Power loss analysis in a new oil-free rotary vane compressor: Experimental investigation and mathematical modeling.

• A new design of an oil-free rotary-vane compressor with a mechanical efficiency exceeding 0.9 has been proposed. • A mathematical model for calculating power losses due to friction for the new design of an oil-free rotary-vane compressor has been developed, with a calculation error not exceeding 10 %. • The power losses due to friction in the working chamber of the new oil-free rotary-vane compressor in the range of rotor speeds from 1000 to 3700 rpm are 4 to 20 times lower than those for the traditional design. Additionally, the frictional power losses in the rotor slot are 20–30 % lower, and on the stator, they are 16–20 times lower. This paper presents the design of an oil-free rotor vane stage with a new tribological scheme. The new scheme differs from existing ones in that the sealing vane contain protrusions that rest on rolling unloading bearings located in the end covers of the cylinder. Experimental results on friction power losses in the new and traditional stages are provided, demonstrating that the implementation of the new stage design allows for an average reduction in friction power losses by a factor of 10. A mathematical model for calculating friction power losses in the rotor vane type compressor stage, implementing the new tribological scheme, has been developed. The analysis based on the mathematical model confirms the possibility of achieving mechanical efficiency values higher than 0.9 in oil-free rotor vane stages with a pressure ratio of 3 and a rotor speed of 3000 rpm, through the use of the new tribological scheme. It has been found that there is a redistribution of the importance and values of the main design parameters recommended for the design of oil-free rotor vane stages with the new tribological scheme, which determine its structural configuration, compared to its traditional design. [ABSTRACT FROM AUTHOR]