Rotor Profile Optimization: Improving Energy Efficiency from the Source of Fluid Mechanics
Asymmetric tooth design: adopting asymmetric rotor with 5:6 tooth ratio reduces the gas reflux loss by 12%-15% compared with the traditional symmetric tooth profile, and improves the isothermal efficiency by 8%-10%. ZAKF can customize the rotor profile according to the customer's working conditions (e.g. altitude, temperature), such as designing a large pitch rotor for customers in high altitude areas to compensate for the loss of air intake.
Gap dynamic control: through finite element analysis (FEA) to optimize the fit gap between rotor and cylinder (controlled at 0.03-0.05mm), to avoid leakage loss under small flow conditions.ZAKF's scale production capacity of 2,500 air compressors per month ensures that the gap precision error of each unit is ≤±0.01mm, which is 50% higher than the industry average.
High-efficiency motor and frequency conversion technology: energy-saving core for single-phase power supply
For the characteristics of single-phase power supply (220V/50Hz), ZAKF's optimization solutions include:
Permanent magnet synchronous motor (PMSM) upgrade: replacing the traditional asynchronous motor, the efficiency is increased from 80% to more than 95%, especially in the 30%-70% load energy saving effect is significant. ZAKF's annual output value of 500 million yuan production capacity support, the permanent magnet motor models account for 60% of the total, and can realize 72 hours of rapid customized delivery. Rapid customized delivery.
Single-phase inverter control algorithm: Developing special DSP controller to solve the problem of phase fluctuation of single-phase power supply, the response time of speed adjustment is ≤0.3 seconds, which is 20% higher than that of three-phase inverter model. Combined with ZAKF's self-developed intelligent monitoring system, it can optimize the motor power factor in real time (maintained above 0.95).
Cooling and sealing system: the key link to reduce energy loss
The oil cooling system is finely designed: adopting high-efficiency plate heat exchanger, the heat exchange area increases by 30% compared with the traditional tubular design, and the oil temperature is controlled in the optimal range of 65-75℃, avoiding the decrease of lubricating oil viscosity caused by the high temperature (for every exceeding of 10℃, the efficiency will be decreased by 3-5%). 2000 sets of post-processing equipments are produced by ZAKF every month, which ensures the delivery of the cooling system and the main machine synchronously, and shortens the delivery time of the cooling system. ZAKF's monthly production capacity of 2,000 units ensures that the cooling system is delivered at the same time as the host machine, shortening the customer's installation period.
Combined sealing structure: The combination of “labyrinth seal + carbon ring seal” at the shaft end reduces the leakage to less than 0.5%, which is 70% less than the single labyrinth seal. This technology has been applied to ZAKF's models exported to Southeast Asia, and with the spare parts inventory of 7 warehousing bases, it realizes 15 days' quick repair and replacement.
Intelligent Control and System Integration: ZAKF's Customized Solution for Energy Efficiency
Adaptive Load Adjustment: Through the linkage between the pressure sensor and PLC, the screw speed will be adjusted automatically (adjustment range 40%-100%) when the air consumption drops, avoiding the phenomenon of “big horse pulling small car”. A case study of a food factory shows that this solution saves 28% energy compared with fixed-frequency models, and ZAKF can customize the control logic according to the customer's gas consumption curve.
Energy Recovery System: Developing the waste heat utilization module of screw machine, the compression heat is used for hot water supply (60-80℃), and the comprehensive energy efficiency is improved by 15%-20%. 3 independent operating companies of ZAKF overseas can provide localized transformation services, for example, the customers in the Middle East region have already realized the linkage operation between the waste heat recovery system and solar energy equipment.
V. ZAKF Factory Advantage: Energy Efficiency Guarantee from Technology to Delivery
Scale Production and Precision Control
60,000 square meters production base is equipped with German imported rotor grinder, with rotor profile machining precision up to ±0.005mm, to ensure the consistency of energy efficiency of each device. With an annual production capacity of 500 million yuan, the development cycle of customized models is 40% shorter than the industry average.
Global service network support
7 warehousing bases cover major markets such as Southeast Asia and the Middle East, and the turnover rate of core spare parts for single-phase screw compressors reaches 3 times per month, which is coupled with the 15-day speedy shipping mechanism to ensure that the customer's energy-efficiency optimization solutions are quickly implemented. The global after-sales center provides 24-hour online diagnosis, with a response time of ≤2 hours.
Industry Application Cases: Practical Value of ZAKF's Energy Efficiency Solutions
Small Manufacturing Scenario: An electronic component factory adopts ZAKF's customized single-phase
Screw Compressor (flow rate of 15m³/min), and through the optimization of rotor profiles and frequency control, the annual power consumption is reduced from 120,000 kWh to 85,000 kWh, which is an energy-saving of 30%, with an investment payback period of 1.8 years.
Commercial Service Scenario: A hospital chain in Southeast Asia chooses ZAKF oil-free single-phase screw compressor, combined with the waste heat recovery system, to save $12,000 per year in hot water supply cost, and at the same time, meet the cleanliness requirements of medical grade.
ZAKF
screw air compressor manufacturer has always driven the optimization of energy efficiency with “technological innovation + capacity assurance”. Whether it's the hydrodynamic design of rotor profiles or breakthroughs in single-phase inverter technology, we're committed to turning every 1% improvement in energy efficiency into tangible benefits for our customers. For a customized energy efficiency solution based on your operating conditions, contact the ZAKF team and let the precision manufacturing and global service network of our 60,000 m2 production base help you achieve your energy saving goals.
