When configuring air compressors for 6 machining centers, comprehensive selection should be made according to actual gas consumption, working pressure and compressed air quality requirements, it is recommended to select screw air compressor with displacement of 12-18m & sup3;/min, rated pressure of 0.8-1.0MPa, And with gas storage tanks and post-processing equipment. Specific analysis is as follows:
1. core parameter calculation
- gas consumption estimation
- gas consumption of single machining center: According to the equipment model and process, the air consumption of a single processing center is usually between 1-3m & sup3;/min. Assuming that the average gas consumption of a single unit is 2m & sup3;/min, the total gas consumption of 6 units is:
6 x 2m & sup3;/min = 12m & sup3;/min - allowance Reservation: In order to cope with peak gas consumption (such as multiple equipment starting at the same time) and system leakage, 10%-20% margin should be added to the total demand:
12m³/min×1.2=14.4m³/min
therefore, it is recommended to select the rated displacement of the air compressor. 12-18m³/min(e. g. 15m & sup3;/min model).
- Determination of working pressure
- gas end pressure demand: Pneumatic tools in machining centers (such as spindle air seals and tool magazine cylinders) usually require a working pressure of 0.6-0.7MPa.
- Pressure margin: Considering the pipeline pressure loss (about 0.1-0.2MPa), the rated exhaust pressure of the air compressor should be 0.1-0.2MPa higher than the air pressure:
0.7MPa + 0.2MPa = 0.9MPa
therefore, it is recommended to choose a rated pressure 0.8-1.0MPa the air compressor.
2. air compressor type selection
- screw air compressor
- advantage: High gas quality, low noise, stable operation, suitable for continuous production scenarios.
- Applicability: The gas consumption of 6 processing centers belongs to small and medium scale (12-18m & sup3;/min), screw air compressor is the mainstream choice.
- Power Reference: Take 15m & sup3;/min, 0.8MPa screw air compressor as an example, the drive motor power is about 75-110kW (specific need to be adjusted according to brand and efficiency).
- Other types of comparison
- piston air compressor: Low price, but large vibration, frequent maintenance, suitable for small gas volume, intermittent gas scenarios, not recommended.
- Centrifugal air compressor: Suitable for atmospheric volume (≥ 50m & sup3;/min), high cost, not applicable.
3. key supporting equipment
- gas tank
- role: Buffer gas fluctuation, stabilize air pressure and reduce frequent start and stop of air compressor.
- Capacity selection: Usually 1-2 times the displacement of the air compressor, it is recommended to choose 15-30m & sup3; the gas tank.
- Post-processing equipment
- freeze dryer: Reduce the pressure dew point of the compressed air to 3-10°C to prevent moisture from causing corrosion to the equipment.
- Precision filter: Filter accuracy ≤ 1μm, remove oil and particles, and ensure the cleanliness of compressed air.
4. selection considerations
- avoid "big horse-drawn cars"
- too much selection of air compressor will lead to waste of energy consumption, while too little selection may accelerate equipment wear due to long-term full-load operation.
- Example: if the actual gas consumption is 12m & sup3;/min, select 15m & sup3;/min model (25% balance) is more energy-efficient than 20m & sup3;/min model (67% balance).
- Frequency conversion and fixed frequency selection
- variable frequency air compressor: The rotating speed can be automatically adjusted according to the gas demand, saving energy by 20%-40%, suitable for scenes with large gas fluctuations.
- fixed frequency air compressor: Low cost, suitable for gas stable scenes (such as 24 hours continuous production).
- Brand and Maintenance
- choose brands with reliable quality and good after-sales service (such as Atlas Copco, Ingersoll Rand, Jaguar, etc.) to reduce post-maintenance costs.
- Regularly replace the lubricating oil and filter element to ensure long-term stable operation of the equipment.
