High-Performance Compressor Design, Model Analysis and Application

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Machine Design and Theory".

Deadline for manuscript submissions: 31 December 2026 | Viewed by 2775

Editor


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Guest Editor
Centre for Compressor Technology, University of London, London EC1V 0HB, UK
Interests: mathematical modelling and computer simulation of thermal and fluid flow processes, including turbulence models; experimental methods for investigating the performance of thermal machinery and systems, especially of positive displacement compressors and boilers; the application of analytical and experimental techniques to the design of positive displacement compressors, boilers, furnaces and pipe networks; industrial investigations of large-scale thermal power plants

Special Issue Information

Dear Colleagues,

Compressors are considered a mature product in today’s age. They are subjected to a highly competitive market, especially in air compression and refrigeration. Orchestrated efforts of many companies driven by market forces have resulted in the creation of a compact and efficient compressor machine. Every detail counts. Even a virtually negligible difference will result in a small but distinct improvement, which may provide a competitive advantage.

Although evolutionary improvements may only be expected to move compressor performance forward, there is still space left for more breakthrough methods and procedures for developing an improved product. New compressor rotor generation, optimization of rotors, compressor design for certain compressive tasks and their specialized design are areas that can still benefit from innovation, improvement and development, specifically regarding positive displacement compressors. Nonetheless, the efficient operation of compressors is mainly dependent upon rotor profiles and their clearance distribution. Other components, such as housing ports, bearings, seals and lubrication systems, must be designed so as to take full advantage of their potential—if the goal is to achieve maximum performance gains. 

Mathematical modeling, experimental validation, design of critical components, complete machine design, product development, training in machine design, advanced computerized design tools, machine process modeling, 2D and 3D computational fluid dynamics, modern experimental techniques, computerized data acquisition and rotor and compressor optimization are all essential stages that are needed for appropriate compressor development. 

The ever-increasing market demand for efficient compressors requires their designs to be tailored based on their intended use, capacity and manufacturing capabilities. A suitable procedure for the optimization of compressors’ shapes, dimensions and operating parameters is also necessary. Such procedure should be based on a generation algorithm for rotor profile creation, combined with a numerical model of the compressor’s fluid flows and thermodynamic processes. 

Appropriately designed compressors can thus achieve higher delivery rates and display better efficiencies than those using traditional approaches. It has been shown that the optimum rotor profile parameters, compressor speed, oil flow rates and temperatures may significantly vary in accordance to the presence of different gases or vapors in specific compressor modes, which can be adjusted for optimal compressor performance.

Prof. Dr. Nikola Stosic
Guest Editor

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Keywords

  • compressor design
  • compressor technologies
  • compressor efficiency
  • compressor performance prediction

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Published Papers (3 papers)

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Research

18 pages, 2314 KB  
Article
Experimental Investigation on Refrigerant Charge Optimization of Vapor Compression Refrigeration System Driven by Oil-Free Linear Compressors
by Xueliang Fang and Xinwen Chen
Machines 2026, 14(7), 726; https://doi.org/10.3390/machines14070726 - 27 Jun 2026
Viewed by 397
Abstract
Vapor compression refrigeration systems account for a substantial share of global electricity consumption in residential and commercial applications, with environmental impacts arising from both energy use and refrigerant leakage. Refrigerant charge optimization offers an economical means of improving system performance without hardware modifications. [...] Read more.
Vapor compression refrigeration systems account for a substantial share of global electricity consumption in residential and commercial applications, with environmental impacts arising from both energy use and refrigerant leakage. Refrigerant charge optimization offers an economical means of improving system performance without hardware modifications. Oil-free linear compressors mitigate lubricant-induced degradation of heat transfer, yet the combined influence of charge amount on the coefficient of performance (COP) and total equivalent warming impact (TEWI) has not been thoroughly quantified. An experimental investigation was conducted on a vapor compression refrigeration system equipped with an oil-free linear compressor using R134a. The experiments covered refrigerant charges of 220–330 g, piston strokes of 9–12 mm, and pressure ratios of 2.0–3.5. Component-level refrigerant distribution and system performance characteristics were analyzed systematically. The condenser holds 74.7% of the total refrigerant charge at the optimal charge of 280 g. Rising charge reduces superheat and increases subcooling, both of which serve as practical indicators of the charge level. The mass flow rate, cooling capacity, and COP all exhibit characteristic non-monotonic trends. The maximum COP of 4.67 and the maximum cooling capacity of 472.7 W are both achieved at 280 g, which is identified as the optimal operating condition. The oil-free design eliminates lubricant interference and yields a clearly condenser-dominated refrigerant distribution. The TEWI increases by only 3.6% when the charge is raised to 330 g, and this slight environmental drawback is offset by the gain in energy efficiency. A distinct COP reduction is observed at a charge of 220 g. The charge of 280 g achieves the best balance between energy efficiency and lifecycle CO2 emissions. This work provides quantitative guidance for charge selection in oil-free linear compressor refrigeration systems. Full article
(This article belongs to the Special Issue High-Performance Compressor Design, Model Analysis and Application)
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24 pages, 5233 KB  
Article
Research on Inertial Force Balance and Optimization of V-Type High-Pressure Air Compressors for Ships
by Jun Feng, Huiqing Zou, Jing Liu and Xiaohan Jia
Machines 2026, 14(4), 436; https://doi.org/10.3390/machines14040436 - 14 Apr 2026
Viewed by 716
Abstract
To address the vibration and noise issues induced by inertial forces in marine V-type air compressors during operation, this study systematically investigates inertial force balancing and optimization. Based on dynamic analysis, analytical expressions for the first- and second-order reciprocating inertial forces and the [...] Read more.
To address the vibration and noise issues induced by inertial forces in marine V-type air compressors during operation, this study systematically investigates inertial force balancing and optimization. Based on dynamic analysis, analytical expressions for the first- and second-order reciprocating inertial forces and the rotating inertial force under unbalanced conditions are precisely derived. Considering the characteristics of a V-type air compressor with a V-angle of γ = 60°, the synthesis model of the first-order reciprocating inertial force is modified. The positive–negative rotating wheel system method is employed for preliminary balancing design, and the rigid–flexible coupling dynamics theory is innovatively introduced to construct a high-precision multi-body dynamics model that accounts for the flexible deformation of the crankshaft and connecting rod. Through joint simulation using ANSYS (2024R1) and Adams (2024.2), the dynamic responses of the pure rigid-body model and the rigid–flexible coupling model are compared to determine the optimal balancing configuration. The Adams/Insight module is utilized to perform multi-objective optimization of the balance iron mass. Results indicate that the rigid–flexible coupling model more accurately reflects the dynamic characteristics of the air compressor compared to the pure rigid-body model, significantly enhancing simulation accuracy. The optimized balance iron configuration effectively suppresses system vibration, with the peak X-direction bearing reaction force decreasing from 3750 N to 3610 N (a reduction of 3.7%), the vibration intensity reducing by 45.3%, and the radiated noise sound power level decreasing by 7.45%. This study provides a systematic theoretical approach and technical pathway for vibration and noise reduction, as well as for structural reliability design of marine air compressors. Full article
(This article belongs to the Special Issue High-Performance Compressor Design, Model Analysis and Application)
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23 pages, 4226 KB  
Article
Synergistic Optimization Strategy for Cavitation Suppression of Piston Pumps Based on Low-Pressure Loss Flow Passages
by Yue Wang, Lin Chen, Fei Xiao, Jin Zhang, Xu Wang, Ying Li and Xiangdong Kong
Machines 2025, 13(10), 901; https://doi.org/10.3390/machines13100901 - 1 Oct 2025
Cited by 3 | Viewed by 1072
Abstract
For axial closed-circuit piston pumps, cavitation often causes a reduction in volumetric efficiency during operation, and flow passage pressure loss is a key factor inducing cavitation. To address this issue, this study aims to suppress pump cavitation and improve volumetric efficiency through a [...] Read more.
For axial closed-circuit piston pumps, cavitation often causes a reduction in volumetric efficiency during operation, and flow passage pressure loss is a key factor inducing cavitation. To address this issue, this study aims to suppress pump cavitation and improve volumetric efficiency through a synergistic approach involving low-pressure loss flow passages and parameter optimization. First, a flow field model based on a full cavitation model is established to meet the requirements for accurate cavitation simulation of piston pumps. The segmented approximation method is used to decompose complex flow passages inside the pump, a mathematical model of flow passage pressure loss is developed, and the traditional flow rate model is optimized by introducing a pressure loss correction term, thus reducing flow rate prediction error. Further, variance-based sensitivity analysis is used to quantify the effects of pressure loss influencing parameters on cavitation. Results indicate that inlet pressure is the core independent parameter affecting cavitation, and interaction effects between parameters are dominated by antagonism. Accordingly, a single-parameter control and a multi-parameter optimization strategy is proposed based on the sensitivity of different parameters, providing technical support and a quantitative basis for pump cavitation suppression and volumetric efficiency improvement. Full article
(This article belongs to the Special Issue High-Performance Compressor Design, Model Analysis and Application)
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