Bond Graph Modeling of Two Stage

Reciprocating Air Compressor

By
[BHAVE SAGAR RAJSHEKHAR]
Guide
Prof. S.A.KULKARNI

1 M.E. Mechanical - Mechatronics Engineering

Presentation Overview
 Introduction
 Literature Review
 Model of Single Stage Reciprocating Air Compressor
 Model of two Stage Reciprocating Air Compressor
 Experimentation
 Results and Discussion
 Conclusion and Future Scope

2 M.E. Mechanical - Mechatronics Engineering

1. Introduction
 Modeling and Simulation of Dynamical System
 Mathematical Modeling
 Bond Graph Modeling
 Energy, Information variable- Effort and Flow
 Software-20Sim, Symbols Shakti, TUTSIM , BondSim.

3 Bond Graph Modelling

1.1.Effort and Flow in Various Energy Domain
Energy Domain Effort Flow

Translational Mechanics Force Velocity

F [N] V [m/s]
Rotational Mechanics Angular moment Angular velocity
M [Nm] ω [rad/s]
Electrical Voltage Current
U [V] I [A]
Magnetic Domain Magnetomotive Force V [A] Magnetic flux rate
Φ [Wb/s]
Hydraulic Domain Total Pressure Volume flow rate
P [N/m2] Q [m3/s]
Thermodynamic Temperature Entropy flow rate
T [k] S [J/K/s]
Chemical domain Chemical potential Molar flow
Μ [J/mole] N [mole/s]

4 Bond Graph Modelling

1.2 Bond Graph Element
1. I Element
I

𝐹𝑙𝑜𝑤 = 𝑎 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑜𝑟 𝑓𝑢𝑛𝑐𝑡𝑖𝑜𝑛 × න 𝐸𝑓𝑓𝑜𝑟𝑡 𝑑𝑡

Inductor, Inertia
2. C Element
C
𝐸𝑓𝑓𝑜𝑟𝑡 = (𝑎 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 𝑜𝑟 𝑓𝑢𝑛𝑐𝑡𝑖𝑜𝑛) × ‫𝑡𝑑 𝑤𝑜𝑙𝑓 ׬‬
Capacitor, Spring
3. R Element
R
𝐸𝑓𝑓𝑜𝑟𝑡 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 × 𝐹𝑙𝑜𝑤 𝑜𝑟 𝐹𝑙𝑜𝑤 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 × 𝐸𝑓𝑓𝑜𝑟𝑡
Resistor, Damper

5 M.E. Mechanical - Mechatronics Engineering

4. Source of Effort
Se
Voltage Source in Electrical System, Source of Force in Mechanical
System
5. Source of Flow
Sf
Current source in Electrical System, Source of velocity in mechanical
system
6. 0 Junction
Effort is Same and addition of flow is zero
7. 1 Junction
Flow is Same and addition of Effort is zero

6 M.E. Mechanical - Mechatronics Engineering

8. TF Element
TF
effort to effort and flow to flow transformation
𝐸𝑓𝑓𝑜𝑟𝑡1 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 × 𝐸𝑓𝑓𝑜𝑟𝑡2
𝐹𝑙𝑜𝑤2 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 × 𝐹𝑙𝑜𝑤1
Transformer, Gear-box, Belt and Pulley arrangement

9. GY Element
GY
effort to flow and flow to effort transformation
𝐸𝑓𝑓𝑜𝑟𝑡1 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 × 𝐹𝑙𝑜𝑤2
𝐹𝑙𝑜𝑤2 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 × 𝐸𝑓𝑓𝑜𝑟𝑡1
DC Machine

7 M.E. Mechanical - Mechatronics Engineering

10. Energy flow direction

11. Notation of Causality

8 M.E. Mechanical - Mechatronics Engineering

1.3 Motive

9 M.E. Mechanical - Mechatronics Engineering

2. Literature Review
2.1 Electrical System ( W. Borutzky[1])
Se : Source of Voltage R:Ra: Resistance
I:La : Inductance I : Jm : Inertia of Rotor R: Ra : Resistive Load

Bond Graph Model of Motor[1]

10 M.E. Mechanical - Mechatronics Engineering

2. Literature Review (Continued)
2.2 Thermo Mechanical System ( J. Granda [2])
C : Force generated at the top of Piston I : Inertia
TF: Force to torque transformation R : Friction during Motion

Bond Graph Model of Single Cylinder IC Engine

11 M.E. Mechanical - Mechatronics Engineering

2. Literature Review (Continued)
2.3 Thermofluid system (T.Bera et al [3])

Bond Graph Model of Single Cylinder Internal Combustion Engine

12 M.E. Mechanical - Mechatronics Engineering

2. Literature Review (Continued)
2.4 Single Stage Reciprocating Air Compressor( H. Engja[5])

13 M.E. Mechanical - Mechatronics Engineering

2. Literature Review (Continued)
Sf : RPM Given by the Motor, MTF : Converts rotary Motion into Linear
Motion, TF : Velocity of Piston into rate of Change of Volume, C: Integrates
Volume and computes pressure Generated

Bond Graph Model of Single Stage Reciprocating Air Compressor

14 M.E. Mechanical - Mechatronics Engineering

3. Objectives and Synoptic Representation

15 M.E. Mechanical - Mechatronics Engineering

4. Model Development of Single Stage Air
Compressor
1. Input angular Velocity and Belt-Pulley arrangement
2. Slider-Crank mechanism
3. cylinder
4. Suction and Discharge valve
4.1 Input angular Velocity and Belt-Pulley arrangement

 Motor Input RPM = 1440 (Sf)

 Belt and Pulley arrangement RPM = 720 (TF)
 𝑇𝑜𝑟𝑞𝑢𝑒(𝑚𝑜𝑡𝑜𝑟) = 0.5 × 𝑇𝑜𝑟𝑞𝑢𝑒(𝐶𝑟𝑎𝑛𝑘)
𝑅𝑃𝑀 𝐶𝑟𝑎𝑛𝑘 = 0.5 × 𝑅𝑃𝑀(𝑀𝑜𝑡𝑜𝑟)
 Equation Model for TF
Parameters
real r = 0.5;
equations
p1.e = r * p2.e; //P1.e & p1.f torque & rpm at i/p
p2.f = r * p1.f; //p2.e & p2.f torque & rpm at o/p
4.2. Slider Crank Mechanism
Crank
ሶ = 𝐿𝐶𝑅 sin(𝜃)𝜔
𝑌𝐶𝑅
𝜏 = 𝐹𝐶𝑅 × 𝐿𝐶𝑅
𝐿𝐶𝑅 = 0.0275 m
Equation Model for Crank
parameters
real global CrL;
variables
real global theta;
equations
theta = int(p1.f);
if theta > 2 * pi then
theta = theta - 2*pi;
else
theta = theta;
end;
p1.e = CrL * p2.e;
p2.f = CrL*sin(theta)*p1.f;
Connecting Rod
𝜑 = 𝑠𝑖𝑛−1 𝐿𝑐𝑟 sin 𝜃 /𝐿𝑐𝑜
𝑑𝜑
ሶ
𝑌𝐶𝑂 = −𝐿𝐶𝑂 𝑠𝑖𝑛(𝛷)
𝑑𝑡
𝐿𝐶𝑂 = 0.073 m
Equation Model for ConRod
parameters
real global CrL,CoL;
variables
real global phi;
real global theta;
equations
phi =arcsin(CrL*sin(theta)/CoL);
p.f = CoL*sin(phi)*ddt(phi);
Simulation of Slider Crank Mechanism
Piston

Q = 𝐴𝑝 𝑋𝑝ሶ
𝐹𝑜𝑟𝑐𝑒 = 𝐴𝑃 × 𝑃𝑟𝑒𝑠𝑠𝑢𝑒
𝐹𝐶𝑅 = 𝐹𝑜𝑟𝑐𝑒 × 𝐶𝑂𝑆 (∅)
Equation Model for Piston
variables
real global area;
real Force;
real global phi;
equations
Force = area * p2.e;
p1.e = Force*cos(phi);
p2.f = area * p1.f;
1.3. Cylinder
𝑣2 = 𝑣1 − ‫𝑡𝑑𝑄 ׬‬
𝐶
𝑝2 =
𝑣2 𝑛
Equation Model for C element
equations
state = int(p.f);
v2 = Lpv1 - state;
if theta < pi then
C = pa * v1^n;
else
C = pc * cvol^n;
end;
p.e = C/(v2)^n;
if (p.e > pmax) then
p.e = pmax;
end;
if (p.e < pmin) then
p.e = pmin;
end;
Parameters considered for LPC

Parameters Symbol Value Units

Minimum Pmin 1.012(105) N/m2
Pressure
Maximum P𝑚𝑎𝑥 1.914(105) N/m2
pressure
Stroke 𝑠𝑝 0.055 M
diameter of the 𝑑𝑝 0.065 M
piston
polytrophic index n 1.25 -
clearance volume 𝑣𝑐𝑙 3.5955e-5 m3

24 M.E. Mechanical - Mechatronics Engineering

Simulation of Pressure
PV Diagram for LPC
4.4. Inlet and Exhaust valve

 Treated as simple Orifice

 𝑚ሶ = 𝜌𝑐𝑑 𝐴 2(𝑃𝑢 − 𝑃𝑑 )/𝜌
 Equation Model for Valves
equations
Ao = pi/4*(Do)^2;
if p - p2.e > 0 then
inlet = true;
p2.f = rho*Cd*Ao*sqrt(2*
g_n*(p-p2.e));
else
inlet = false;
p2.f = 0;
end;
Simulation Parameters for Valves

Parameters Symbols Used Value Units

Coefficient of Cd 0.62 -

discharge
Diameter of Do 0.013 m
orifice

28 M.E. Mechanical - Mechatronics Engineering

Mass flow through Valves

29 M.E. Mechanical - Mechatronics Engineering

4.5. Complete Model
5. Two Stage Reciprocating Compressor
Simulation of Torque at the Crank without Intercooler

32 M.E. Mechanical - Mechatronics Engineering

5.1 Adding Intercooler
 Equation Model for R element
parameters
real r =0.9;
equations
p.e = r * p.f; // Q = T/R

 Equation Model for C element

parameters
real c = 0.8;
equations
state = int(p.f);
p.e = 293+state / c; //Tb = 293+ int(dQ)/C

 Equation Model for R1 Element

parameters
real r = -0.27;
equations
𝑸
p.e = (r * p.f)+293; // 𝑻𝒐𝒖𝒕 = 𝑻𝒊𝒏 − 𝒎𝒄
𝒑

34 M.E. Mechanical - Mechatronics Engineering

Simulation of Torque at the Crank without Intercooler

35 M.E. Mechanical - Mechatronics Engineering

Parameters Considered for HPC

Parameters Symbols Used Value Units

Minimum 𝑝𝑚𝑖𝑛 1.912× 105 N/m2
pressure
Maximum 𝑝𝑚𝑎𝑥 10.514× 105 N/m2
pressure
Stroke 𝑠𝑝 0.055 M
Diameter of 𝑑𝑝 0.050 M
piston
clearance volume 𝑣𝑐𝑙 1.75e-5 m3
Polytrophic n 1.25
Index

36 M.E. Mechanical - Mechatronics Engineering

Simulation of HPC and Intercooler

37 M.E. Mechanical - Mechatronics Engineering

38 M.E. Mechanical - Mechatronics Engineering
5.2 Adding Receiver
 Mass flow to Receiver
 Integration of mass flow
 PV = MRT
 Equation Model for Receiver
parameters
real v = 0.16;
real global R;
real rho = 1.29;
variables
real Tnew,Ti,pi,m,p,volumeflow;
initialequations
Ti = 293;
pi = 1.013e5;
equations
volumeflow = minlet/rho;
m = int(minlet);
p = m * R * Ti / v + pi;
Simulation of Pressure in the Receiver
5.3 Complete Bond Graph Model
5.4 Result Table
Simulation Result of pressure and massflow

SR. NO Output Pressure in Intermediate Mass flow (Kg/s)

(bar) pressure (bar)

1 3.013 1.613 0.001999

2 5.013 1.713 0.001567

3 7.013 1.763 0.001485

4 9.513 1.813 0.001414

5 10.513 1.913 0.001323

Simulation Result of Temperature

Sr. No 𝑻𝟏 𝑻𝟐 𝑻𝟑 Inlet 𝑻𝟒 Outlet 𝑻𝟓 Inlet 𝑻𝟔 Outlet

Intercool Receiver to LPC of LPC of HPC of HPC
er Temperat
temperat ure
ure
1 34 31 29 95 44 148
2 35 31 29 100 45 151
3 35 31 29 103 50 161
4 35 31 29 108 52 174
5 37 31 29 110 54 187
6. Experimental Verification
6.1 Experimental Set-up
3.2 Important Specification of Experimental Set- up
The Electric Motor

Parameters Symbols Used Values Units

Power of Motor P 7.5 hp
Maximum Speed N 1440 RPM
Rated Speed 𝑁1 720 RPM
Diameter of Motor 𝐷1 0.09 m
Pulley
Diameter of 𝐷2 0.18 m
Compressor Pulley
Low Pressure Cylinder

Parameters Symbols Used Values Units

Stroke 𝑆𝑝 0.055 m
Diameter of piston 𝑑𝑝 0.065 m
Polytrophic Index n 1.25
Clearance Volume 𝑣𝑐𝑙 3.5955e-5 𝑚3
No of Fins 8
High Pressure Cylinder
Parameters Symbols Used Values Units
Stroke 𝑆𝑝 0.055 m
Diameter of piston 𝑑𝑝 0.050 m
Polytrophic Index n 1.25
Clearance Volume 𝑣𝑐𝑙 1.75e-5 𝑚3
No of Fins 9
Reservoir
Parameters Symbols Used Value Units
Maximum Working P 12× 105 N/𝑀 2
Pressure
Tank Capacity L 160 l
6.2 Experimental Procedure
1. Fill the manometer with water up to half level
2. Keep delivery valve in closed position
3. Start the compressor and allow it to get it stabilize
4. Maintain pressure of air inside receiver constant, by adjusting delivery
valve
5. With a delivery pressure constant, measure motor speed using
tachometer and note down it
6. With the same delivery pressure, note the intake temperature,
intermediate temperature, temperature at inlet of intercooler,
temperature at outlet of intercooler, temperature at outlet of high
pressure compressor, temperature at receiver, water manometer
readings and intermediate pressure.
7. The same procedure is repeated for 4 different values of delivery
pressure.
 6.3 Result and Discussion
Observation of pressure and massflow

SR. NO Output Pressure in Intermediate Manom Mass flow (Kg/s)

(bar) pressure (bar) etric
Head
(cm)
Experime Simulation Experi Simulati Experime Experimental Simulation
ntal mental on ntal

1 3.013 3.013 1.613 1.613 2.7 0.0022137 0.001999

2 5.013 5.013 1.713 1.713 2.3 0.001972 0.001567

3 7.013 7.013 1.763 1.763 1.9 0.001792 0.001485

4 9.513 9.513 1.813 1.813 2 0.001839 0.001414

5 10.513 10.513 1.913 1.913 1.8 0.001744 0.001323

Observation of Temperature
Sr. No 𝑻𝟏 𝑻𝟐 Receiver 𝑻𝟑 Inlet to 𝑻𝟒 Outlet 𝑻𝟓 Inlet of 𝑻𝟔 Outlet
Intercooler Temperatur LPC of LPC HPC of HPC
temperature e

Experi Simul Exper Simul Exper Simu Expe Simu Expe Simu Expe Simu
mental ation iment ation iment latio rime latio rime latio rime latio
al al n ntal n ntal n ntal n

1 63 34 31 31 29 29 82 95 48 44 114 148
2 65 35 31 31 29 29 86 100 51 45 120 151
3 64 35 32 31 29 29 91 103 54 50 126 161
4 65 35 33 31 29 29 93 108 58 52 132 174
5 65 37 33 31 30 29 95 110 60 54 140 187
7. Conclusion and Future Scope
 Power of Bond Graph Modeling
 The resultant torque is seen to be decreasing because of addition of
intercooler
 The portability of the components so developed through modeling.
 The work done on the air is clearly seen reduced with addition of
intercooler.
 Simulation results are verified experimentally
Future Scope
 The heat transfer through the cylinder via fins is not considered in this
dissertation work.
 The electrical motor is not added to the air compressor input.
 The model is possible to develop further so that these two key features
could be included to confirm the total phenomenon in total.
References
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