Optimization Design of Flow Channels in the Gas Distribution Block of a Parallel Air Compressor Unit for Small Modular Anchor Rod Drills

The air distribution block serves as a critical component in compressed air power units, with its design directly influencing energy consumption losses and system energy efficiency. To address the significant pressure loss in parallel air compressor units of compact modular bolter drill rigs, this study implemented an optimized design for the flow channels within the air distribution block. Initially, CFD (computational fluid dynamics) simulations were performed to analyze pressure and velocity distributions within the flow channels, revealing that substantial pressure losses primarily resulted from the intersection of multiple flow channels and abrupt directional changes. Subsequently, fluid topology optimization techniques were employed to redesign the flow channel configuration. The optimized channels demonstrated improved geometric features including rounded corners and tapered transitions at critical junctions. Following structural reconstruction of the topology-optimized design, CFD validation tests confirmed a 35.3% reduction in pressure loss across the air distribution block. This optimization strategy effectively enhances the energy efficiency of parallel air compressor systems while maintaining operational requirements.