CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of United States Provisional Application No. 62/911,592, filed October 7, 2019, the disclosure of which is incorporated by reference herein in its entirety.

BACKGROUND

[0002] Screw compressors typically include a plurality of rotating rotors each having external screw thread. The screw threads interfit with screw threads on the other rotors to define compression chambers. An entrapped fluid is compressed, and delivered toward a downstream location. Compressed fluid is delivered into a discharge plenum.

[0003] Screw compressors can be operated at various pressure ratios (e.g., the ratio of the pressure of the fluid at the inlet of the compressor to the pressure of the fluid at the outlet of the compressor). Various parameters in the screw compressor can be optimized based on the desired pressure ratio.

SUMMARY

[0004] A screw compressor according to an exemplary embodiment of this disclosure, among other possible things includes an outlet housing. The outlet housing includes a passage that is configured to communicate compressed fluid from a screw rotor to a discharge. A removable cover plate is configured to cover a portion of the passage.

[0005] In a further example of the foregoing, the portion of the passage includes at least one sub-portion. The cover plate includes first and second legs joined by a bracket, and each of the first and second legs cover first and second sub-portions of at least one sub-portion.

[0006] In a further example of any of the foregoing, each of the first and second legs has a thickness. The thickness corresponds to a side of the first and second sub-portions, respectively.

[0007] In a further example of any of the foregoing, the first and second legs each have a first side adjacent the bracket and a second side opposite the first side. The cover plate includes an open edge between the second side of the first and second legs. [0008] In a further example of any of the foregoing, the cover plate is attached to the outlet housing by one or more removable fasteners.

[0009] In a further example of any of the foregoing, the cover plate is a first cover plate that is configured to cover a first portion of the passage. The first cover plate is interchangeable with a second cover plate that is configured to cover a second portion of the passage.

[0010] In a further example of any of the foregoing, the first portion of the passage is a different size than the second portion of the passage.

[0011] In a further example of any of the foregoing, two screw rotors are configured to compress the fluid.

[0012] In a further example of any of the foregoing, the passage includes a rotor sweep surface, and the cover plate reduces an effective length of the rotor sweep surface.

[0013] A method of varying a volume index for a screw compressor according to an exemplary embodiment of this disclosure, among other possible things includes providing a removable cover plate for an outlet housing of a screw compressor. The outlet housing includes a passage that is configured to communicate compressed fluid from a screw rotor to a discharge. The cover plate is configured to cover a portion of the passage.

[0014] In a further example of the foregoing, the removable cover plate is selected from a group of removable cover plates.

[0015] In a further example of any of the foregoing, a desired volume index for the screw compressor is selected, and a removable cover plate from the group of removable cover plates is selected based on the desired volume index.

[0016] In a further example of any of the foregoing, the removable cover plate is configured to cover a portion of the passage. The size of the portion corresponds to the desired volume index.

[0017] In a further example of any of the foregoing, the removable cover plate is a first removable cover plate in the group of cover plates, and includes interchanging the removable cover plate with a second cover plate from the group of cover plates.

[0018] In a further example of any of the foregoing, the first removable cover plate is configured to cover a first portion of the passage, and the second cover plate is configured to cover a second portion of the passage, and the first portion has a different size than the second portion.

[0019] In a further example of any of the foregoing, the portion of the passage includes at least one sub-portion. The cover plate includes first and second legs joined by a bracket. Each of the first and second legs cover first and second sub-portions of at least one sub-portion.

[0020] In a further example of any of the foregoing, each of the first and second legs has a thickness. The thickness corresponds to a side of the first and second sub-portions, respectively.

[0021] In a further example of any of the foregoing, the first and second legs each have a first side adjacent the bracket and a second side opposite the first side. The cover plate includes an open edge between the second side of the first and second legs.

[0022] In a further example of any of the foregoing, the cover plate is attached to the outlet housing by one or more removable fasteners.

[0023] In a further example of any of the foregoing, the passage includes a rotor sweep surface, and the cover plate reduces an effective length of the rotor sweep surface

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 schematically shows an example screw compressor.

[0025] Figures 2A-B schematically show an example outlet housing for a screw compressor.

[0026] Figures 3A-C schematically show an example cover plate for the outlet housing of Figures 2.

DETAILED DESCRIPTION

[0027] An example screw compressor 20 is schematically illustrated in Figure 1. A compressor case 22 carries screw rotors 24/26. Though Figure 1 shows two screw rotors 24/26, more or less screw rotors could be used. The screw rotors 24/26 have threads or lobes which interfit to compress and drive a fluid toward a discharge 38. Fluid enters at an opposed end through an inlet 39. The rotors 24/26 each have shafts 30 which are mounted within bearing assemblies 32. The bearing assemblies 32 extend into chambers 34 in an outlet housing 36. [0028] The outlet housing 36 includes a passage 40 which communicates with the discharge 38 and serves to deliver the compressed fluid downstream. A discharge case 46 includes a chamber 50 which communicates with the passage 40.

[0029] Turning now to Figures 2A-B, an example outlet housing 136 is shown. In this example, the outlet housing 136 includes two chambers 134 which each receive a bearing 32 that corresponds to a screw rotor 24/26 (Figure 1). Though this example shows two chambers 134 that correspond to two screw rotors 24/26, more or less chambers 134/screw rotors could be used depending on the number of screw rotors.

[0030] A passage 140 is configured to communicate with discharge 38 and deliver compressed fluid to a downstream discharge as discussed above. In this example, the passage 140 has a radially outer edge 140a with an arcuate shape. The radially outer edge 140a joins a radially inner edge, which defines a rotor sweep surface 140b. The rotor sweep surface 140b is bound by two sides 140d, 140e. In one example, the sides 140d, 140e are non-straight. In a particular example, the left side 140d is convex with respect to a center of the passage 140 and the right side 140e is concave with respect to a center of the passage 140. The rotor sweep surface 140b has a length L defined between the sides 140d, 140e. The rotor sweep surface 140b maintains the fluid flow in a compressed state as it exits the discharge chambers 38. The side walls 140D and 140E have a curved profile that generally tracks the shape of the screw rotor 24/26 lobes at the discharge 38. The side wall 140D is convex and 140E is concave because one of the rotors 24/26 is male and the other of the rotors 24/26 is female, so when the lobes of these rotors 24/26 open to the discharge 38, the walls of the lobes of the rotors 24/26 at the discharge 38 track their respective curvatures. In this example, the rotor 24 is male, and the rotor 26 is female. In this example, a central portion 140c of the radially inner edge 140b protrudes down into a space between the chambers 134, with a “W” shape, which is also referred to as a “butterfly” shape, at the radially innermost edge. However, other profiles are contemplated.

[0031] The length L of the rotor sweep surface 140b, and ultimately the cross- sectional area of the passage 140, is related to a volume index of the screw compressor 20. The volume index is a ratio of the volume of fluid confined between the screw rotors 24/26 at the beginning of the compression process, e.g., near the inlet 39, to the volume of fluid confined between the screw rotors 24/26 where the screw rotors 24/26 open to the discharge 38 Changing the length L and thus the cross-sectional area of the passage 140 changes the volume index of the screw compressor 20 by changing the volume of fluid trapped between the screw rotors 24/26 as the screw rotors 24/26 open to the discharge 38.

[0032] The pressure ratio of the screw compressor 20 is the ratio of the pressure of the fluid at the inlet 39 to the pressure of the fluid at the discharge chambers 38. For a given pressure ratio, there is a volume index that maximizes efficiency of the screw compressor 20.

[0033] Figures 3A-B show the outlet housing 136 with a removable or interchangeable cover plate 200. Figure 3C shows the cover plate 200 in isolation. The cover plate 200 is attached to the outlet housing 136 via removable fasteners 202, such as screws, or another type of fastener. In the example shown, there are four fasteners 202, but more or less fasteners could be used.

[0034] The cover plate 200 has an open area 204 which corresponds to effective cross-sectional area of the passage 140 when the cover plate 200 is installed. The cover plate 200 covers a portion of the passage 140 so that the effective cross-sectional area of the passage 140 is reduced, and thus the volume index for the screw compressor 20 is increased. In the example of Figures 3A-C, the cover plate includes two legs 206a, 206b on either side of the opening 204. The legs 206a, 206b are joined by a bracket 208 at a first end of each leg 206a, 208a. Each of the legs 206a, 206b cover a sub-portion P of the passage 140 on either side of the passage 140 (shown in Figure 3B). The top (radially outer) edge of the opening 204 is rectangular in shape, though other shapes are contemplated.

[0035] The cover plate 200 has an open edge between a second end of the legs 206a, 206b opposite the end of the legs 206a, 206b joined by the bracket 208. Additionally, the second end of each leg 206a, 206b includes a divot 210a, 210b respectively. The shape of the divots correspond to the shape of the sides 140d, 140e of the passage 140 (shown in Figures 2A-B). Therefore, the shape or profile of the rotor sweep surface 140b is maintained, and only the effective length Le of the rotor sweep surface is changed by the cover plate 200.

[0036] Each of the legs 206a, 206b has a thickness t (Figure 3C) that corresponds to a size of the sub-portion P (shown in phantom in Figure 3B) on either side of the passage 140 covered by the respective leg 206a, 206b. The larger the thickness t of the legs 206a, 206b, the larger the cumulative portion (e.g., the sum of sub-portions P) of the passage 140 that is covered, the smaller the effective length Le of the rotor sweep surface 140b, and the smaller the effective cross-sectional area of the passage 140. Therefore, the larger the thickness t, the greater the volume index of the screw compressor 20.

[0037] The example cover plates 200 are part of a group of cover plates 200. The cover plates 200 in the group can have varying thicknesses t for the respective legs 206a, 206b. All of the cover plates 200 in the group are removable, meaning they can be removed and/or interchanged with others of the cover plates 200 in the group to vary the effective length Le of the rotor sweep surface and the cross-sectional area of the passage 140. In this way, the volume index for the screw compressor 20 can be varied. As was discussed above, the cover plate 200, and thus volume index, can be selected to maximize efficiency for a given pressure ratio for the screw compressor 20.

[0038] Although the different examples are illustrated as having specific components, the examples of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the embodiments in combination with features or components from any of the other embodiments.

[0039] The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.