A hydraulic air compressor is an air compressor powered by the hydraulics on a vehicle or machine. It allows operators to convert their hydraulic power into air power, ultimately equipping a vehicle or machine with both hydraulic and air power.
How Does a Hydraulic Compressor Work?
A hydraulic compressor utilizes hydraulic power and transforms it into mechanical energy, which is then converted to air power.
Initially, a hydraulic pump sends hydraulic fluid into a hydraulic motor, prompting it to rotate. This rotation, whether via a belt or direct drive, energizes the air compressor system, switching mechanical power to air power.
Figure 1: A hydraulic motor (left) and direct-drive air compressor by VMAC
This explanation is simplified since various other components, such as manifolds, hoses, valves, and cooling systems, can be involved.
At its core, any hydraulic air compressor system contains these key elements:
- Hydraulic Pump – pushes hydraulic fluid through the system
- Manifold – controls the fluid flow to the motor
- Hydraulic Motor – driven by hydraulic fluid
- Air Compressor – activated by the hydraulic motor
- Cooler/Reservoir – returns hydraulic fluid from the motor to a cooler, then into a reservoir tank
Together, these components turn hydraulic power into air power.
Benefits of a Hydraulic Air Compressor
Hydraulic air compressors offer numerous advantages, particularly for those needing to operate air tools. Pneumatic tools, powered by air compressors, are exceptionally robust and enable users to execute tasks swiftly and effectively.
Common Tools Powered by Hydraulic Air Compressors
Hydraulic air compressors can power various air tools across many applications. Some frequently used pneumatic tools include:
- Impact wrenches
- Jackhammers
- Air chucks
- Grinders
- Chipping hammers
- Air spades
- Moles
- Post pounders
Additional Benefits of Hydraulic Air Compressors
In addition to powering air tools, hydraulic air compressors have other noteworthy benefits:
- Seamless access to hydraulic and air power
- Compatible with existing power sources
- Eliminates the need for an additional compressor engine
- Cost-effective compared to other integrated air compressors
- Easy to install and operate
- Reliable and safe
- Can be transferred between vehicles with similar hydraulic setups
When to Consider Using a Hydraulic Air Compressor
Hydraulic air compressors are ideal for operators who already rely on hydraulics and wish to add air power. Additionally, upgrading a vehicle to include new hydraulics and an air compressor is a beneficial option. These compressors provide a neat and simple installation by leveraging the existing hydraulic system.
Historically confined to trucks with hydraulic cranes, hydraulic air compressors are now used extensively in modern mobile air industries. They are found on excavators, hi-rail excavators, pile drivers, and other specialized hydraulic equipment. If you work with any of these machines, considering a hydraulic air compressor is wise when adding air power to your machinery.
Additional Hydraulic & Air Compressor Resources
Hydraulic compressor
Air compressor driven by a hydraulic motor
A hydraulic compressor is a means of compressing air using hydraulic energy. There are two main types of hydraulic compressors.
One type involves a mechanical air compressor driven by a hydraulic motor, converting hydraulic power to pneumatic power. This type is typically used in applications where hydraulic power is available, and a small amount of compressed air is needed, though it is less efficient than an electrically driven compressor.
The other type uses the potential and kinetic energy of a water stream to carry air into a separation chamber at a higher pressure. This method, featuring minimal moving parts, is used where kinetic or potential water energy is economical.
Design
The second type of hydraulic compressor has the benefit of isothermal compression without moving parts, making it reliable with low maintenance costs. Water flow carries air downward through a 'downcomer' pipe by static pressure differential. As the air-water mixture descends, pressure increases. In the stilling chamber, the air separates by buoyancy, rising to exit through a 'raiser' pipe, while water drains away.
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The main issue involves the scale and cost of the compressed air storage chamber. The chamber price can exceed installation costs. Though it has higher energy costs, it increases renewable energy production.
Cost Breakdown
Figure 2: 0: Energy Cost, 1: Compressor Cost, 2: Maintenance Cost (Based on 24/7 operation, $0.08/kWh, full load operation)
Energy cost is the significant expense in compressor integration. The type and size of the compressor affect utility and power draw. Efficiency comes from matching air production capacity with air requirements, avoiding energy loss.
Pipe design can also impact system cost. A design without sharp corners or dead-ends maintains pressure and passage efficiency. Aluminum pipes, lighter and more corrosion-resistant than steel, simplify installation. However, pipe diameter is crucial for reducing pressure differential, which otherwise converts more pressure energy to heat, decreasing compressor lifespan.
Efficiency
Measuring compressed airflow power involves the equation \( W = mRT*ln(\beta) \). Real-world scenarios must account for airflow loss, using the energy conservation equation for isothermal flow: \( loss = m[RT*ln(P0/P1)-V^2/2]\). Factors like wall collision and friction impact air loss.
Compressed air flow increases with the liquid mass flow rate in the system, calculated for specific hydraulic pump parts. Configurations may include parallel or series pumping, with pump curve efficiency determined by the quadratic equation \( Q = -b \pm *\surd (b^2 - 4a(c-H))/2a\), graphed against electrical power consumption.
See also
- Airlift pump – Uses density differences due to air injection
- Compressor – Increases gas pressure by volume reduction
- Compressed air – Air under greater-than-atmospheric pressure
- Pneumatics – Branch of engineering focused on air/gas
- Pneumatic tool – Tool driven by air compressor
- Hydraulic power – Different uses
- Hydropower – Energy from water movement
- Fluid power – Using pressurized fluids for power transmission
References
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