the air suctioned by means of suction conduit  5 , and the pressure prevailing in the oil separator  8 . 
     With the exception of the pressure drops in the oil separator  8 , in particular in the filter  10  thereof, in the air cooler  14  and in the air outlet system, this pressure corresponds to the working pressure of the compressor. These pressure drops are relatively small and therefore will be disregarded in the following. 
     The required minimum temperature in the oil separator  8  and, thus, also the outlet temperature of the compressor element  1  in order to avoid condensation, is equal to the saturation temperature or condensation temperature Tv in  10  the oil separator  8  and can be calculated by means of the following equation:                  Ps        (   Tv   )         Pk   -     Ps        (   Tv   )           =       Hr   ·     Ps        (   Ta   )           Po   -     Hr   ·     Ps        (   Ta   )                     (   A   )                                
     wherein: 
     Pk=the pressure in the oil separator  8 =the working pressure; 
     Po=the pressure of the suctioned air (the barometer pressure); 
     Hr=the relative humidity of the suctioned air; 
     Ta=the environmental temperature; 
     Ps(Tv)=the vapour tension of steam at temperature T. 
     For given inlet conditions Po, Ta and Hr, from equation (A) the saturation temperature Tv can be calculated for a certain working pressure. 
     The compressor unit is placed into a testing cell, such that the humidity and the temperature of the air suctioned by the compressor element  1  can be adjusted. 
     For the worst case, this is with the highest occurring moisture content in the environment, by means of said equation (A), the required minimum temperature or the saturation temperature Tv with varying environmental temperatures Ta for the air is calculated, and such for different chosen working pressures. 
     In FIG. 2, a graphic chart is represented in which the result of these calculations is represented. For each working pressure, a curve  23  is obtained which is almost straight. 
     The outlet temperature Tu of the compressor element  1 , which thus is equal to the real temperature Tx in the oil separator  8 , is a linear function of the number of revolutions N of the compressor element  1 . 
     
       
           Tu=Tx=Toi+A+B.N   (B) 
       
     
     Herein, Toi is the oil injection temperature in the compressor element  1 , which usually is equal to the temperature after the oil cooler  17 , and A and B are constants depending on the compressor element  1 . 
     Thus, in order to keep the temperature Tx for a certain working condition constant and above the saturation temperature Tv with a variable number of revolution N, the oil injection temperature Toi must be varied. By regulating the speed of the motor  19  of the fan  18 , the cooling air flow rate through the oil cooler  17  and, therefore, also the cooling capacity and parallel thereto, the oil outlet temperature from the oil cooler  17  and, thus, also the oil injection temperature Toi varies. 
     From the general equation for an air-oil heat exchanger or cooler equation, it is obvious that: 
     
       
         Changed power= Kf.A.Δt   1n =mass flow rate oil. Cpo.Δto   (C), 
       
     
     wherein: 
     Kf=the heat exchanging coefficient (is influenced by cooling air flow rate); 
     A=the heat-exchanging area; 
     Δt 1n =the logarithmical temperature difference over the heat exchanger for both media; 
     Cpo=the heat capacity of the oil; 
     Δto=the temperature difference [T(oil in)−T(oil out)]. 
     With the variation of the number of revolutions of the fan, the heat exchanging coefficient Kf also varies into the same direction and, thus, according to the cooling equation (C) together with the exchanged power and said temperature difference [T(oil in)−T(oil out)]. 
     By combining the above equations (A,B,C), thus, by varying the number of revolutions of the fan  18 , the exiting oil temperature T(oil out) from the oil cooler  17  and, thus, the oil injection temperature Toi and, thus, the outlet temperature Tu of the compressor element  1  and the temperature Tx, being equal to it, in the oil separator  8  can be regulated. 
     From the curves  23 , it becomes obvious that for the same environmental conditions the necessary minimum temperature or saturation temperature Tv in the oil separator  8  is the higher, the higher the pressure Pk therein or the working pressure is. 
     From the equation (C) further follows that for a certain number of revolutions of the fan and, thus, a certain exchanged power, the Δto will be smaller, the larger the mass flow rate of the oil is. 
     Thus, for higher working pressures, parallel to a higher mass flow rate of the oil through the compressor, for one and the same number of revolutions of the fan the cooling of the oil will be lower than for lower working pressures. 
     Therefore, for a certain number of revolutions of the fan, the oil will automatically exit the oil cooler  17  at a higher temperature when the working pressure Pk is higher, and at a lower temperature when the working pressure Pk is lower. 
     Due to this self-regulating feature, in practice a single simple adjustment curve for the number of revolutions of the fan  18  in function of the number of revolutions of the compressor element  1  and, thus, of the number of revolutions of the motor  2  may suffice, independent from the working pressure Pk. 
     Such curve  24  is represented in FIG. 3, with on the vertical axis the speed Vv of the motor  19  of the fan  18  in percent of its maximum speed and on the horizontal axis the speed Ve of the motor  2 , also in percent of its maximum. 
     This fixed adjustment curve  24  is programmed, either in the control system  22  controlling the frequency transformer  20  in function of the load, or directly in the frequency transformer  20 . 
     Due to this programmed curve  24 , the control system  22 , he frequency transformer  20  with relatively large capacity, respectively, gives a signal depending on the frequency of this frequency transformer  20  and, thus, in function of the speed Ve of the motor  2 , to the frequency transformer  21  with smaller capacity which controls the motor  19  of the fan  18 . 
     As is obvious in FIG. 3, the motor  19  of the fan  18  is revolving at its maximum speed between 100% and approximately 80% of the maximum speed of the motor  2 . 
     The temperature increase over the compressor element  1  is sufficiently high, such that there is no danger of condensation formation. 
     If the speed of the motor  2  drops further and, thus, also the temperature increase over the compressor element  1  is reduced, also the speed of the motor  19  of the fan  18  diminishes in order to avoid condensation. 
     In practice, thus, within the application range of the compressor unit with a minimum number of revolutions of the motor  2 , being approximately ⅙ of the maximum number of revolutions of this motor  2 , a linear curve for the relation between the speeds of the motors  2  and  19  may suffice. 
     The regulation of the speed of the motor  19  of the fan  18  in function of the speed of the motor  2  of the compressor element  1 , described in the aforegoing, does not only avoid the formation of condensate in the oil, but offers important energy economizations as the taken-up capacity of the fan  18  at a minimum number of revolutions only equals approximately 3% of its capacity at a nominal number of revolutions. 
     Moreover, a lower number of revolutions of the fan  18  offers a lower noise level, such that the average noise level is lowered by adjustment. 
     Major thermic shocks in the radiator  16  are avoided, and the entire thermic balance of the compressor unit is improved. 
     In the form of embodiment represented in FIG. 4, the compressor unit is an air-cooled oil-free two-stage compressor unit. 
     As a result thereof, it comprises a low-pressure compressor element  26  and a high-pressure compressor element  27  which are gear compressor elements. 
     The gear rotors  28  of the low-pressure compressor element  26  are driven by an electric motor  29 , the speed of which is controlled by means of a frequency transformer  30  by a control system  31 . 
     The gear rotors  32  of the high-pressure compressor element  27  are driven by a second electric motor  33 , the speed of which is controlled by means of a frequency transformer  34  by said control system  31 . 
     The control system  31  controls the two motors  29  and  33  in a manner coupled to each other. Usually, it is such that the high-pressure stage and, thus, the compressor element  27 , provide for the desired pressure, this is the working pressure, whereas then the low-pressure stage, this is the compressor element  26 , provides for the required air flow rate. 
     The speeds of both compressor elements  26  and  27  usually alter in the same sense and in a known ratio. 
     To the compressor element  26 , on one hand, connects the suction conduit  35  and, on the other hand, the intermediate conduit  36  which forms the suction conduit for the second compressor element  27 . To this latter element then the actual pressure conduit  37  is connected. 
     The radiator  38  of the intermediate cooler  39  is mounted in the intermediate conduit  36 , whereas the radiator  40  of the aftercooler  41  is mounted in the pressure conduit  37 . 
     Although no oil is injected on the gear rotors  28  or  32 , the bearings and gear wheels must be lubricated, resulting in that the compressor unit comprises an oil circuit with an oil reservoir  42 , an oil conduit  43  connected thereto in which successively a pump  44 , the radiator  45  of an oil cooler  46  and a filter  47  are arranged. 
     From the filter  47 , two conduits  48  and  49  extend towards the two compressor elements  26  and  27 , respectively, whereas a third conduit  51 , operated by a return valve  50 , for a possible excess of oil extends towards the oil reservoir  42 . 
     From each compressor element  26  and  27 , a conduit  52 ,  53 , respectively, returns to the oil reservoir  42 . 
     The intermediate cooler  39 , the aftercooler  41  and the oil cooler  46  have the same fan  54  with an electronically adjustable electric motor  55 , and the radiators  38 ,  40  and  45  thus are mounted adjacent to each other, opposite to the fan  54 . 
     The speed of the motor  55  can be regulated by means of a frequency transformer  56  which also is controlled by control system  31 . 
     In such compressor unit, it is important to avoid a condensation of moisture from the suctioned air occurring in the intermediate cooler  39 . 
     Droplets formed in this intermediate cooler  39  may influence the working of the high-pressure compressor element  27  in a disadvantageous manner. 
     After the intermediate cooler  39 , a liquid separator can be placed, however, this is expensive and time-consuming. 
     In order to avoid the formation of water droplets, the temperature in the intermediate cooler  39  always must remain above condensation temperature. 
     The lowest temperature in this intermediate cooler  39 , this is, thus, the temperature at the outlet thereof, is depending on the cooling effect of the fan  54  and, in a manner analogous to the manner described heretofore for the temperature in the oil separator  8 , can be regulated by varying the speed of the fan  54 . 
     The only difference is that the temperature in the oil separator  8  was influenced upon by the temperature of the injected oil, whereas in this oil-free application, the radiator  38  of the intermediate cooler  39  is an air/air heat exchanger and the air temperature in the radiator  38  is influenced directly by the speed of the fan  54 . 
     By means of tests, empirically the lowest-possible temperature of the intermediate cooler  39  is calculated, whereby there still is no condensation in the most unfavourable circumstances, and with equations, analogous to those used with the form of embodiment according to FIG. 1, a programmable curve  25  can be obtained which shows the ratio of the number of revolutions or the speed of the motor  55  of the fan  54  in function of the number of revolutions or the speed of one of the motors  29  and  33 , for example, of the motor  33  driving the high-pressure compressor element  27 . 
     This curve  25  seems to be practically linear and is represented in FIG.  5 . 
     Thus, there is a coupling between the frequency transformers  34  and  56 , either directly or by means of the control system  31  which regulates the speed of the motor  29  or  33  by means of the frequency transformer  34 . 
     In a variant of the preceding form of embodiment, both compressor elements  26  and  27  can be driven by means of transmissions by a single motor. 
     Such variant is represented in FIG. 6, in which the two oil-free compressor elements  26  and  27  moreover do not comprise gear rotors  28  and  32 , but screw rotors. 
     In this case, for example, only the motor  33  is present which, by means of a gearwheel transmission  57 , drives the two compressor elements  26  and  27 . In the same manner as described in the aforegoing, the speed of the motor  55  of the fan  55  is regulated in function of the speed of the motor  33 . 
     If radiators  16  or  38  are very large, oil cooler  17 , intermediate cooler  39 , respectively, may comprise several fans  18  or  54 , the motors  19  or  55  of which are controlled together and in the same manner as described in the aforegoing. 
     Also if several radiators are present, such as in the examples described in the aforegoing, several fans  18  or  54  can cooperate therewith, whereby then the motors of these fans  18  or  54  can be controlled together as well as separate. 
     At least the fan  18  or  54  mounted opposite to the radiator  16  or  38  of the oil cooler  17 , the intermediate cooler  29 , respectively, are regulated in the manner described in the aforegoing. 
     Although the invention in the first place can be applied for compressor units for compressing air, it can also be applied for gases other than air which can comprise moisture which can condensate. 
     The invention is in no way limited to the forms of embodiment described heretofore and represented in the figures, on the contrary may such compressor unit be realized in different variants, while still remaining within the scope of the invention.