Essentially, all air compressors use an element or air end to produce pressurized air. By compressing the air, air compressors are able to drive a variety of pneumatic tools and equipment.
This air is stored in air tanks until it is released through hoses and valves for a variety of industrial uses. This air powers a variety of equipment, used in everything from automotive repair and home improvement projects to the medical and hospitality industries.
Basic working principle of air compressors
Air compressors compress air into a smaller volume through mechanical movement, thereby increasing its pressure. The compressed air can be stored in air tanks and is always available for use by pneumatic tools and equipment.
Structural composition of air compressors
The structure of an air compressor consists of several key components, each of which has its specific function and role. Here we briefly introduce 4 important structural components.
- 1. First, an electric motor is needed to provide power to make the air compressor operate. The compressor host is the core part of the air compressor, which reduces its volume and increases the air pressure by compressing the air.
- 2. The cooling system includes air cooling or water cooling system, which is used to cool the compressor host and compressed air to prevent overheating.
- 3. Pressure switches/sensors, drain valves, safety valves, etc. monitor and adjust the working pressure of the compressor to ensure that the compressor operates within the set pressure range.
- 4. Here we also need to introduce a key device, which is the frequency converter. So why does the air compressor need a frequency converter?
Traditional air compressors will still run at full speed when a large amount of gas is not needed, while the frequency converter can slow down the air compressor when the demand is low, further reducing energy consumption. Frequency converters usually have protection functions such as overload, overvoltage, undervoltage and short circuit, which effectively protect the safe operation of the motor and air compressor system.
Therefore, the frequency converter achieves precise control of the compressor output pressure and flow by adjusting the speed of the motor. The air compressor-specific frequency converter developed by ZONCN inverter is to improve the working efficiency of the air compressor and save energy and reduce consumption.
Main Types of Air Compressors
There are two main types of air compressor element designs – piston and rotary screw.
Piston air compressors compress air by reciprocating a piston in a cylinder. They are simple in structure, relatively cheap, and suitable for intermittent work. They are mainly used in small factories, repair shops, and household tools.
Screw air compressors compress air by meshing two spiral rotors. They can supply air continuously and are highly efficient, making them ideal for medium and large operations.
Screw air compressors are slightly more expensive to purchase, but they have energy-saving features and technologies. Due to their simple design, piston air compressors are less suitable for smart factories and modern equipment.
Main Applications of Air Compressors
- Industrial Manufacturing: Drives pneumatic tools and equipment. Used in processes such as spraying, packaging, handling, and assembly.
- Construction and Maintenance: Drives pneumatic nail guns, drills, spray equipment, etc. Used in civil engineering, building construction, and road maintenance.
- Automotive Maintenance: Provides power to pneumatic wrenches, paint spray guns, tire inflators, and other equipment.
- Home and Small Workshop: Drives pneumatic tools such as pneumatic nail guns, paint spray guns. Used for home repairs, DIY projects, small-scale production.
Approximate cost range of air compressors
Famous brands of air compressors:
Such as Atlas Copco, Ingersoll Rand, Kaeser, etc., usually have higher prices, but the quality and service are guaranteed.
Cost range of air compressors:
Small piston air compressors: $500 – $3,000
Medium screw air compressors: $8,000 – $42,000
Large industrial screw air compressors: $45,000 – $150,000
Centrifugal air compressors: $72,000 – $430,000
The greater the power and air flow, the higher the price. For example, a small portable air compressor may only have 1-2 kilowatts and cost a few hundred dollars, while a large industrial air compressor may reach hundreds of kilowatts and cost more than 100,000 dollars. The installation and commissioning of large air compressors requires professionals, and additional fees may be required.
The cost of an air compressor depends on many factors. When purchasing, you should consider factors such as demand, budget, brand, after-sales service, etc. to choose the most suitable air compressor equipment.