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China, Chinese Reciprocating Piston Oil Free Process Air Compressor Body Frame1 Industrial Products Supplier Manufacturer Details, price list catalog:
China Industrial Products Supplier Manufacturer List Catalog
CompressorReciprocating CompressorAir CompressorRefrigerator Compressor
Weifang Dashan Petrochemical Co., Ltd.
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Product Description Compressor BodyAs the core load-bearing component of a compressor, the structural design, material selection, and manufacturing process of the compressor body directly influence the equipment's performance, reliability, and lifespan. This article provides an in-depth analysis from five dimensions: technical principles, design essentials, material innovation, maintenance strategies, and industry trends.I. Technical Principles and Structural ClassificationPositive Displacement Compressor BodiesReciprocating Type: For piston compressors, the body is typically made of high-strength gray cast iron (e.g., HT250/300) through integral casting, divided into the cylinder block and crankcase. Symmetrical balance designs (e.g., H-type, M-type) are used to counteract inertial forces and reduce vibration by offsetting crank angles.Rotary Type:Screw Compressors: Split-body structures house male and female rotors with bearings, using labyrinth or mechanical seals to prevent gas leakage.Scroll Compressors: The body integrates fixed and orbiting scrolls driven by an eccentric shaft for compact compression, requiring high machining precision.Dynamic Compressor BodiesCentrifugal Compressors: Casings are often horizontally split or barrel-shaped. Barrel structures are suitable for pressures >3.923 MPaG, while split designs facilitate maintenance.Axial Compressors: Comprising stators and rotors with blades mounted directly on the shaft, they handle high-flow, low-pressure applications.II. Material Engineering and Performance OptimizationTraditional MaterialsCast Iron: Gray cast iron (HT250/300) is cost-effective and wear-resistant but heavy..Cast Steel: ZG270-500 and similar grades are used for high-pressure scenarios, offering strength but requiring complex machining.Aluminum Alloy: A356 alloy is lightweight for small compressors (e.g., refrigerators) but faces challenges with thermal expansion.Advanced MaterialsTitanium-Based Composites: Heat-resistant composites (600-800oC) developed by Shanghai Jiao Tong University reduce centrifugal compressor impeller weight by 40% while increasing strength by 30%, with potential for future body applications.PEEK Polymer: Polyetheretherketone is used for valve plates and piston rings in food/pharmaceutical industries due to self-lubricating and corrosion-resistant properties.3D-Printed Materials: Inconel 718 and other superalloys enable rapid prototyping of impellers, cutting delivery time by 50%, with potential for customized bodies.III. Design Innovation and Manufacturing ProcessesStructural OptimizationIntegral Gear Design: Multistage centrifugal compressors use multi-shaft gearboxes for independent impeller speed control, increasing single-stage pressure ratio by 30% and efficiency by 5-8%.Ionic Liquid Sealing: Developed by Dongde Industrial, this technology achieves zero leakage for high-purity gases like hydrogen.Manufacturing TechniquesPrecision Casting: Lost foam casting reduces machining and improves surface accuracy for complex structures.Additive Manufacturing: 3D printing lowers prototyping costs by 30%, as demonstrated by Dongbei Group for compressor housings.Welding: TIG welding with stress-relief treatment enhances fatigue resistance in stainless steel bodies.IV. Maintenance Strategies and Fault DiagnosisPreventive MaintenanceVibration Monitoring: Accelerometers and spectral analysis detect bearing wear or rotor imbalance in advance.Leak Detection: Helium mass spectrometers ensure annual leakage rates <0.1%.Repair TechnologiesCrack Repair: Metal stitching or epoxy bonding (e.g., pinning for thin cracks, patch plates for large damage).Wear Restoration: Laser cladding of nickel-based alloys on sliding surfaces restores dimensional accuracy.Fault CasesReciprocating Compressors: Excessive vibration may stem from crankshaft imbalance or loose foundations.Centrifugal Compressors: Casing deformation causing inter-stage leakage requires FEA optimization or material upgrades.V. Industry Trends and Technological FrontiersSmart DesignDigital Twin: Shengu Group's simulation system optimizes start-stop controls, reducing loading time to <30 minutes.AI Predictive Maintenance: Machine learning predicts faults using vibration and temperature data.Green ManufacturingLow-Carbon Materials: Bio-based composites (e.g., carbon fiber-reinforced epoxy) cut carbon emissions in hydrogen compressors.Energy Efficiency: Shanghai Haili's rotary compressors improve cooling-to-weight ratio by 15%, reducing annual power consumption by 8%.Extreme Ultra-High Pressure: Ionic liquid-sealed compressors achieve 100 MPa discharge pressure for hydrogen storage.Cryogenic Applications: Dongbei Group's -86oC deep-freeze compressors use dual suction valves to surpass traditional single-suction limits....
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