1.0 ABSTRACT A vital part of many commercial, manufacturing, industrial, and automotive applications is an air compressor.

Air compressors are versatile mechanical tools that use one or numerous pistons to pump compressed air into a defined space. There are three basic types of air compressors: reciprocating, rotary, and centrifugal. These general types of air compressors can be further categorized into single or multi stage, packaged or non-packaged, air cooled or water cooled, and lubricated or nonlubricated. There are two types of piston-like air compressors: single-stage, and two-stage. These piston-like air compressors will keep the storage tank at a predetermined PSI (Pounds per Square Inch). The air compressors motor will turn off and turn on as needed to insure the proper PSI. Single-stage air compressors have one or more cylinders that pump air directly into the storage tank. Two-stage air compressors use two or more cylinders to pump air into another cylinder before pumping the air into the storage tank. Most singlestage air compressors are sufficient for normal use. Two-stage air compressors are used primarily by industries that have applications that require high-pressure. Compact air compressors are popular for easy around-the-home projects. These small air compressors do not have a storage tank; therefore they must always be running to supply the air needed for a project. Many glue guns, caulking guns, and painting guns use compact air compressors. Air compressors require the proper size hoses for optimal performance. Purchasing the right size and length of hose will keep PSI loss to a minimal. Check the hose for cracks, sun damage, or cuts often. If any of these are found, replace your hose immediately. Any leaks that may be caused by a faulty hose will add to an air compressors operating cost. Air compressors should be approached with caution. Secure the hose to guarantee minimal damage should your hose break free from the air compressor. Aftercoolers are heat exchangers that cool the heated compressed air. Once the compressed air has been condensed, the removal of the excess moisture can follow. Keeping the compressed air free from moisture is essential to most applications requiring air compressors. Air compressors will last much longer, and be more efficient, if they remain free from moisture.

Air compressors range in horse power, performance, price, operating cost, and ease of use. Always check hoses, values, bearings, and the electrical outlet of all air compressors. This will not only add to the longevity of the air compressor, but keep the operator safe.

2.0 OBJECTIVE 2.1 EXPERIMENT 1 To investigate the motor output power. 2.2 EXPERIMENT 2 To investigate the air flow rate and volume discharge of compressor cylinder. 2.3 EXPERIMENT 3 To investigate the compressor indicated power and mechanical efficiency of compressor. 2.4 EXPERIMENT 4 To investigate the compressor isothermal power and isothermal efficiency. 2.5 EXPERIMENT 5 To investigate the time taken to fully occupied the compressor receiver tank.

3.0 PROCEDURE 3.1 EXPERIMENT 1 1. Connect plug to 1 phase 240V AC power supply 2. Switch on ELCB and main switch on the control panel. 3. Make sure all the meters is showing zero before experiment except temperature meter. If the meter initial value is not zero set it by press the up button. 4. Adjust the compressor to desirable speed by the speed controller on the inverter. 5. Push the run button on the inverter operation panel and ensure that the run key is light. 6. Record down motor speed (RPM), power (Watt),and torque (Nm) each 30s time interval 7. The data continuous mark down until the pressure is automatically cut off. 8. Release air in receiver tank before next experiment. 9. Repeat step 3 to 7 by changing the speed of compressor to next desirable speed.

10. Plot graph of the pressure against temperature, indicated power against compressor speed and efficiency of compressor against compressor speed.

3.2 EXPERIMENT 2 1. Connect plug to 1 phase 240V AC power supply 2. Switch on ELCB and main switch on the control panel. 3. Make sure all the meters is showing zero before experiment except temperature meter. If the meter initial value is not zero set it by press the up button. 4. Adjust the compressor to desirable speed by the speed controller on the inverter. 5. Push the run button on the inverter operation panel and ensure that the run key is light. 6. Record down motor speed (RPM), power (Watt), and torque (Nm) each 30s time interval 7. The data continuous mark down until the pressure is automatically cut off. 8. Release air in receiver tank before next experiment. 9. Repeat step 3 to 7 by changing the speed of compressor to next desirable speed. 10. Plot graph of the pressure against temperature, indicated power against compressor speed and efficiency of compressor against compressor speed.

3.3 EXPERIMENT 3 1. Connect plug to 1 phase 240V AC power supply 2. Switch on ELCB and main switch on the control panel. 3. Make sure all the meters is showing zero before experiment except temperature meter. If the meter initial value is not zero set it by press the up button.

4. Adjust the compressor to desirable speed by the speed controller on the inverter. 5. Push the run button on the inverter operation panel and ensure that the run key is light. 6. Record down the pressure (P1, P2) motor speed (RPM), power (Watt),and torque (Nm) each 30s time interval 7. The data continuous mark down until the pressure is automatically cut off. 8. Release air in receiver tank before next experiment. 9. Repeat step 3 to 7 by changing the speed of compressor to next desirable speed. 10. Plot graph of the pressure against temperature, indicated power against compressor speed and efficiency of compressor against compressor speed.

3.4 EXPERIMENT 4 1. Connect plug to 1 phase 240V AC power supply 2. Switch on ELCB and main switch on the control panel. 3. Make sure all the meters is showing zero before experiment except temperature meter. If the meter initial value is not zero set it by press the up button. 4. Adjust the compressor to desirable speed by the speed controller on the inverter. 5. Push the run button on the inverter operation panel and ensure that the run key is light. 6. Record down the pressure (P1,P2)each 30s time interval 7. The data continuous mark down until the pressure is automatically cut off. 8. Release air in receiver tank before next experiment. 9. Repeat step 3 to 7 by changing the speed of compressor to next desirable speed. 10. Plot graph of the pressure against temperature, indicated power against compressor speed and efficiency of compressor against compressor speed.

3.5 EXPERIMENT 5 1. Connect plug to 1 phase 240V AC power supply 2. Switch on ELCB and main switch on the control panel.

3. Make sure all the meters is showing zero before experiment except temperature meter. If the meter initial value is not zero set it by press the up button. 4. Adjust the compressor to desirable speed by the speed controller on the inverter. 5. Push the run button on the inverter operation panel and ensure that the run key is light. 6. Record down the tank pressure (P1) each 30s time interval 7. The data continuous mark down until the pressure is automatically cut off. 8. Release air in receiver tank before next experiment. 9. Repeat step 3 to 7 by changing the speed of compressor to next desirable speed. 10. Plot graph of the tank pressure against time (s).

4.0 RESULTS AND DISCUSSION Experiment 1 Motor Speed Controller = 10Hz Time Data RPM Torque (NM) Motor Input Power (kW) Motor Output Power (kW) Motor Efficiency (%) 0 18.501 15.510 13.486 11.590 5.375 4.327 2.357 1.239 0 0.108 0.114 0.110 0.112 0.074 0.057 0.034 0.017 0 0.588 0.735 0.818 0.969 1.389 1.322 1.457 1.437

0 0 0

30s 464 2.1

60s 442 2.35

90s 418 2.52

120s 366 2.93

150s 218 3.27

180s 139 3.93

210s 80 4.1

240s 40 4.25

Motor Speed Controller = 20Hz Time Data RPM Torque (NM) Motor Input Power (kW) Motor Output Power (kW) Motor Efficiency (%) 0 41.08 12.11 35.51 35.88 29.92 28.58 26.31 27.63 0 0.33 0.11 0.36 0.40 0.35 0.37 0.38 0.39 0 0.815 0.941 1.021 1.101 1.183 1.295 1.434 1.394

0 0 0

30s 987 3.06

60s 916 3.49

90s 872 3.97

120s 898 4.2

150s 763 4.43

180s 752 4.7

210s 749 4.81

240s 743 4.95

Motor Speed Controller = 30Hz Time Data RPM Torque (NM) Motor Input Power (kW) Motor Output Power (kW) Motor Efficiency (%) 0 67.95 9.96 56.94 54.68 52.70 51.00 46.53 39.05 0 0.68 0.11 0.71 0.73 0.74 0.75 0.74 0.62 0 0.999 1.145 1.244 1.332 1.404 1.466 1.589 1.593

0 0 0

30s 1507 3.92

60s 1450 4.47

90s 1406 4.81

120s 1361 5.11

150s 1323 5.34

180s 1277 5.59

210s 1232 5.73

240s 1200 4.95

Motor Speed Controller = 40Hz Time Data RPM Torque (NM) Motor Input Power (kW) Motor Output Power (kW) Motor Efficiency (%) 0 86.03 8.53 73.95 71.04 67.94 65.61 0 1.03 0.11 1.07 1.10 1.10 1.10 0 1.199 1.336 1.447 1.542 1.619 1.681

0 0 0

30s 1998 4.61

60s 1935 5.09

90s 1878 5.44

120s 1819 5.75

150s 1765 5.95

180s 1718 6.13

210s -

240s -

Motor Speed Controller = 50Hz Time Data RPM Torque (NM) Motor Input Power

0 0 0 0

30s 2636 4.22 1.065

60s 2583 4.7 1.345

90s 2514 5.21 1.307

120s 2453 5.59 1.416

150s 2395 5.9 1.426

180s 2332 6.07 1.506

210s -

240s -

(kW) Motor Output Power (kW) Motor Efficiency (%) 0 119.39 8.48 104.96 101.42 103.78 98.44 0 1.27 0.11 1.37 1.44 1.48 1.48 -

Output Power vs Time

1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 0 30 60 90 Time 120 150 180 210 10Hz 20Hz 30Hz 40Hz 50Hz

As we can see from the graph, the output power increases over time. The output power for 50Hz is higher than the others because of the compressor need lot of energy for running at speed.

Experiment 2 Motor Speed Controller = 10Hz Time Data RPM (motor) RPM (compressor) Air Flow Indicated

Output Power

0 0.00 0.00 0.00

30s

60s

90s

120s

150s

180s

210s 80.00 30.48 8.53

240s 40.00 15.24 4.27

464.00 442.00 418.00 366.00 218.00 139.00 176.78 168.40 159.26 139.45 49.50 47.15 44.59 39.04 83.06 23.26 52.96 14.83

Motor Speed Controller = 20Hz Time Data RPM (motor) RPM (compressor) Air Flow Indicated

0 0 0.00 0.00

30s 987

60s 916

90s 872

120s 898

150s 763

180s 752

210s 749

240s 743

376.05 349.00 332.23 342.14 290.70 286.51 285.37 283.08 105.29 97.72 93.02 95.80 81.40 80.22 79.90 79.26

Motor Speed Controller = 30Hz Time Data RPM (motor) RPM (compressor) Air Flow Indicated

0 0 0.00 0.00

30s 1507

60s 1450

90s 1406

120s 1361

150s 1323

180s 1277

210s 1232

240s 1200

574.17 552.45 535.69 518.54 504.06 486.54 469.39 457.20 160.77 154.69 149.99 145.19 141.14 136.23 131.43 128.02

Motor Speed Controller = 40Hz Time Data RPM (motor) RPM (compressor) Air Flow Indicated

0 0 0.00 0.00

30s 1998

60s 1935

90s 1878

120s 1819

150s 1765

180s 1718

210s 0 0.00 0.00

240s 1998 761.24 213.15

761.24 737.24 715.52 693.04 672.47 654.56 213.15 206.43 200.35 194.05 188.29 183.28

Motor Speed Controller = 50Hz Time Data RPM (motor) RPM (compressor) Air Flow Indicated

0 0

30s 2636

60s 2583

90s 2514

120s 2453

150s 2395 912.50 255.50

180s 2332 888.49 248.78

210s -

240s -

0.00 1004.32 984.12 957.83 934.59 0.00 281.21 275.55 268.19 261.69

Air Flow Indicated vs Time

300 Air Flow Indicated 250 200 150 100 50 0 0 30 60 90 Time 120 150 180 210 10Hz 20Hz 30Hz 40Hz 50Hz

The pattern of air flow indicator for 10Hz, 20Hz, 30Hz, 40Hz and 50Hz are increasing at the beginning and slowly decreasing at the end. This is because the compressor need a lot of air at the beginning to full the tank and when tank are filled the air intake to the compressor reduce.

Experiment 3 Motor Speed Controller = 10Hz Time Data P1 (bar) P2 (bar) RPM Torque (Nm) Power (kW) Indicated Power

0 0 0 0 0 0 0

30s -0.09 0.4 464 2.1 0.108 3.192

60s -0.08 0.6 442 2.35 0.114 7.307

90s -0.06 0.8 418 2.52 0.110

120s -0.01 0.8 366 2.93 0.112

150s -0.01 0.9 218 3.27 0.074

180s -0.01 1.0 139 3.93 0.057 9.100

210s -0.01 0.8 80 4.1 0.034 2.753

240s -0.01 0.6 40 4.25 0.017 0.662

14.393 17.542 10.451

Motor Speed Controller = 20Hz Time Data P1 (bar) P2 (bar) RPM Torque (Nm) Power (kW) Indicated Power

0 0 0 0 0 0 0.00

30s -0.4 0.9 987 3.06 0.33 47.31

60s -0.33 1.5 916 3.49 0.11

90s -0.31 2.0 872 3.97 0.36

120s -0.2 2.5 898 4.2 0.40 1,687. 09

150s -0.21 2.9 763 4.43 0.35 2,738. 45

180s -0.17 3.3 752 4.7 0.37 4,839. 93

210s -0.16 3.7 749 4.81 0.38 8,208. 08

240s -0.13 4.0 743 4.95 0.39 11,791 .35

229.73 651.47

Motor Speed Controller = 30Hz Time Data P1 (bar) P2 (bar) RPM Torque (Nm) Power (kW) Indicated Power

0 0 0 0.00 0 0 0.00

30s -0.71 1.5

60s -0.64 2.3

90s -0.54 3.0

120s -0.52 3.7

150s -0.43 4.4

180s -0.46 5.0

210s 0.41 5.6

240s 0.37 6.1

574.17 552.45 535.69 518.54 504.06 486.54 469.39 457.20 1507 1450 1406 1361 1323 1277 1232 1200 3.92 247.53 4.47 1,210. 35 4.81 3,641. 09 5.11 9,841. 47 5.34 5.59 5.73 4.95 19,194 35,544 62,644 96,232 .94 .53 .81 .12

Motor Speed Controller = 40Hz Time Data P1 (bar) P2 (bar) RPM Torque (Nm) Power (kW) Indicated Power

0 0 0 0 0 0 0.00

30s -0.104 2.5 1998 4.61 1.03 1,854. 21

60s -0.097 3.4 1935 5.09 0.11 6,765. 13

90s -0.086 4.3 1878 5.44

120s -0.080 5.2 1819 5.75

150s -0.068 6.0 1765 5.95

180s -0.065 6.7 1718 6.13

210s -

240s -

1.07 1.10 1.10 1.10 19,613 51,655 90,781 158,33 .14 .70 .27 3.64

Motor Speed Controller = 50Hz Time Data P1 (bar) P2 (bar) RPM Torque (Nm) Power (kW) Indicated Power

0 0 0 0 0 0 0.00

30s -0.154 1.6 2636 4.22 1.27 313.11

60s -0.141 2.4 2583 4.7 0.11 1,446. 96

90s -0.130 3.6 2514 5.21 1.37 8,401. 97

120s -0.120 4.6 2453 5.59

150s -0.112 5.6 2395 5.9

180s -0.108 6.6 2332 6.07

210s -

240s -

1.44 1.48 1.48 28,084 63,820 146,40 .94 .87 9.08

Indicated Power vs Time

180000 160000 140000 120000 100000 80000 60000 40000 20000 0 0 50 100 Time 150 200

Indicated Power

10 Hz 20Hz 30Hz 40Hz 50Hz

For experiment 3 its show that power consumption increasing with time increase. Its because single air compressor need high power to generate the compress air inside the tank. The higher the Hz the higher power need.

Experiment 4 Motor Speed Controller = 10Hz Time Data T1 (C) P1 (bar) P2 (bar) RPM Torque (Nm)

0 0 0 0 0 0

30s 38.0 -0.09 0.4 464 2.1

60s 38.7 -0.08 0.6 442 2.35

90s 39.2 -0.06 0.8 418 2.52

120s 39.4 -0.01 0.8 366 2.93

150s 38.7 -0.01 0.9 218 3.27

180s 37.6 -0.01 1.0 139 3.93

210s 37.3 -0.01 0.8 80 4.1

240s 37.2 -0.01 0.6 40 4.25

Motor Speed Controller = 20Hz Time Data T1 (C) P1 (bar) P2 (bar) RPM Torque (Nm)

0 0 0 0 0 0

30s 44.2 -0.09 0.4 448 1.70

60s 47.2 -0.08 0.6 428 2.10

90s 49.6 -0.06 0.8 378 2.47

120s 51.7 -0.01 0.8 244 3.49

150s 53.7 -0.01 0.9 54 3.50

180s 55.6 -0.01 1.0 164 3.57

210s 57.2 -0.01 0.8 170 3.58

240s 58.7 -0.01 0.6 25 3.71

Motor Speed Controller = 30Hz Time Data T1 (C) P1 (bar) P2 (bar) RPM Torque (Nm)

0 0 0 0 0 0

30s 63.6 -0.76 1.2 1538 3.51

60s 68.6 -0.67 2.0 1468 4.11

90s 73.2 -0.61 2.8 1420 4.50

120s 77.2 -0.52 3.5 1370 4.85

150s 80.6 -0.52 4.1 1326 5.06

180s 83.6 -0.41 4.8 1280 5.30

210s 86.3 -0.44 5.3 1235 5.52

240s 88.4 -0.39 5.9 1185 5.66

Motor Speed Controller = 40Hz Time Data T1 (C) P1 (bar) P2 (bar) RPM Torque (Nm)

0 0 0 0 0 0

30s 90.4 -0.76 1.2 1538 3.51

60s 95.9 -0.67 2.0 1468 4.11

90s 100.3 -0.61 2.8 1420 4.50

120s 104.3 -0.52 3.5 1370 4.85

150s 107.9 -0.52 4.1 1326 5.06

180s 110.9 -0.41 4.8 1280 5.30

210s -

240s -

Motor Speed Controller = 50Hz Time Data T1 (C) P1 (bar) P2 (bar) RPM Torque (Nm)

0 0 0 0 0 0

30s 91.1 -1.51 1.61 2625 4.17

60s 97.1 -1.37 2.70 2552 4.83

90s 104.2 -1.29 3.80 2487 5.26

120s 110.5 -1.19 4.90 2430 5.62

150s 116.0 -1.11 5.80 2368 5.86

180s 121.4 -1.00 6.80 2306 6.05

210s -

240s -

Torque vs Time
7 6 5 Torque 4 3 2 1 0 0 50 100 Time 150 200 10Hz 20Hz 30Hz 40Hz 50Hz

Experiment 5 show that torque increase when time increase. As rotational motion increases, the amount of friction and constraints on the materials. If torque were to increases linearly,

the amount of the friction would also increase, and depending on the amount of friction/heat the materials could take, would eventually cause a breakdown.

Experiment 5 Motor Speed Controller = 10Hz Time Data Pt (bar)

0 0

30s 0.10

60s 0.40

90s 0.80

120s 1.00

150s 1.10

180s 1.18

210s 1.19

240s 1.20

Motor Speed Controller = 20Hz Time Data Pt (bar)

0 0

30s 0.85

60s 1.55

90s 1.90

120s 2.70

150s 3.40

180s 4.00

210s 4.60

240s 5.25

Motor Speed Controller = 30Hz Time Data Pt (bar)

0 0

30s 1.15

60s 2.05

90s 2.80

120s 3.60

150s 4.40

180s 5.00

210s 5.60

240s 6.25

Motor Speed Controller = 40Hz Time Data Pt (bar)

0 0

30s 1.30

60s 2.55

90s 3.50

120s 4.60

150s 5.30

180s 6.30

210s -

240s -

Motor Speed Controller = 50Hz Time Data

30s

60s

90s

120s

150s

180s

210s

240s

Pt (bar)

1.60

2.90

4.10

5.20

6.20

7.30

Tank Pressure vs Time

8 Tank Pressure 6 4 2 0 0 50 100 Time 150 200 10Hz 20Hz 30Hz 40Hz 50Hz

For experiment 5 the pressure increase with increase of time. To compress air inside the tank need pressure so to achieve desire amount of air compressor pressure will increase until its full fill the quantity its need.

5.0 CONCLUSION In this experiment we learn that the relationship between the RPM, motor output power, air flow rate and volume discharge of compressor cylinder, mechanical efficiency of compressor, compressor isothermal power and isothermal efficiency and time taken to fully occupied the compressor receiver tank. We also learn how to operate the compressor and its safety and precaution steps.