AIR

COMPRESSOR
GROUP 1
 How Does an Air
Compressor Work?
Air compressors work by forcing atmospheric air under pressure to
create potential energy that can be stored in a tank for later use.

Generally, air compressor operation requires a pump cylinder,

piston and crankshaft to transfer energy for a wide variety of tasks.
These basic components can help supply air for filling up objects
like tires or inflatable pool toys, or they can supply power for
operating tools such as drills, nail guns, grinders, sanders and spray
guns.

Compressors themselves are more compact and lightweight than

other centralized power sources
Piston Air Compressor
Functionality
The compressor draws in air and creates a vaccum to reduce its volume.
The vacuum pushes the air out of the chamber and into its storage tank.
Once the storage tank reaches its maximum air pressure, the compressor
turns off.

For those that use pistons, it involves two parts: Raising the pressure and
reducing the volume of the air. Most compressors use reciprocating piston
technology.
An air compressor typically uses:
• An electric or gas motor
• An inlet and a discharge valve to draw in and release air
• A pump to compress the air
• A storage tank
What Is Air Displacement?

Air displacement is at the core of each air compressor. To compress air, the
internal mechanisms within the compressor move to push air through the
chamber.
 POSITIVE DISPLACEMENT:
Two primary types of Most air compressors use this method, in which air is
pulled into a chamber. There, the machine reduces the
volume of the chamber to compress the air. Next, it is
air displacement used moved into a storage tank and saved for later use.

for this purpose

DYNAMIC DISPLACEMENT

Also called nonpositive displacement, this method uses an

impeller with rotating blades to bring air into the chamber.
The energy created from the motion of the blades builds
up air pressure in a shorter amount of time

Dynamic displacement can be used with turbo-

compressors because it works quickly and generates large
volumes of air. Turbochargers in cars often use dynamic
displacement air compressors.
 Types of Positive Displacement Air Compressors

Rotary screw
Typical for industrial use and has sizes to fit many applications. These compressors have two screws inside the motor,
turning continuously in opposite directions. The motion of the screws creates a vacuum that sucks in air. That air
becomes trapped between the screws’ threads and is compressed as it is forced between them. Finally, it is sent through
the output or into a containment tank.
 Types of Positive Displacement Air Compressors

Rotary screw
• Atmospheric air enters the compressor at the inlet valve.
• The air travels through the pressure control line to the regulator valve, a process that sets the system’s air pressure.
• Air then enters the compressor, where it combines with oil into a mist.
• Air travels the length of the two internal screws as they rotate in opposite directions.
• The screw motion creates a vacuum, trapping and compressing air in the space between the screws.
• The pressurized air is forced through the output and into the primary oil separator tank while still combined with
the oil as a mist.
• The centrifugal force inside the tank causes most oil molecules to form into droplets and collect at the bottom as
reusable oil.
• Air then enters a secondary separation filter where more oil is removed, purifying the air further.
• The oil-free air exits the system, where it is stored in a tank or used immediately in a connected pneumatic tool or
machinery.
 Types of Positive Displacement Air Compressors

Rotary vane
Has a similar principle to a rotary screw. With a rotary vane, a motor is placed off-center inside a rounded cavity. The
engine has blades with automatically adjusting arms. As the arms approach the air input, they are elongated, creating a
large air cavity. As the motor spins, moving air with it, the arms approach the output and get smaller, creating a smaller
space between the vanes and the round casing, which compresses the air.
 Types of Positive Displacement Air Compressors

Rotary vane

• Atmospheric air enters through the inlet valve and travels into the compressor.
• Vanes are mounted on the internal spinning rotor, which is placed off-center inside the cavity.
• Arms with self-adjusting length divide the space, creating several cavities of varying size.
• Air fills the cavity and travels around, following the rotor’s rotation.
• As the cavity gets smaller, air pressure builds up and compresses the air.
• The pressurized air is then forced through the compressor’s output.
 Types of Positive Displacement Air Compressors

Reciprocating/piston
In a reciprocating air compressor, a rotor’s spin forces a piston to move up and down. When the piston goes down,
freestanding air is pulled into a chamber. Then, the air is compressed and forced back outward as the piston rises back
up. Some compressors, called single-stage compressors, use only one piston. Others, called two-stage compressors, use
two pistons and are able to pressurize more air. The reciprocating type of air compressor is one of the most common.
The Mechanics of an Air Compressor
How air compressors work can vary according to design. Piston-based air compressors
can have one of two types of compression cycle

Single-stage: The piston compresses the air in one stroke. A stroke is one full rotation
of the crankshaft driving the piston. The simple, single-stage design makes many of
these compressors ideal for private projects.

Here are the technical steps of single-stage air compressor operation:

• The rotor’s spin forces a single piston to move up and down.
• When the piston moves down, atmospheric air is pulled into the compression
chamber through the opened valve.
• When the piston moves up, the air is compressed as it’s pushed into the output
chamber.
• The pressurized air is then forced through the compressor’s output.
Two-stage: The first piston compresses the air before moving it to a smaller
cylinder, where another piston compresses it further. This design allows the
compressor to generate higher pressures, making it ideal for factories and
workshops.

Here’s how a two-stage air compressor operates:

• The rotor spins to control two pistons simultaneously, forcing each
piston to move conversely up and down.
• The larger piston pulls air into the first compression chamber, then
pushes it out to the intercooler.
• The intercooler uses a continuous stream of water to cool the air.
• The smaller piston compresses a large volume of air into a compact
space, further pressurizing it.
• The pressurized air is then forced through the output by the small piston.
 How Does an Air Compressor
Regulator Work?
For many single-stage air compressors, the preset pressure limit is 125 psi.
When this limit is reached, a pressure switch goes off to stop the motor and
the production of compressed air.

When the specified pressure is reached, the regulator shuts off the pump at any point in its cycle, which means the piston
can be halfway through a stroke, with pressurized air in the chamber, when it stops. This air can put undue pressure on
the starting circuit, which needs more power to start the motor. An unloader valve is a simple addition that releases the
trapped air to avoid this problem.

A regulator is bookended by two gauges — one to monitor the pressure of the tank and another to monitor the pressure
within the air line. Also, the tank has an emergency valve that triggers if the pressure switch malfunctions.
What Is a Reciprocating Piston?

The reciprocating piston involves the following parts:

• Crankshaft
• Connecting rod
• Cylinder
• Piston
• Valve head

Compressors that use pistons can be louder than some other designs because of how the machine’s components move and
generate friction. But new technologies and advancing designs are bringing dual and multi-piston models that can make
things quieter by splitting up the workload.
The Rotary Screw Air Compressor
While the piston air compressor uses pulsation and the alternating nature of the piston mechanic, a rotary screw compressor
is continuous. A pair of rotors mesh together to pull air in and compress it as it moves through a spiral. The rotary motion
moves the air through a chamber and ejects it. Fast rotational rates can minimize leakage.
Rotary screw compressors can vary widely, with rates from 10 CFM to those in the 4-5 figure range. Control schemes
include:
• Stop/start: This approach either provides power to the motor, or it does not, according to the application.
• Load/unload: The compressor is powered continuously, with a slide valve that reduces the tank’s capacity when a
specific compression demand is met. This scheme is common in factory environments, and if it involves a stop
timer, it is called a dual-control scheme.
• Modulation: Modulation also uses a sliding valve to adjust pressure by throttling/closing the inlet valve, matching
the compressor’s capacity to the demand. These adjustments are less effective on rotary screw compressors than
other types. Even when set to a 0 capacity, the compressor would still consume about 70
percent of its full power load. Still, modulation is applicable for operations in which frequently stopping the
compressor is not an option.
• Variable displacement: This control scheme adjusts the volume of air that is pulled into the compressor. In rotary
screw compressors, this method may be used alongside modulating inlet valves to
improve efficiency and pressure control accuracy.
• Variable speed: Variable speed is an efficient way to control a rotary compressor’s capacity, though it may respond
differently with different types of air compressors. It varies the speed of the motor, which affects the output. This
equipment tends to be more delicate than other designs, so it may not suit particularly hot or dusty work
environments.