Rotary Air Compressors For The Automotive Industry
Key Parts Of A Rotary Screw Air Compressor
June 5, 2018
Surprising Uses For Rotary Air Compressors
June 20, 2018ROTARY AIR COMPRESSORS FOR THE AUTOMOTIVE INDUSTRY
Kaishan USA | June 05, 2018 | Air Compressor Information, Rotary Air Compressors
Could you imagine assembling hundreds of automobile parts without the assistance of technology? Lifting the chassis onto a conveyor belt or placing a windshield into proper alignment sounds nearly impossible without the aid of advanced machinery—especially auto rotary air compressors.
We see automobiles as indispensable and a useful form of transportation to carry out everyday tasks. Whether cars help us travel or transport goods, continued developments in automotive technology allows the formation of safer, more efficient and reliable cars and trucks. Along with the use of computer technology and automated assemblies, air compressors have played a major role in transforming the automotive industry.
What Are Rotary Air Compressors And How Are They Used?
The primary purpose of an air compressor is to supply air flow to different pieces of equipment, whether you need it for pneumatic devices or to pump air into your tire at a gas station. With a precise design for working with tool attachments, air compressors provide pneumatic power to tools such as nail guns, blow guns, air sanders, staplers, spray guns, sandblasters, and more. As auto mechanics can hook up their apparatuses to a variety of air compressors, they can complete tasks faster.
Using one of the three types of motors: electric, gas, or diesel, an air compressor converts power into potential kinetic energy, which is then stored as pressurized air. The compressor forces an extreme amount of air into the system’s storage tank, which causes an increase in pressure. Once the compressor reaches its limit, it shuts off. The compressed air remains in the tank and is used for one of the various applications listed above. After the air compressor reaches its bottom limit, it switches on again to re-pressurize the tank.
Rotary Screw Air Compressors Work Well For Automotive Applications
Rotary screw air compressors are a kind of gas compressor that uses a positive displacement, rotary-type mechanism. Auto shops use rotary screw compressors in place of piston compressors because they are ideal for supplying massive volumes of high-pressure air. The process involves a constant sweeping motion and the compressors experience little pulsation compared to piston compressors.
It is vital to select a model that matches your job demands. For example, small engines are great for minor tasks, while stationary rotary screw compressors deliver higher capacities of compressed air for more expansive jobs. They are excellent for constantly compressed air and better for industrial use. Using twin screws instead of pistons, rotary air compressors require routine maintenance like filter changes and lubrication.
With their high load capacity control systems, rotary screw compressors have various models and sizes available to match your system demands. Rotary screw compressors operate using two interlocking helical screws also called rotors. In an oil-injected rotary screw compressor, oil fills the gap between rotors. The oil creates a hydraulic seal and transfers energy between the driven and driving rotor.
Subsequently, gas enters and passes through the threads, allowing the screws to rotate. The gas is forced through the compressor and exits toward the end of the screws. How well the rotary compressor works depends on the exact fitting between the individual screws, between the screws and the chamber surrounding them that seals the compression cavities. It is inevitable that some leaking will occur, but high rotational speeds help maximize effective flow.
The size of rotary air compressors is related to HP, standard cubic feet, and PSI. As HP increases, so does the economy of scale. Rotary screw mechanisms run smoothly with limited vibration and often do not require a special mounting system or foundation. You can mount them using standard isolation mounts.
While rotary screws are used for a wide range of applications, they primarily supply compressed air for industrial applications that demand continuous air, including auto manufacturing industries. Screw compressors are more complex and run in a different mode in relation to load/unload compared to reciprocating compressors. Designed for continuous use, the units have excellent cooling systems and consume less power than reciprocators at full load.
Oil-injected machines require fewer maintenance costs because you only need oil, filters, and oil separators—as opposed to reciprocating machines that require upkeep with pistons, valves, rings, and other components. Rotary screw compressors rarely turn off when running in load/unload, which limits motor starts but may cause the motor to burn out prematurely. They often consume about 35 percent of compressor full load value.
As the units use rollers instead of pistons, they sit off-center in the shaft with one side touching the wall. Moving at high speeds, one part is always at a different pressure than the other. Gas comes in at low-pressure and exits compressed to high-pressure. The compressors can have a low pressure between 100 to 215 PSI and offer high capacity as large industrial machines. They can start at 10 HP and range up to more than 1000 HP.
Types Of Rotary Air Compressors
An air compressor has two phases of operation: compression and release, and is available in two models: positive displacement and dynamic.
Positive displacement is the most common version and can supplement several DIY, automotive, and industrial-scale functions. Under the category of positive displacement air compressors, there exist rotary screw compressors with a double rotor.
But how do positive displacement compressors work?
A single part of the device takes in air and minimizes the space to create pressurized air molecules. When the system releases the air, the compressed air discharges at high speeds. It works at a constant flow as the cavity of the system allows gas into the machine at atmospheric pressure levels. The cavity then becomes smaller. As the volume of the cavity decreases, the pressure of the gas increases at the same time.
Kaishan Compressor offers two types of rotary screw air compressors: single and two-stage. Our engineers continue to develop our products, which has increased our efficiency by more than 20 percent compared to earlier models.
Single Stage Rotary Compressors
Our single rotary screw air compressors have a direct drive motor and air end with a 1:1 ratio, which operates with a slow speed male rotor to maximize performance and increase efficiency. Using steady system pressure, it lowers the amount of stress on the system and decreases air demand. It has double SKF bearings for reliability and durability and has tight tolerances to provide maximum efficiency.
Single stage compressors also have a direct flow inlet valve to provide reliable capacity control and a 5/6 rotor profile to create optimal performance while reducing energy consumption. Our professionals have developed efficient airflow within the narrow pressure band to minimize air leaks. They have built a machine that delivers decreased energy consumption to give environmentally-friendly results.
Our single stage models include:
- KRSB
- KRSD
- KRSP
- KRST
Features of our KRSD single stage rotary screw air compressors include:
- High-efficiency air intake filters
- 316 stainless steel control tubing
- Air cooling fans
- Digital control panel
- Direct drive 1:1 drive ratio—no gearbox
- Direct flow inlet valve
- High-efficiency electric motor
- Premium discharge bearings
- SKK series air end
- 3-stage tangential oil separation
With our KRSD series control system, you can manage all the operating parameters for your air compressor and, with the variable speed drive, you can receive significant energy savings. The series also provides turnkey solutions. You can learn more about our other series by contacting a representative for further information.
2-Stage Rotary Air Compressors
Kaishan engineers have developed a KRSP 2-stage compressor that consists of a direct drive motor and air end operating at slower speeds. With a 2-stage air end design, the KSRP2 has a high flow rate and low power consumption. As it has steady system pressure, it lowers stress and air demand. Its narrow pressure band results in efficient air flow and reduces air leaks. With its 5/6 rotor profile, the compressor creates optimal performance.
Our 2-stage rotary screw compressor has slow speed male rotors to upturn performance and reliability. The two-in-one intake valve design boosts efficiency and the direct flow intake valve provides capacity control. It also has tight tolerances and triple SKF bearings. We have engineered the unit to reduce excessive part-load energy consumption and decrease energy consumption, resulting in environmentally friendly savings.
The KRSP2 compressor includes features such as:
- SKY series air end
- High-efficiency air intake filters
- 316 stainless steel control tubing
- Centrifugal cooling fans
- Digital control panel
- High-efficiency electric motors
- Laminar flow inlet valve
- Single-pass oil and after coolers
- 3-stage tangential oil separation
- Triple discharge bearings
Our turn-key industrial solutions support the auto industry and with the variable speed drive option available, you can benefit from energy savings.
Oil-Injected Air Compressors
An oil-injected rotary screw air compressor relies on an oil compression cavity for sealing, lubrication ,and cooling. However, some oil has the potential to mix with the air during use. Oil can accumulate in any process during automotive assembly or other tasks for diverse industries. You can decrease the problem by using an oil-injected system accompanied with filters, but it does not always guarantee a 100 percent oil-free system.
Oil-injected devices operate at lower shaft speeds and the male and female rotors engage like 2 gears. A timing gear is not necessary, and the compressor reclaims the oil and recirculates it after compression. It requires an oil separator to isolate the oil from the air. Although the process for oil-injected rotary compressors requires an oil separator to create the clean, compressed air and almost all the material stays in the compressor, sometimes there is oil carryover, meaning that it is not 100 percent oil-free.
Fixed Vs. Variable Speed Compressors
When choosing the best rotary screw air compressor for automotive air tools, it is wise to consider the difference between a fixed and variable speed system. A fixed compressor runs at a constant speed and is resourceful when functioning 100 percent on full load. A running motor produces compressed air yet becomes inefficient when the engine quits. When the fixed machine stops building pressure, the motor still turns, which wastes energy.
A variable speed air compressor turns its motor in relation to the quantity of needed air. Its motor increases in speed when demand increases and vice versa. It only produces the required amount of air and only uses the required amount of energy, so it does not waste energy. Variable speed compressors can decrease energy consumption by an average of 35 percent.
How Can You Use Rotary Screw Air Compressors In The Automotive Industry?
The automotive industry consists of a vast compilation of parts and pieces being constructed together to create millions of cars each year. Compressed air devices are vital everywhere, from conveyor belt systems to pneumatic tools, from painting to cleaning and drying.
Rotary air compressors keep everything moving on an assembly line. Workers use these compressors to complete several tasks efficiently, by using air-powered wrenches and air ratchets to remove nuts and bolts. Technicians use air-powered saws for cutting and grinding metal, too. Aside from pneumatic tools, rotary screw air compressors also support the precise movements of robotic machinery. Robotic arms used in the auto production business transport, lift, and position components like placing side panels, door pillars, quarter panels, and roof pieces.
As mentioned before, something to keep in mind is oil contamination. If oil is present in compressed air, it can damage equipment—resulting in high-cost replacements and downtime for your company. Oil can even prevent the proper adhesion of paint or cause it to bead or crack on the surface of cars, affecting the look of the finish and its ability to prevent corrosion. Lower the risk of oil contamination by using compressors with oil filters.
Applications for air compressors within the auto industry include:
- Assembly
- Cleaning
- Conveying
- Installation
- Maintenance
- Painting
- Testing
Kasihan Technologies understands that auto facilities have high demands and must keep up with the rising cost of tools, labor, paint, and other expenses. Assembly and re-work can be expensive, so we provide top-quality results with rotary systems offering essential dry and clean compressed air. Used for fleet services, repairs, tires services, and body and paintwork, our rotary compressors reduce operating costs because they deliver matching air treatment solutions. They optimally use waste heat and avoid losing air for regeneration, and our mechanisms do not require decentralized equipment on your production line.
Air Compressors Used In Auto Construction
The best rotary screw air compressors for auto body work help with the assembly of vehicles, which requires hundreds of parts for proper construction. An auto assembly line relies on technicians to put together different components, but not everything is completed by hand like in the old days. Workers require rotary air compressors to deliver air power to essential tools and other operations along the production line. Air compressors operate robots as well as pneumatic tools.
Although cars were traditionally made of steel, they are now made of petroleum products like plastic, which reduces the weight of modern vehicles. The use of pneumatic tools in the auto industry results in faster and easier assembly using a variety of materials.
- General Vehicle Assembly: The manufacturing of automobiles requires several stages. Thousands of parts combine at an assembly plant building each car from the bottom up. The process begins with the chassis. Placed on a conveyor belt to run downline, the chassis transforms with each step. The conveyor belt functions with the help of air compressors.
- Chassis Construction: Throughout the production line, the chassis has additional components added on, such as the suspension, gas tank, wheel drums, axles, and steering components. Air compressors play a vital role in putting each part together with precision.
- Engine Building: When the engine and transmission combine, robotic arms place the heavy pieces in the right position and bolt down the radiator. Robotic arms rely on air compressor systems to carry out the heavy lifting. Subsequently, professional technicians use air-powered tools and wrenches to fasten each screw.
- Small Parts Production: For manufacturers to build the body of an automobile, dozens of smaller pieces are required, which is where pneumatic tools become crucial. Compressed air enables workers to attach parts in seconds—a task which would require hours if done by hand.
Compressed air tools play a dynamic role in robotic machinery and conveyor belts. Robotic arms can transport, lift, and position more substantial pieces that a worker may not be able to handle, whereas conveyor belts can create a streamlined process. Door pillars, quarter panels, roof pieces, and side panels can be positioned with precision, which makes for an efficient assembly. Robots can even bolt and weld pieces with higher levels of speed and accuracy compared to a technician, and they can withstand harsh environments like gas, smoke, and sparks.
Compressors And The Auto-Painting Process
As the body and chassis of a car are constructed on different lines, robotic arms perform and complete most of the welding while bolting is done by techs. The manufacturer then adds additional parts to the body like the hood, doors, bumper, and fender. While the body undergoes more add-ons, the shell connects to another conveyor belt, which initiates the painting process. The best rotary screw air compressor for automotive painting is the one that ensures a clean finish.
Cleaning Before Painting
Before technicians paint the body of a car, they examine it for surface defects. This is done in a white room with bright lights, where workers cover the body with highlight oil, which makes it easier for them to spot problems with the sheet metal. Mechanics search for scratches, bumps, and dents, and then make the required repairs. They subsequently rinse the body of the car to remove the oil and contaminants, and dry it with compressed air.
The Painting Method
Rotary screw air compressors play one of the most significant roles in the painting of automobiles. Applying an undercoat of primer first helps form a layer, allowing for a solid adherence to paint. Once the vehicle dries, robotic arms begin painting.
A smooth layer of paint is applied as the machines monitor the precise amount of color necessary to cover the vehicle. The robotic technology can function because of auto air compressors, which reduce the amount of moisture and provide consistent power to pneumatic painting tools.
Throughout the steps of assembling and painting, water-based paint is usually used, but it’s sensitive to oil that may come from compressors. Therefore, you can invest in an oil-injected rotary air compressor with filters. If oil contaminates the air and reaches the paint, it can cause uneven layers and even corrosion.
Compressed air is also used to agitate paint in a bath in order to reduce clumping and mix the liquid for consistent coloring. Technicians use air compressors for spray paint in order to propel the color onto a clean car surface.
The Interior Procedure And Performance Of Air Compressors
As the body of the car continues down the conveyor belt, it reaches the interior assembly stage where specialists install door panels, seats, dashboards, lights, pedals, clutches, mirrors, radios, vents, and much more. However, glass parts like windows and windshields rely on robotic arms for proper placement. With suction cups at the end, the arms install heavy windshields and a urethane sealer is applied to the edges before being set.
Final Installation Stages
During the final steps, robotic arms continue to complete final installation. They mount panels and seats—which results in less back-breaking work for employees—so they can focus on bolting everything into place. Each vehicle then goes through a water test to make sure it is waterproof.
The last stage is where the body and frame come together. Lifted by robotic arms onto the chassis, the body is bolted down by technicians. The workers use pneumatic tools powered by rotary screw air units to connect the two pieces. Once joined, the automobile continues down the belt where mechanics attach the battery and tires and fill the oil tank and coolant reservoirs with appropriate liquids.
How You Can Use Air Compressors For Automobile Testing
After going through the assembly line, vehicles are now ready for driving—but must go through rigorous testing beforehand. Each car is assessed for performance and quality, such as engine power, tire balance, light operation, and several other aspects. If anything is not functioning, employees send the automobile to another section where workers troubleshoot any problems. Once it passes inspection, specialists prepare the vehicle for the market.
Since hundreds of parts come from different locations, audits are necessary to ensure each is in top-notch condition. Planning the production of cars is a complicated process, where manufacturers must produce, test, and deliver each piece when operations are set to begin. Component manufacturers must test and inspect each part before shipping to make sure everything is in superior condition for assembly. Audits also ensure the parts have the Statistical Process Control seal and are not defective.
Quality control helps specialists oversee the entire process and assists them in tracing the development of each automobile from beginning to end. Each vehicle has a Vehicle Identification Number which allows quality control to execute a step-by-step examination. If the experts notice any imperfections or defects, they correct them before the piece moves onto the next step.
Quality control creates a more efficient method, saves money, and is safer than inspecting cars after completion. Testing is also more efficient because air-compressed power tools offer precise power to perform various functions at superior speeds.
Auto Maintenance And The Use Of Totary Screw Air Compressors
Choosing the best air compressor for auto body work depends on your specific application. Manufacturers or large-scale auto shops use rotary screw air compressors for different reasons and on an industrial scale, while repair shops and DIYers find great use in them on a smaller scale.
Automotive repair shops use air compressors to carry out maintenance practices, especially when a car needs new paint—whether it's a touch-up or entire redo of the body. Rotary air compressors produce a smooth layer of color by using the right amount of pressure, while providing little to no moisture.
If you are good with your hands and perform maintenance on your car, air compressors are ideal for the average at-home mechanic. Being knowledgeable about vehicle repair and best practices allows you to repair or repaint your vehicles using pneumatic tools.
With regard to repairs, rotary screw air compressors deliver more power. While DIY maintenance may be intimidating because of the physical work involved, an air compressor can remove the difficult strains in repairing engine parts and replacing tires. You can use the system by plugging it into a standard outlet, and it can help with operating your pneumatic tools. Compressors can power an air-impact wrench if you are removing front-crank pulleys or any other device you require.
Other functions you can perform with small to medium-sized auto rotary air compressors include removing nuts and bolts, and using an air ratchet. You can grind metal using an air grinder and cut metal with an air saw. Pneumatic tools powered by automobile compressors include pressure guns and vacuum machines, too.
If you work in a repair shop or work at home, you can see the impact of rotary screw auto air compressors when you use various tools, including airbrushes. Investing in a device that delivers an exact, consistent, and splotch-free coat of paint can help create a sleek and glossy finish. You will have to understand the capacity of your airbrush regarding pressure, consumption, and HP, to match it with the right system. Further, painting at home requires dry, clean, and debris-free compressed air, so choose a rotary screw air compressor that has a filtration system.
Automotive Rotary Screw Air Compressors From Kaishan
Automotive air compressors influence every aspect of the auto industry, from the assembly line on conveyor belts to cleaning, painting, and performing maintenance. Regardless of the application for which you need a compressor, it is ideal to invest in a company providing efficient and reliable solutions.
As an engineering-based company, Kaishan Compressor offers portable rotary screw air compressors, gas compressors, and stationary air compressors for auto manufacturers, repair shops, and at-home mechanics. We are here to help you meet your compressor requirements for any operation, by offering complete solutions as well as compressor filters.
Given our extensive industry knowledge and experience, you can trust our air solutions. We meet not only your expectations but also industry standards and regulations. Our line of auto rotary air units will prove to be highly-efficient in supporting your company. Our products will keep up a steady flow of operations, resulting in more uptime.
We adhere to high standards of quality for spray paint applications as our compressors avoid paint defects. When you choose a rotary screw air compressor that is high in quality and reliability, you can reduce your operating costs. If the machine matches your exact air treatment needs, it will act as a long-term benefit to your business.
At Kaishan Compressor, we make more than 60,000 rotary air compressors and 250,000 reciprocating air compressors each year. We sell our products to 60 different countries, including the U.S., Germany, Australia, Africa, Russia, and South Korea. We implement a vertically-integrated production system that allows our experts to respond to significant changes in various market demands. It keeps us fully geared to give you the most energy-efficient and reliable products and services.
We develop high-value machinery worldwide with the support of our modern manufacturing facilities in 7 different locations. With the Kaishan Compressor research and development facility in Seattle, we have 32 subsidiary companies that deliver optimum rotary screw air compressor solutions to our clients. As the third largest manufacturer of compressed air equipment, Kaishan uses skilled engineering with low-cost manufacturing to offer you incredible automobile air compressors.
A more in-depth look at our single and 2-stage compressors shows that, for each unit of power input, they produce more compressed air. They also have expanders that use waste heat to yield electricity. An example of our sustainable approach is that the compressor core has an SKY air end in our KRSP and KRSP2 models. With triple SKF bearings for resilience and dependability, they have tight tolerances to maximize efficiency.
Kaishan rotary screw air units offer maximum output with less energy, low cost of operation, and quieter operation. We offer portable air compressors in Mexico and Central and South America. The advantage of this mobile system includes excellent power balance and overhauls reaching between 40,000 and 80,000 hours. Finally, Kaishan Compressor offers oil-injected rotary compressors that are perfect for the automotive industry. You can apply the compressors to various applications, as the sealing systems we have designed for them guarantee reliable, safe, and efficient operation.
Buying An Automobile Rotary Air Compressor
Being in business for 60 years allows Kaishan Compressor to uphold a strong reputation within the auto industry. Our experts offer value, reliability, and a vast range of efficient products—as well as a lifetime warranty on our compressors. We are a market leader in pricing, so contact a Kaishan representative about our rotary screw air compressor solutions. We can also help you with product selection and pricing information.
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Could you imagine assembling hundreds of automobile parts without the assistance of technology? Lifting the