belt compressor

Types of Belt Compressors

A belt compressor is a machine that increases the pressure of a gas by reducing its volume. There are several types of compressors that operate using different working principles.

• Reciprocating Compressors: The core components of a reciprocating air compressor are inlet and outlet valves, a piston, a crankshaft, a cylinder, and a gas reservoir. The valves function to allow the airflow in one direction and prevent reverse flow. The crankshaft converts rotary motion into linear motion, driving the piston in the cylinder. The gas reservoir is also known as an air receiver tank, and it is where compressed air is temporarily stored. When the crankshaft spins, the valve pops open, allowing ambient air to flow into the cylinder through the inlet valve. As the piston moves, it compresses the air. Once compressed, the outlet valve opens, and the compressed air is pushed out. The cycle continues.
• Screw Compressors: As its name implies, a screw air compressor has two screw rotors. One rotor is the driving rotor, and the other is the driven rotor. The drive motor turns the shaft to make the driving screw rotate, which compresses the air and makes the other screw rotate. The compression process happens in three stages: suck, hold, and release. Ambient air is sucked into the chamber between the two screws, then the air is held and compressed as the screws rotate, and finally, the compressed air is released. A special feature of the screw compressor is that it can have a reservoir to store the compressed air or work continuously.
• Scroll Compressors: A scroll compressor has two spiral components, the fixed scroll and the moving scroll. The fixed scroll is mounted vertically, while the moving scroll is located inside the fixed scroll, and it orbits around. Ambient air enters the gap between the two spirals, and as the moving spiral orbits, the gap decreases, and the air gets compressed. The fixed and moving spirals push out the compressed air through a discharge port. Some scroll compressors feature an unload function that allows the motor to run without compressing air.
• Diamond Compressors: This type of compressor has a heavy-duty cylinder, stainless steel valves, and anodized aluminum pistons. It works efficiently for both industrial and recreational use by compressing and transferring gasses like oxygen, air, carbon dioxide, and nitrous oxide through its optimized gas transfer system. Depending on the system that makes it up, a diamond compressor can have single-stage compression or multi-stage compression. When there is single-stage compression, ambient air is sucked in through the suction valve and moved out through the discharge valve after compression. In multi-stage compression, there are reservoirs in which the compressed air is kept. Then, the compressed air is passed into another compression chamber for further compression.

Specification & maintenance of belt compressors

Specification

• Airflow (CFM)

  The volume of compressed air flowing through a system, typically measured in cubic feet per minute (CFM), represents the machine's output capacity. The controller can therefore determine the amount of air that the 3hp belt-driven air compressor is capable of generating.

• Horsepower (HP)

  This amount of work that the compressor's motor can do is calculated. This is directly linked to the compressor's capacity to produce compressed air output.

• Tank Size (Gallons)

  This refers to a storage vessel that holds compressed air until it is used. The tank's dimensions influence how long the compressor can deliver a steady supply of compressed air.

• Operating Pressure (PSI)

  This is the force at which the compressor pumps air into the storage tank or air delivery system. The operating pressure affects the volume of compressed air the compressor can produce and the force of the air. Operating pressure is typically measured in pounds per square inch (PSI).

• The overall dimensions and weight of the machine

  When it comes to industrial compressors, construction vehicles, and other heavy-duty applications, compressing air may be the most economical way to store and transfer energy. Machines with greater weight and volume may be suitable in other contexts.

Maintenance

Maintenance of a belt-driven air compressor is critical to ensuring reliable performance, extended service life, and optimal operation. Correctly handling and using the air drill bits will also allow users to employ some air tools without the need for maintenance reminders.

A small maintenance schedule for a compressor could include things like:

• daily or weekly checks of things like nut/bolt tightness; leaks in the system, lub oil levels; correct operation of pressure switches; and health of guages, belts, and other critical parts.
• Stop/Start Mechanism

Generally, the stop/start mechanism of industrial belt-driven air compressors works smoothly, but it may need adjustments after prolonged use to ensure proper functioning.

Identify the Problem

Check if the compressor is running continuously or not starting as it should. Note any unusual sounds or other issues with the compressor's functionality.

Inspect the Stop/Start Mechanism

Examine the pressure switch to ensure the contacts are in good condition and functioning correctly. Look for any loose or damaged wiring that may need to be repaired. Adjust the pressure switch to ensure it's stopping and starting the compressor at the right pressure levels.

Check the Relay

Inspect the relay that controls the electrical circuit stopping and starting the compressor. Look for signs of wear or damage, and ensure the connections are secure.

Belts

Since this is a belt-driven compressor, it is also essential to check that the belts are properly tensioned and not worn or damaged.

Test the Mechanism

Once everything has been inspected and any issues addressed, test the stop/start mechanism by manually activating the pressure switch. Observe whether the compressor starts/stops as it should.

Document and Monitor

Document any adjustments or repairs made to the stop/start mechanism. Monitor the performance regularly to ensure it's functioning smoothly.

A comprehensive manual guide is provided with most products, but in case further assistance is required, it is always useful to refer to it.

Application scenarios of belt compressors

Belt-driven air compressors have diverse applications across various industries due to their ability to generate compressed air. Here are some of the key industrial applications where belt air compressors are utilized:

• Manufacturing: Belt-driven air compressors are widely used in manufacturing industries as a power source for operating various manufacturing equipment. They are used to power pneumatic tools (such as drills, wrenches, grinders, and sanders) and provide pressure for packaging and bottling production lines, product spraying and painting, and moisture removal and cleaning. The versatile applications of belt air compressors allow them to assist efficiently in different manufacturing processes.
• Automotive: In the automotive industry, belt-driven air compressors provide compressed air to automate various production processes. They are commonly found in automotive repair shops as well, helping to power pneumatic tools used in vehicle maintenance and repair. Additionally, some vehicles are equipped with a small belt compressor that is designed to boost the vehicle's engine output (known as a supercharger).
• Construction: Belt air compressors are one of the essential pieces of equipment at construction sites. They power pneumatic tools, nail guns, spray guns, and air motors, offering convenience and efficiency for various construction tasks. Their portability and ease of use make them ideal for use in on-site construction work.
• HVAC: Belt compressors act as cooling machines that provide air conditioning systems with the compressed refrigerant (which is the working fluid of the cooling cycle). The role of the refrigerant is to absorb heat from the air and thus lower the temperature of the cooled air (the cold air supplied to the living space).
• Food and beverage production: Belt compressors help provide a clean and sterile production environment for the food and beverage industry through pneumatic conveying, packaging, bottling, and spraying processes.
• Agriculture: In agricultural applications, farming equipment and tractors can be powered by a belt compressor through the use of pneumatic systems, helping to achieve various agricultural production tasks.
• Oil and gas extraction: Belt air compressors are also frequently used in the oil and gas extraction industry. They provide the compressed air needed for offshore platforms and would be used together with other equipment such as air dryers and pipelines to facilitate drilling operations.

How to choose a belt compressor

When purchasing a new machine, it's always best to research the options available so that one's needs can be met. In the case of the belt-driven air compressor, customers need to look at a few things before deciding on the purchase.

• Required volume of air:

  This is the first thing to consider. What amount of air or pressure does one need to do the tasks at hand? Identify the tools one plans to use with the compressor and their CFM requirements. Consider whether the intended applications are burst-oriented or runtime-dependent. If using nail guns, spray paint, or sanders, etc., check the tools' CFM. Tools that operate with about 100-120 psi are generally considered. If the RMS is sanders or grinders, etc., check if they work at a higher pressure. Typically, higher CFM tools require that compressors be used. For higher CFM, one may need to look at belt-driven compressors with big tanks, multi-stage models, or the variable speed drive function.

• The machine's environment:

  Consider the surroundings the compressor will be working in. Will the machine's environmental factors like heat, moisture, and pressure affect the performance? If yes, a possible solution would be to go for a compressor with a control panel that includes pressure and temperature monitoring to detect any issues early on. Or choose one that has a cool, weather-resistant housing that can withstand different environmental conditions.

• Horsepower:

  Decide on the horsepower needed. It is critical to understanding that horsepower performance directly affects the amount of compressed air generated. In turn, this affects the compression of the air and the power needed to perform the task.

• The energy source:

  Consider the available energy source when choosing the air compressor. Is it electricity? If so, then a belt-driven option can be considered, especially for a fixed application. If the job requires a portable solution running on gasoline or diesel, then a fuel-powered compressor may have to be chosen.

• Noise levels:

  The amount of noise the compressor will make is also something to consider. Belt-driven motors are generally quieter than direct-drive compressors. It may be necessary to wear hearing protection while the machine is in use. However, if the compression machine is to be placed near working or living areas, it might be better to get one with a low noise level. Check compression machines with sound ratings at one-meter distance to determine which one is quieter. Consider also getting additional soundproofing or attenuation if that's what it takes to reduce the noise level further.

• Budget:

  The last thing to consider but is important is the budget range. When it comes to a belt-driven air compressor, plenty of options are available at different prices. Consider looking through the function, specs, and benefits of each machine before making a choice.

Q&A

Q1: Which one is better, a Diesel compressor or a belt compressor?

A1: Many factors must be considered before determining which is better between the two. A diesel engine will compress air at a higher CFM and may also have a capacity of around 200 PSI. A diesel compressor will also work well in extremely cold weather. Thus, belt compressors are generally preferable due to their lower maintenance costs.

Q2: Are belt air compressors any good?

A2: Yes, many people prefer using the belt air compressor due to its quiet operating capabilities. It is also durable and tends to have a lower purchase cost compared to other compressors.

Q3: Do compressors have belts?

A3: Yes, many air compressors have belts. However, not all air belts have compressors. The model and type of the air compressor will determine whether or not it has a belt.

Q4: What are the two types of air compressors?

A4: Generally, air compressors are divided into two main categories: positive displacement air compressor and dynamic air compressor. The positive displacement air compressor comes with many subtypes, including rotary screw, drag, and piston, and the dynamic air compressor comes turbine and axial flow subtypes.