Stereoscopic valve flow path topology design in reciprocating compressors: Structural optimization via the response surface method

The enhancement of energy efficiency in reciprocating compressor valves has long been constrained by the non-analytical nature of multi-parameter coupling effects. Traditional single-parameter strategies are inadequate for revealing the complex nonlinear interactions within flow paths. To address this limitation, this study proposes a response surface method (RSM)-based strategy for the topological optimization of stereoscopic flow channels. By constructing spatial interactions among contact surface tilt angles, flow path angles, and port-slot ratios, the study for the first time quantifies the influence of multi-parameter coupling mechanisms on effective flow area and flow coefficient. The optimal parameter combination obtained via RSM (α=71.8°, β=14.2°, γ=2:1) exhibited superior performance, as confirmed by both experimental and industrial tests: compared with the passive plate valve, the discharge volume increased by 50.1 % and the specific energy consumption per unit discharge volume decreased by 7.6 %; relative to the single-parameter numerical optimization group, the discharge volume further increased by 3.3 % and the specific energy consumption decreased by 2.7 %. The discrepancy between simulation and experimental results was less than 5 %, validating the reliability and accuracy of the proposed method. This study establishes an integrated methodological framework of “parameter coupling analysis-flow field characteristic regulation—system energy efficiency verification,” providing a novel paradigm for the intelligent design and energy-efficient optimization of high-performance fluid machinery.