Compressed air is the air mass that is contained in any container, while its pressure exceeds atmospheric. It is used in industry in a variety of manufacturing operations. A typical compressed air system is a unit operating at pressures up to ten bar. In such cases, the air mass is compressed ten times from its original volume.
general information
At a pressure of seven bar, compressed air is practically safe to use. It is able to provide a sufficient driving force of the tool no worse than the electric feed. This requires less cost. In addition, such a system is characterized by faster response, which in the end result can make it much more convenient. However, this will require consideration of the options below.
- The longer the path of the consumer compressor, the more energy is expended.
- Compressed air is very effective with a large number of operations of the same type, in which case there is an advantage over electrical installations. After all, it is more efficient to install an air cylinder than an electric motor.
- You must constantly monitor for leaks.
- When using water, domestic gas, etc., we are already used to being economical, but when using this type of energy, many become wasteful, considering it free. It is necessary to constantly improve pneumatic systems in production, for example, in the countries of Western Europe, new nozzle designs are constantly appearing, in which air is consumed much less, while the noise level is significantly reduced.
Compressed air application
Quite often, manufacturers use this type of energy to quickly and efficiently clean equipment from dirt and dust. In addition, compressed air is widely used for blowing pipes in boiler rooms. In the woodworking industry, it is used to clean wood dust, equipment and even clothing. In most countries, standards for the use of this type of energy have already appeared, for example, in Europe it is CUVA, and in the USA - OSHA. In addition to using it in production operations, tools that work directly on the air are widespread - screwdrivers, pneumatic drills, wrenches, jack hammers (during equipment installation and construction), and spray guns (during major repairs). In addition, compressed air is now widely used in spray cans in pneumatic weapons.
Security
Using compressed air, the safety precautions below must be observed.
- It is forbidden to direct the jet into the mouth, eyes, nose, ears and other places.
- It is impossible to treat open wounds with compressed air, because bubbles can form under the skin, if they reach the heart, they will lead to a heart attack, and if they reach the brain, they can provoke a hemorrhage in the brain. In addition, getting into the wound, air can introduce an infection into it, which is located in the compressor system or in the pipes.
- It is forbidden to indulge and direct a stream of compressed air at other people.
- Do not pressurize the compressor system above normal.
- All elements of the pneumatic installation must be carefully fixed in order to avoid tearing and, as a result, injuries.
- It is forbidden to clean equipment from dust and dirt in the presence of an open flame and welding. This can cause an explosion due to the presence of dust in suspension.
- When working with compressed air systems, personal protective equipment, such as glasses or a mask, must be used.
- It is forbidden to tighten couplings, threaded connections, bolts in knots or on pipes under pressure.
- When installing the pneumatic system, hoses should be fixed in places with the least risk of damage (on ceilings, walls).
The benefits of compressed air
Now we will consider what are the advantages of using this type of energy on production lines.
- Pneumatic tools are characterized by low weight at a sufficiently high power.
- Such installations can be used for a long time without overheating.
- Low system maintenance costs.
- Pneumatic compressors can be used as a source of energy in a fire hazardous production with explosive and flammable substances (underground tunnels, mines).
- These tools are suitable for workshops with high aggressive environments. However, it must be borne in mind that the operating temperature of the compressed air exceeds the ambient temperature by ten degrees Celsius. In addition, with an increase in this parameter, the humidity of the air stream will also increase in direct proportion.
- The use of pneumatic systems can significantly simplify the automation of production processes. For example, such as drying, painting and others.
- Reduces equipment downtime.
Compressed air networks
For optimal operation and high efficiency of the installation, the following requirements must be met. In the pneumatic system, losses should be minimized, in addition, the air should come to consumers drained and clean, this is achieved by installing a special desiccant that allows moisture to condense. Also, special attention must be paid to trunk pipelines. Proper installation of air ducts is the key to a long-term functioning, as well as lower maintenance costs. By increasing the pressure level in the compressor, it is possible to compensate for the drop in the pipeline.
Calculation of compressed air consumption
Compressor plants always include the so-called receivers (air collectors). Depending on the performance and power of the equipment, the system may contain several receivers. Their main purpose is to smooth out pressure pulsations, in addition, the gas mass cools inside the air intake, and this leads to condensation. The calculation of compressed air is to determine the consumption of the receiver. This is done according to the following formula:
- V = (0.25 x Q c x p 1 x T 0 ) / (f max x (p u -p l ) x T l ), where:
- V is the volume of the air receiver;
- Q c - compressor performance;
- p 1 - pressure at the outlet of the installation;
- T l - maximum temperature;
- T 0 - temperature of compressed air in the receiver ;
- (p u -p l ) is the given pressure difference of the load and unload;
- f max is the maximum frequency.