DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE

WM522 PNEUMATICS AND HYDRAULICS

CHAPTER 2: AIR GENERATION AND DISTRIBUTION

The air compressor features.

The air receiver function.

The air dryer principles.

The air service equipment.

The air distribution system.

DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
WM522 PNEUMATICS AND HYDRAULICS

AIR GENERATION AND DISTRIBUTION

Objectives:-

At the end of this lesson the students will be able to:

• Explain the air compressor features.

• Explain the air dryer principles.
• Explain the air service equipment.
• Determine the air distribution system
DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
WM522 PNEUMATICS AND HYDRAULICS

2.1 AIR COMPRESSOR

A compressor is a machine that compresses air or another type of gas from a low inlet
pressure (usually atmospheric) to a higher desired pressure level. This is
accomplished by reducing the volume of the gas. Air compressors are generally
positive displacement units and are either of the reciprocating piston type or the rotary
screw or rotary vane types.

2.1.1 Piston Compressor

In this type of compressor a cylinder bore encloses a moving piston. As the crankshaft
of the compressor rotate, the piston moves within the cylinder, similar to the piston in
a car engine. As the piston is pulled down, the volume increases, creating a lower
atmospheric pressure in the piston chamber. This difference in pressure causes air to
enter via the inlet valve. As the piston is forced upwards the volume of air reduces.
The air pressure therefore increases. Eventually the pressure forces the outlet valve to open.
DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
WM522 PNEUMATICS AND HYDRAULICS

To avoid an excessive rise in temperature. Multi-stage compressors with INTERCOOLERS

have been developed. These compressors can generate higher pressures than single stage
compressors. The most common type is the Two-Stage compressor. The following figures
show how this compressor works.

2.1.2 Vane Compressor

The following figure shows a cutaway view of the sliding-vane-type rotary compressor. The
air inlet is placed where the volume of the compression chamber is greatest, the outlet where
the volume is smallest. Consequently, as the vanes turn, the space between them is reduced.
This reduction in volume compresses the air as it travels from the inlet to the outlet.
DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
WM522 PNEUMATICS AND HYDRAULICS

2.`1.3 Screw compressor

There is a current toward increased use of the rotary-type compressor due to technological
advances, which have produced stronger materials and better manufacturing process. The
following figure shows a cutaway view of a single-stage screw type compressor. Precise
positioning of the screw is essential for its performance. Oil provides a seal between the
rotating screws as well as lubricating the parts and cooling the air. The oil is then separated
from the air before it enters the system.

2.1.4 Lobe compressor

In this type of compressor the rotors do not touch and certain amount of slip exists. This slip
increases as the output pressure increases. It is therefore operated at maximum speed for the
highest efficiency. 17.3 bar is obtainable with this type of constant displacement compressor.
DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
WM522 PNEUMATICS AND HYDRAULICS

2.2 AIR DRYERS

Condensate (water) enters into the air network through the air intake of the compressor. The
accumulation of condensate depends largely on the relative air humidity. The relative air
humidity is dependent on the air temperature and the weather situation.

The absolute humidity is the mass of water vapour, actually contained in one m3 of air. The
saturation quantity is the mass of water vapour, which one m3 of air can absorb at the
respective temperature. The following formula applies if the relative air humidity is specified
in percent:
Relatives humidity = absolute humidity x 100%
saturation quantity

Since the saturation quantity is dependent on temperature, the relative humidity changes with
the temprature, even if the absolute humidity remains constant. If the dew point is reached,
the relative humidity increases to 100%.

2.2.1 Dew point

The dew point temperature is the temperature at which relative humidity is 100%. The lower
the dew point the more the water will condense and reduce the amount entrapped in the air.
The service life of pneumatic systems is considerably reduced if excessive moisture is carried
through the air system to the components.

Therefore it is important to fit the necessary air drying equipment to reduce the moisture
content to a level which suits the application and the components used. There are three
auxiliary methods of reducing the
moisture content in air:
• Low temperature drying
• Adsorption drying
• Absorption drying
DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
WM522 PNEUMATICS AND HYDRAULICS

2.3 AIR SERVICE UNIT

The air service unit is a combination of the following

• Compressed air filter
• Compressed air regulator
• Compressed air lubricator.

2.3.1 Air Filter

The air needs to be filtered to be free of moisture and contamination. Air filter is used
to do this job. The filter elements remove the particles and moisture as small as 5 microns.
DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
WM522 PNEUMATICS AND HYDRAULICS

2.3.2 Pressure Regulator

The pressure regulator is used to adjust the desired pressure for the pneumatic system. This
use a piston to sense downstream pressure fluctuations. The piston, in turn, works against a
set spring pressure. As the pressure downstream drops it is sensed by the diaphragm and the
popper valve opens. This adjusts the position of the poppet valve, which limits the
downstream pressure to the pre-set valve.

2.3.3 Air Lubricator

A lubricator ensures proper lubrication of internal moving parts pneumatics components. The
proportional increase in oil mist by an increase of air flow is achieved by the spring loaded
poppet assembly. As the flow increases and the valve opens, the area is increased and a
pressure differential created.
DIPLOMA ENGINEERING IN AIRCRAFT MAINTENANCE
WM522 PNEUMATICS AND HYDRAULICS

2.4 AIR DISTRIBUTION SYSTEM

The air supply for a particular pneumatic application should be sufficient and of adequate
quality. Air is compressed to approximately 1/7th of its volume by the air compressor and
delivered to an air distribution system in the factory. To ensure the quality of the air is
acceptable, air service equipment is utilized to prepare the air before being applied to the
control system.

Malfunctions can be considerably reduced in the system if the compressed air is correctly
prepared. A number of aspects must be considered in the preparation of the service air:
• Quantity of air required to meet the demands of the system
• Type of compressor to be used to produce the quantity required
• Storage required
• Requirements for air cleanliness
• Acceptable humidity levels to reduce corrosion and sticky operation
• Lubrication requirements, if necessary
• Low temperature of the air and effects on the system
• Pressure requirements
• Line sizes and valve sizes to meet demand
• Material selection and system requirements for the environment
• Drainage points and exhaust outlets in the distribution system
• Layout of the distribution system to meet demand.
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WM522 PNEUMATICS AND HYDRAULICS

As a rule pneumatic component is designed for a maximum operating pressure of 8- 10 bar

(800-7000 kPa) but in practice it is recommended to operate at between 5 and 6 bar (500-600
kPa) for economic use. Due to the pressure losses in the distribution system the compressor
should deliver between 6.5 and 7 bar (650-700 kPa) to attain these figures.

An air receiver should be fitted to reduce pressure fluctuations. In normal operation the
compressor fills the receiver when required and the receiver is available as a reserve at all
times. This reduces the switching cycles of the compressor.

Air supply system