Simulation and experimental study of high pressure switching expansion reduction considering real gas effect

Switching expansion reduction （SER） uses a switch valve instead of the throttle valve to realize electronically controlled pressure reduction for high pressure pneumatics. A comprehensive and interactive pneumatic simulation model according to the experimental setup of SER has been built. The mathematical model considers heat exchanges, source air pressure and temperature, environmental temperatures and heat transfer coefficients variations. In addition, the compensation for real gas effect is used in the model building. The comparison between experiments and simulations of SER indicates that, to compensate the real gas effect in high pressure discharging process, the thermal capacity of air supply container in simulation should be less than the actual value. The higher the pressure range, the greater the deviation. Simulated and experimental results are highly consistent within pressure reduction ratios ranging from 1.4 to 20 and output air mass flow rates ranging from 3.5 to 132 g/s, which verifies the high adaptability of SER and the validity of the mathematic model and the compensation method.