A compressor, the heart of a refrigeration system, is a driven fluid machine that elevates low-pressure gas to high-pressure gas. It draws in low-temperature, low-pressure refrigerant gas through the suction pipe, compresses it using a piston driven by a motor, and then discharges high-temperature, high-pressure refrigerant gas through the discharge pipe, providing power for the refrigeration cycle. This achieves the refrigeration cycle of compression → condensation (heat release) → expansion → evaporation (heat absorption). Compressors are classified into reciprocating compressors, screw compressors, centrifugal compressors, linear compressors, etc.
During operation, the compressor's actual function is to increase pressure, raising the intake pressure to the exhaust pressure. Compression ratio is a technical representation of pressure difference, meaning the absolute pressure on the high-pressure side divided by the absolute pressure on the low-pressure side. The compression ratio must be calculated using absolute pressure values. To avoid negative values, absolute pressure, not gauge pressure, must be used. Using absolute pressure values ensures a positive compression ratio, which is meaningful. Below, we will examine the application of pressure sensors in industrial air compressors.
Industrial air compressors typically range in pressure from 2 hp to 10,000 hp. They are primarily used in pneumatic control, actuation, injection equipment, pneumatic tools, and air exhaust operations. Common air compressors operate at around 125 psi (approximately 8.6 atmospheres) with gas flow rates from 1 CFM to 15,000 CFM. When air containing impurities or contaminants passes through a compressor, its efficiency is significantly reduced, shortening its lifespan. Therefore, manufacturers typically install separators/filters to remove dirt, moisture, and oil from the air. As the filter absorbs more contaminants, the pressure drop of the filtered gas increases. Thus, pressure sensors are used to monitor this pressure drop. When the pressure drop reaches 10 psi, the pressure sensor triggers an alarm system in the circuit, notifying operators to clean or replace the filter. The pressure drop is affected by various factors, including the operating environment, the filter's lifespan, and the volume of air filtered.
This large-range pressure sensor can be used in industrial-grade compressors and can be connected to virtually any microcontroller. Its simple communication protocol requires no programming of the device's internal registers. A gel-protected and anti-magnetic stainless steel cap protects the pressure chip. It is widely applicable to smartphones, tablets, personal navigation devices, and tire pressure gauges.
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