Description:A) TECHNICAL FIELD
[001] The present invention generally relates to a reciprocating air compressor arrangement used for water-cooled air compressor models with canopy to deliver the compressed air. The present invention particularly relates to a reciprocating air compressor arrangement which is used for water-cooled air compressor models with canopy to deliver the compressed air. A suction filter is placed above the 1st stage cylinder of the compressor bare by which fresh air from the atmosphere enters the suction filter. Fresh air intake reduces the thermodynamic work required by the compressor and thereby improves performance of the compressor. The intercooler is placed under the compressor bare. LP cylinder and HP cylinder flanges are assembled to intercooler flanges with help of fasteners. This eliminates the unnecessary piping. The aftercooler is supported above the compressor bare. HP cylinder outlet flange is assembled to aftercooler inlet flange with help of the fasteners. This eliminates unnecessary piping. Because of reduced piping interstage pressure losses are minimised. The electric motor is placed besides the compressor bare along X-direction. This arrangement reduced the footprint of the reciprocating air compressor arrangement in Z direction.

B) BACKGROUND OF INVENTION
[002] The prior art case describes an enclosed canopy compressor wherein the problem due to hot air present inside the canopy/enclosure/package resulted from compressor component heating and other means which is resolved using fans. These fans are mounted inside the compressor package / enclosure/canopy to circulate the ambient air for compressor package. In prior art cases main electric motor drive is assembled on baseframe near the compressor bare on flywheel side. In the prior art watercooled reciprocating air compressor arrangement with canopy, the suction filter is mounted under the 1st stage cylinder of compressor bare. The suction filter intakes the air present inside the canopy. The air temperature in canopy is greater than ambient temperature due to sun radiations and heated compressor components. Suction of this hot air present in canopy into the suction filter increases the thermodynamic work required and degrades the overall compressor performance. The intercooler and aftercooler are supported above the compressor bare. Metal piping is used to connect intercooler/ aftercooler to the cylinders of the compressor bare. This air piping contributes to significant pressure losses. The electric motor is mounted on base frame on flywheel side of the compressor bare along Z-direction. This increases the width of the reciprocating air compressor arrangement in Z-direction.

[003] Unlike the prior art, in the new arrangement of water-cooled reciprocating air compressor with canopy, the suction filter (1) is placed above the 1st stage cylinder of the compressor bare (2). Fresh air enters the suction filter (1) from cut out provided on the top cover of the canopy (9). Because of this, the suction air filter (1) intakes the fresh air from the atmosphere. which overcomes the drawback of heating & improves the performance of compressor. The intercooler (3) is placed under the compressor bare (2). LP cylinder and HP cylinder flanges are assembled to intercooler flanges with help of the fasteners. The aftercooler (4) is supported above the compressor bare (2). HP cylinder outlet flange is assembled to aftercooler inlet flange with help of fasteners. This eliminates unnecessary piping. Because of reduced air piping interstage pressure losses are minimised. The electric motor (5) is mounted on the baseframe (6) besides the 1st stage cylinder of the compressor bare (2) along the X-direction. This arrangement reduced the width of the reciprocating air compressor arrangement.

[004] The above-mentioned shortcomings, disadvantages and problems are addressed herein, as detailed below.

C) OBJECT OF INVENTION
[001] The primary objective of the present invention is to provide a new arrangement of water-cooled reciprocating air compressor with canopy wherein a suction filter is placed above the 1st stage cylinder of the compressor bare by which fresh air from the atmosphere enters the suction filter thereby reducing thermodynamic process of the compressor.

[002] Another objective of the present invention is to provide a new arrangement of the water-cooled reciprocating air compressor wherein reduced air piping further minimises interstage pressure losses.

[003] It is yet another objective of the present invention to provide a new arrangement of water-cooled reciprocating air compressor wherein the width of reciprocating air compressor is reduced by the electric motor being mounted on the baseframe besides the 1st stage cylinder of the compressor bare along the X-direction.

[004] These and other objects and advantages of the embodiments herein will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.

D) SUMMARY OF INVENTION
[005] The reciprocating air compressor is used to produce compressed air for various applications. The reciprocating air compressor consists of various major components like suction filter (1), compressor bare (2) containing cylinder, piston, piston rod, crosshead, connecting rod, crank shaft and crankcase, intercooler (3), aftercooler (4), electric motor (5), base frame (6), motor pulley, flywheel, beltguard (7), control panel (8) and canopy (9) . The components apart from compressor bare (2) are included in the compressor package. When the piston inside the cylinder moves from the HE (Head End) to the CE (Crank End) the pressure inside the cylinder drops and thus the suction valve opens. Thus, the air is sucked inside the cylinder from atmosphere. The air going into the cylinder might contain certain impurities and dirt so a suction filter (1) is placed before the suction port of the compressor. When the piston moves from CE (Crank End) to HE (Head End) the air gets compressed and it is delivered through the delivery port of the compressor. The air gets heated during the compression so it is necessary to cool this air before it enters into 2nd stage cylinder. Therefore, an intercooler (3) is placed after the delivery port of the 1st stage cylinder. The cooling medium inside the intercooler (3) decides the type of intercooler (3). If the cooling medium is water, the intercooler (3) is watercooled and the compressor in called water cooled compressor and if the cooling medium is air, the compressor is called air cooled compressor. The air is then cooled in the intercooler (3) and it enters into 2nd stage cylinder where it again gets compressed. Therefore, for the air to be used at customer end it must be cooled again so an aftercooler (4) is placed after the discharge of 2nd stage cylinder. An electric motor (5) is used to provide the rotational energy to the compressor through a belt and pulley arrangement. The belt and pulley arrangement is covered using a beltguard (7). The entire assembly of compressor is mounted on a baseframe (6). Reciprocating compressors make a lot of noise therefore to provide good working conditions for the workers working near the compressor a canopy (9) is used. Canopy (9) is a cover over the compressor which provides the sound isolation. Because of the enclosed structure of the canopy (9), the air inside the canopy becomes hot because of heat generated by the moving components of the compressor and also by the electric motor (5). If compressor intakes this hot air, its performance reduces.
[006] According to one embodiment of the present invention, the suction filter (1) is mounted above the compressor so that the compressor intakes fresh air from the atmosphere.
[007] According to one embodiment of the present invention the intercooler (3) is placed below the compressor bare (2). Because of this no air piping is required for the air to enter into the intercooler (3). Similarly, the aftercooler (4) is placed above the compressor and no air piping is required for the air to enter into aftercooler.
[008] According to one embodiment of the present invention, the electric motor (5) is placed besides the compressor along X-direction. Therefore, the width of the compressor is reduced.
This arrangement of the water-cooled reciprocating air compressor utilizes the available space effectively and also gives better performance of the compressor.
E) BRIEF DESCRIPTION OF DRAWINGS
[005] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:

[006] FIG. 1 illustrates a perspective view of the water-cooled reciprocating air compressor with the canopy and without the canopy., according to one embodiment of the present invention.

[007] FIG. 2 illustrates a assembly view of the water-cooled reciprocating air compressor without canopy., according to one embodiment of the present invention.

[008] FIG. 3 illustrates a sectional view of the water-cooled reciprocating air compressor without canopy., according to one embodiment of the present invention.

[009] Serial Numbers and Description of component
Serial number Name/ Description of Component
1 Suction filter
2 Compressor bare
3 Intercooler
4 Aftercooler.
5 Electric motor.
6 Baseframe.
7 Beltguard
8 Control panel
9 Canopy

F) DETAILED DESCRIPTION OF THE EMBODIMENTS

[0018] The reciprocating air compressor is used to produce compressed air for various applications. The reciprocating air compressor consists of various major components like suction filter (1), compressor bare (2) containing cylinder, piston, piston rod, crosshead, connecting rod, crank shaft and crankcase, intercooler (3), aftercooler (4), electric motor (5), baseframe (6), motor pulley, flywheel, beltguard (7), control panel (8) and canopy (9). The components apart from compressor bare (2) are included in the compressor package.
[0019] When the piston inside the cylinder moves from the HE (Head End) to the CE (Crank End) the pressure inside the cylinder drops and thus the suction valve opens. Thus, the air is sucked inside the cylinder from atmosphere. The air going into the cylinder might contain certain impurities and dirt so a suction filter (1) is placed before the suction port of the compressor. When the piston moves from CE (Crank End) to HE (Head End) the air gets compressed and it is delivered through the delivery port of the compressor. The air gets heated during the compression so it is necessary to cool this air before it enters into 2nd stage cylinder. So a intercooler (3) is placed after the delivery port of the 1st stage cylinder. The cooling medium inside the intercooler (3) decides the type of intercooler (3). If the cooling medium is water, the intercooler (3) is water-cooled and the compressor in called water cooled compressor and if the cooling medium is air, the compressor is called air cooled compressor. The air is then cooled in the intercooler (3) and it enters into 2nd stage cylinder where it again gets compressed. So, for the air to be used at customer end it must be cooled again so an aftercooler (4) is placed after the discharge of 2nd stage cylinder. An electric motor (5) is used to provide the rotational energy to the compressor through a belt and pulley arrangement. The belt and pulley arrangement is covered using a beltguard (7). The whole assembly of compressor is mounted on a baseframe (6).
[0020] Reciprocating compressors make a lot of noise therefore, in order to provide good working conditions for the workers working near the compressor a canopy (9) is used. Canopy (9) is a cover over the compressor which provides effective sound isolation. Because of the enclosed structure of the canopy (9), the air inside the canopy becomes hot because of heat generated by the moving components of the compressor and also by the electric motor (5). If compressor intakes this hot air, its performance reduces.
[0021] The suction filter (1) filters the air going inside the compressor. The Intercooler (3) cools the hot compressed air coming from the first stage and the cooled air then enters into the second stage. The Aftercooler (4) cools the hot compressed air coming from 2nd stage and this cooled air goes to the receiver tank from where it is utilized at the customer end. Electric motor (5) provides the power required to drive the compressor through a belt pulley arrangement. The suction filter (1), intercooler (3), aftercooler (4) and electric motor (5) are the components of a reciprocating air compressor package. These components along with the compressor package and compressor bare (2) are responsible for the production of compressed air which can be used at the receiver end.
[0022] As seen in Fig. 1 of the present invention of water-cooled reciprocating air compressor with canopy, the suction filter (1) is mounted above the compressor so that the compressor intakes fresh air from the atmosphere. The suction filter (1) is placed above the 1st stage cylinder of the compressor bare (2). Fresh air enters the suction filter from cut out provided on the top cover of the canopy. Because of this, the suction air filter (1) intakes the fresh air from the atmosphere which overcomes the drawback of increase in thermodynamic work of the compressor and reduces the same thereby improving the performance of compressor. The intercooler (3) is placed below the compressor bare (2). LP cylinder and HP cylinder flanges are assembled to intercooler flanges with help of the fasteners. The aftercooler (4) is supported above the compressor bare (2). HP cylinder outlet flange is assembled to aftercooler inlet flange with help of fasteners. This eliminates unnecessary piping.
The intercooler (3) is placed below the compressor bare (2) and aftercooler (4) is placed above the compressor bare (2). So the compressed air coming from the 1st stage directly enters into the intercooler (4) without any air piping and similarly the 2nd stage discharge air enters directly into the aftercooler (4) as the discharge of the 1st stage cylinder is at the bottom and discharge of 2nd stage cylinder is at top. Because of reduced air piping interstage pressure losses are minimized. The electric motor (5) is placed besides the compressor along X-direction. Therefore, the width of the compressor is reduced. This arrangement of the water-cooled reciprocating air compressor utilizes the available space effectively and also gives better performance of the compressor.

[0023] The present invention provides for a water-cooled reciprocating air compressor with canopy wherein the suction filter (1) is mounted above the compressor so that the compressor intakes fresh air from the atmosphere. The intake of fresh, relatively cool air increases the overall mass flow rate thereby reducing the thermodynamic work required by the compressor and thereby improves performance of the compressor.
[0024] As the electric motor (5) in the present invention of the water-cooled reciprocating air compressor with canopy is placed besides the compressor bare (2), the length of compressor package is increased by 25%.
[0025] In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. The embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.

G) ADVANTAGES OF THE INVENTION
[0026] The present invention provides for new arrangement of water-cooled reciprocating air compressor with canopy wherein a suction filter is placed above the 1st stage cylinder of the compressor bare by which fresh air from the atmosphere enters the suction filter. Fresh air intake reduces the thermodynamic work required by the compressor and thereby improves performance of the compressor.

[0027] It is another advantage of the present invention that for new arrangement of water-cooled reciprocating air compressor with canopy, the intercooler (3) is placed below the compressor bare (2) and aftercooler (4) is placed above the compressor bare (2). Therefore, the compressed air coming from the 1st stage directly enters into the intercooler (4) without any air piping and similarly the 2nd stage discharge air enters directly into the aftercooler (4) as the discharge of the 1st stage cylinder is at the bottom and discharge of 2nd stage cylinder is at top, thereby reducing any interstage pressure losses.

[0028] It is yet another advantage of the present invention that the electric motor (5) is placed besides the compressor bare (2) along X-direction. Therefore, this reduces the width of the water-cooled reciprocating air compressor.

[0029] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the claims. , Claims:We claim:
1. A Reciprocating Air Compressor with canopy, comprising:
A baseframe (6);
A compressor bare (2);
A suction filter (1) placed above the compressor bare (2);
An intercooler (3) placed below the compressor bare (2);
An aftercooler (4) placed above the compressor bare (2);
Plurality of intercooler flanges;
Plurality of aftercooler flanges;
Plurality of LP cylinder flanges assembled to intercooler flanges;
Plurality of HP cylinder flanges assembled to intercooler and aftercooler flanges;
An electric motor (5); and
A canopy (9) enclosing the compressor;
wherein; the suction filter (1) placed above the compressor intakes fresh air from the atmosphere reducing the thermodynamic process of the compressor and the assembly of the LP and HP cylinder flanges to the intercooler (3) and aftercooler (4) eliminates requirement of air piping for air to enter into the intercooler (3) and aftercooler (4) thereby reducing loss of interstage pressure.

2. The Reciprocating Air Compressor as claimed in claim 1, wherein the suction filter (1) is placed above the first stage cylinder of the compressor bare (2).

3. The Reciprocating Air Compressor as claimed in claim 1, wherein the LP cylinder and the HP cylinder flanges are assembled to intercooler flanges with help of the fasteners and HP cylinder outlet flange is assembled to aftercooler inlet flange with help of fasteners.

4. The Reciprocating Air Compressor as claimed in claim 1, wherein the electric motor (5) is mounted on the baseframe (6) besides the 1st stage cylinder of the compressor bare (2) along the X-direction.
5. The Reciprocating Air Compressor as claimed in claim 1 and 4, wherein the length of the compressor increases by 25%.
6. The Reciprocating Air Compressor as claimed in claim 1 wherein, the canopy has a cut out provided on its top cover.
7. The Reciprocating Air Compressor as claimed in claim 1, 4 and 5 wherein the width of the compressor is reduced.