“Design Analysis and Optimization of a Commercial Air Compressor System”

Abstract

This study presents a comprehensive design analysis and optimization of a commercial air compressor system, which plays a critical role in numerous industrial, automotive, and pneumatic control applications. Commercial air compressors are vital for delivering compressed air at desired pressures and flow rates for powering tools, machines, and systems across sectors such as manufacturing, transportation, and energy. The project aims to analyze the compressor's thermodynamic cycles, mechanical components, and operational parameters to identify inefficiencies in energy usage, airflow, heat dissipation, and material stress. Special emphasis is placed on understanding the relationship between design geometry, working conditions, and system performance, especially in high-duty cycles and variable-load environments. Advanced modeling and simulation tools—such as SolidWorks for 3D design, ANSYS for thermal and structural analysis, and MATLAB/Simulink for system dynamics and control logic—are used to replicate real-world operating conditions. Parameters including pressure build-up time, volumetric efficiency, isentropic efficiency, power consumption, heat generation, and vibration levels are analyzed in detail. The optimization phase involves iterative improvements through both design and control strategies. Key interventions include redesigning internal components (such as the piston or rotor geometry), improving the cooling and lubrication systems, applying lightweight yet durable materials, and integrating smart control systems like Variable Frequency Drives (VFDs) to allow dynamic response to load changes. The results of the optimized model demonstrate improvements in energy efficiency, thermal stability, output consistency, and mechanical reliability. These findings are validated through simulation-based benchmarking and, where possible, compared with performance metrics of existing commercial systems.