Rotary plunger compression mechanism and hydraulic pump and air compressor thereof

Abstract

The present application belongs to the technical field of high-pressure plunger pump. The stator is a cylindrical cylinder, and the rotor is a rotating cylinder cavity and a rotating plunger. The rotating plunger reciprocates in the rotating radial cylinder cavity to realize compression and expansion of the front and rear chambers of the plunger. The two ends of the combined crankshaft are supported in the eccentric holes of the front and rear end covers, the crankshaft diameter drives the plunger to revolve, and at the same time, the main shaft diameter gear reduces the speed by half to drive the cylinder cavity and the plunger to rotate. The plunger completes one compression stroke per revolution, and the plunger and the cylinder cavity complete the conversion of the compression direction every half revolution. The revolution of the plunger plus the rotation of the plunger and the cylinder cavity realizes the one-way continuous compression of the plunger in the cylinder cavity. Advantages: 1. The chambers at both ends of the plunger work simultaneously, and the efficiency is doubled. 2. The plunger is one-way continuous compression, and the output is stable without intermittent pressure. 3. The plunger compression stroke is long, the compression ratio is large, and the output pressure is large. 4. The volume rate of the cylinder cavity is high, and the displacement ratio is large. 5. All are face seals, which are good in sealing and wear-resistant.

Description

Technical Field

[0001] This invention relates to a volumetric rotary piston compression mechanism, belonging to the field of high-pressure piston pump technology. Background Technology

[0002] There are three main types of hydraulic pumps: 1. Gear pumps, which can continuously output large flow rates but have low output pressure (5-15 MPa). They are mostly used as liquid pressure pumps. 2. Vane pumps, which can continuously output medium flow rates and medium pressures (15-25 MPa). They are used in small hydraulic machinery. 3. Piston pumps, which have small output flow rates but can output high pressures (25-40 MPa). They are used in cranes and excavators.

[0003] The current swashplate piston pump has a maximum output pressure of only 40 MPa. Its structural shortcomings limit further performance improvements: 1. The swashplate angle is limited to 15°-20°, restricting the compression stroke and making it difficult to increase the output pressure further. 2. The force exerted by the swashplate on the piston is only the axial component of the swashplate rotation, accounting for only about 70% of the input power, and there is also frictional resistance between the swashplate and the piston top, resulting in power loss. 3. The switching between the inlet and outlet ports is achieved by the frictional rotation of the distribution plate under back pressure sealing, with frictional resistance consuming about 30% of the power. In total, only about 50% of the prime mover's mechanical energy is converted into hydraulic energy, resulting in low efficiency. 4. Oil suction and discharge require one reciprocating stroke of the piston, with only one end chamber working, leading to intermittent discharge and small flow rates. Multi-chamber alternating discharge reduces oil pressure fluctuations.

[0004] In summary, existing swashplate piston pumps only have a maximum output pressure of 40 MPa, and their flow rate and efficiency are low. With the development of heavy machinery, there is a need for high-efficiency hydraulic pumps with higher output pressure (e.g., 100 MPa) and greater flow rate.

[0005] Brief description of existing air compressor performance: There are two main types of air compressors currently used in pneumatic machinery: 1. Reciprocating piston air compressors, which can generate high air pressure but have intermittent output. Their reciprocating inertial forces are difficult to balance, limiting their speed and resulting in low output flow. 2. Screw air compressors, which have good dynamic balance, can operate at high speeds, and have high output flow. However, their sealing performance is poor, limiting them to medium pressure output.

[0006] In summary: reciprocating piston air compressors can output high-pressure gas, but cannot operate at high speeds and have low output flow rates. Screw air compressors can operate at high speeds and have high output flow rates, but have poor sealing and can only output medium pressures. What is currently lacking are high-efficiency air compressors that can output both high pressure and high flow rates, as required by large pneumatic equipment.

[0007] The purpose of this invention is to provide a compression mechanism that can output ultra-high pressure and large flow rate, and is highly efficient and energy-saving. Its products include hydraulic pumps and air compressors, which are used in the hydraulic systems of large engineering machinery and high-speed pneumatic equipment. Summary of the Invention

[0008] This invention creates a rotary plunger compression mechanism: within the stator housing, a rotating cylinder 5 has a radial cylinder cavity 18. The plunger 6 within the cylinder cavity 18 reciprocates relative to the cylinder cavity 18 as it revolves with the crankshaft diameter 7, causing the chambers at both ends of the plunger 6 to undergo compression and expansion strokes, respectively. The plunger 6 completes one stroke per revolution of the crankshaft diameter 7, that is, it completes the movement from end A to end B of the cylinder cavity 18. During rotation, the B chamber at the front end of the plunger 6 is compressed and discharged, while the A chamber at the rear end of the plunger 6 expands and draws in. Every half-revolution of the cylinder cavity 18, the plunger 6 completes the repositioning of the cylinder cavity and the plunger, allowing the plunger 6 to move back from end B to end A of the cylinder cavity 18 during the next revolution of the crankshaft diameter 7. The combined motion of plunger 6 revolving around crankshaft diameter 7 for one revolution and then rotating half a revolution on its own axis with cylinder cavity 18 achieves a unidirectional compression stroke of plunger 6 from one end of cylinder cavity 18 to the other with each revolution of crankshaft diameter 7. As a result, the chambers at both ends of plunger 6 are continuously drawn in at fixed-point intake port 10 and continuously discharged at fixed-point outlet port 11.

[0009] Innovation Highlight 1: Extra-long Compression Stroke: The plunger 6 revolves once around the crankshaft diameter 7, and simultaneously rotates half a revolution on its own axis. The superposition of these two rotational speeds achieves an extended stroke for the plunger 6, enabling it to perform a linear compression motion from one end of the cylinder chamber 18 to the other. The principle is as follows: the first half of each revolution of the plunger 6 is a 'reciprocating' stroke, and the second half is a 'returning' stroke. To also convert the second half of the revolution into a 'reciprocating' stroke, the plunger 6 needs to rotate half a revolution on its own axis simultaneously with each revolution. This means that the positions of both ends of the cylinder chamber 18 and the plunger 6 are rotated by 180° midway through the stroke, thus transforming the 'returning' stroke of the second half of the plunger 6 into a 'reciprocating' stroke, resulting in an extended compression stroke of 'reciprocating' + 'reciprocating'.

[0010] Innovation Highlight Two: Simultaneous Operation of Both Chambers of the Plunger: The plunger 6 divides the cylinder cavity 18 into two chambers within the radial cavity. The plunger 6 revolves once around the crankshaft diameter 7 within its central bore, and simultaneously rotates half a revolution around the crankshaft diameter within its own cylinder cavity 18. Each revolution of the plunger 6, combined with its half-revolution, creates an extended stroke within the cylinder cavity 18. The front and rear chambers of the plunger 6 operate simultaneously: the front chamber operates during the compression stroke, while the rear chamber operates during the intake stroke. The transition between the compression and intake strokes of the two chambers is achieved by the combined half-revolution of the cylinder cavity 18 and the plunger 6.

[0011] Innovation Highlight Three: Alternating Continuous Compression Exhaust: The first revolution of plunger 6 forms the compression stroke from end A to end B of cylinder chamber 18. Simultaneously, cylinder chamber 18 rotates half a revolution around its center, driving plunger 6 to rotate half a revolution around crankshaft diameter 7, thus converting the chambers at both ends of plunger 6 by 180°, i.e., the rear chamber of plunger 6 becomes the front chamber. Therefore, the second revolution of plunger 6 forms the compression stroke from end B to end A of cylinder chamber 18. This achieves alternating compression strokes in the same direction for both chambers, resulting in continuous compression exhaust from the fixed-point outlet 11.

[0012] Practicality of the Compression Mechanism of this Invention: The feasibility and practicality of the compression mechanism of this invention have been proven through prototype experiments. Advantages: 1. In the rotating cylinder chamber, the piston, along with the piston, performs a reciprocating compression motion relative to the cylinder chamber. While the chamber at one end of the piston is discharging, the chamber at the other end is drawing in. Both chambers at both ends of the piston work simultaneously, doubling the efficiency and achieving energy saving and high efficiency. 2. The cylinder chamber and piston complete the position change during half a rotation, ensuring that each revolution of the piston is a unidirectional, extended compression stroke. Continuous rotation forms a continuous compression stroke, with uninterrupted discharge and stable output pressure. 3. The length of the compression stroke is the 'reciprocating' + 'reciprocating' stroke of one revolution of the crankshaft, twice the piston stroke of the crankshaft connecting rod mechanism. A long compression stroke results in high output pressure and flow rate for liquids, and a high compression ratio and high output gas pressure for gases. 4. This structure has a large cylinder chamber volume ratio and a large output flow rate.

[0013] Brief description of the structure of the present invention: See Figure 1 and Figure 2 The front and rear end caps 3 are fixed at both ends of the combined outer cylinder 20, forming the stator part. The main shaft diameters 8 at both ends of the combined crankshaft 19 are supported on the eccentric holes of the front and rear end caps 3. The two ends of the cylinder 5 are supported on the inner bosses of the front and rear cylinder heads 3. A plunger 6 is fitted on the crankshaft diameter 7 of the combined crankshaft 19, and the plunger 6 is installed in the radial cylinder cavity 18 of the cylinder 5. The cylinder 5 is driven by the main shaft diameter gear 8 of the combined crankshaft. This is the rotating part.

[0014] Stator Components: The combined outer cylinder 20 is composed of a sleeve 2 inserted into an outer shell 1. The outer shell 1 has a suction inlet 10 and a discharge outlet 11 on each side of its middle section. The sleeve 2 has two internal inlet holes 12 and 13 and two internal outlet holes 15 and 16 on each side of its middle section. Between the outer shell 1 and the sleeve 2 of the combined outer cylinder 20, there is a suction inner channel 14 on one side connecting the two internal inlet holes to the suction inlet 10, and a discharge inner channel 17 on the other side connecting the two internal outlet holes to the discharge outlet 11. The outer shell 1 of the combined outer cylinder 20 has two positioning grooves and evenly distributed screw holes on the circumference of each of its two ends for fixing the front and rear end caps 3. The front and rear end caps 3 have the same structure, with two levels of bosses on their inner planes. The outer bosses are used to position and fix the sleeve 2 of the combined outer cylinder 20. The inner bosses are fitted with sliding bearing sleeves to support the two ends of the rotating cylinder 5. The outer plane of the front and rear end caps 3 has a recessed platform, the cavity of which serves as a counterweight chamber. The front and rear end caps 3 have a circular hole with an eccentricity of e on their central bosses. A sliding bushing is installed in the hole to support the main shaft diameters 8 at both ends of the combined crankshaft 19.

[0015] Rotating components: The combined crankshaft 19 is composed of flat shafts with a main shaft diameter 8 inserted into each end of the flat hole in the crankshaft diameter 7. The crankshaft diameter 7 is a cylinder with through flat holes eccentrically positioned at both ends. The main shaft diameter (gear shaft) 8 has a gear in its middle section; one end of the gear is a flat shaft, and the other end is a cylindrical shaft, i.e., the main shaft diameter. The main shaft diameters 8 at both ends of the combined crankshaft 19 are supported in the eccentric holes of the front and rear end caps 3, and counterweights are mounted on the main shaft diameters 8 extending out of the holes. One end of the main shaft diameter is longer and has a spline, connecting to the motor shaft. A plunger 6 is fitted onto the crankshaft diameter 7 of the combined crankshaft 19. The plunger 6 is a rectangular cuboid with rounded corners, cylindrical top surfaces at both ends, and a central hole on its side containing a sliding bearing, which is fitted onto the crankshaft diameter 7. The plunger 6 is installed in the radial cylinder cavity 18, which is located in the middle of the cylinder 5 and is a rectangular elongated hole with rounded corners that runs radially through the cylinder. The cylinder 5 has recessed platforms at both ends, which are supported on the inner protrusions of the front and rear end caps 3. Attached Figure Description

[0016] The numbers in the diagram are: 1-outer shell, 2-sleeve, 3-front and rear end caps, 4-cover plate, 5-cylinder barrel, 6-plunger, 7-crankshaft diameter, 8-main shaft diameter (gear shaft), 9-counterweight, 10-suction inlet, 11-exhaust outlet, 12-inner inlet hole, 13-inner inlet hole, 14-inner inlet channel, 15-inner outlet hole, 16-inner outlet hole, 17-inner outlet channel, 18-cylinder cavity, 19-combined crankshaft, 20-combined outer cylinder.

[0017] Figure 1 This is a longitudinal sectional view of the rotary piston compression mechanism.

[0018] Figure 2 For rotary piston compression mechanism ( Figure 1A cross-sectional view of ( ).

[0019] Figure 3 This is a cross-sectional view of a rotary piston hydraulic pump.

[0020] Figure 4 This is a cross-sectional view of a rotary piston air compressor.

[0021] Figure 5 This is a schematic diagram of the working process of a rotary piston hydraulic pump.

[0022] Figure 6 This is a schematic diagram of the working process of a rotary piston air compressor.

[0023] Figure 7 Photograph of the rotor assembly of a rotary piston compression mechanism.

[0024] Figure 8 Photograph of the cylinder part of a rotary piston compression mechanism.

[0025] Figure 9 Photograph of the plunger component of a rotary plunger compression mechanism. Detailed Implementation

[0026] Transmission method: When the electric motor drives the main shaft diameter 8 of the combined crankshaft 19 to rotate, the crankshaft diameter 7 of the combined crankshaft 19 carries the plunger 6 to revolve. At the same time, the gear reduction of the main shaft diameter (gear shaft) 8 of the combined crankshaft 19 drives the internal gear on the cylinder 5, causing the cylinder 5 to rotate at half speed. The plunger 6 in the cylinder chamber 18 on the cylinder 5 also rotates at half speed. Each revolution of the plunger 6 plus the half-revolution of the plunger 6 realizes the reciprocating motion of the plunger 6 relative to the cylinder chamber during rotation, so that the chambers at both ends of the plunger 6 alternately complete the working stroke of suction and discharge.

[0027] Specific applications: The rotary piston compression mechanism is optimally used as a hydraulic pump, but it can also be used as a gas compressor. Both have the same rotor structure and operating process; only the discharge port differs. Details are as follows.

[0028] Working process of rotary piston hydraulic pump: See Figure 3 , Figure 5 Sleeve 2 has two inlet holes on one side and two outlet holes on the other side. Liquids are incompressible, but can be pressurized and transmitted. The hydraulic pump operates by immediately discharging fluid; discharge begins as soon as compression starts. The output pressure depends on the length of the compression stroke and the speed of compression.

[0029] Figure 5 (1) As shown, when the cylinder cavity is in the vertical position, the A end of the plunger 6 is at the top dead center, the volume of the cavity at the A end is at its minimum, the volume of the cavity at the B end is at its maximum, and the crankshaft diameter 7 is directly above the center of the circle at the top dead center.

[0030] Figure 5(1) to (2) to (3) to (4), as shown, when the cylinder cavity and plunger 6 rotate clockwise successively through 45°, 90° and 135°, the crankshaft diameter 7 rotates at double speed successively through 90°, 180° and 270°, driving the plunger 6 to move towards end B of the cylinder cavity, so that end B cavity continuously discharges liquid under pressure, while end A cavity continuously draws liquid.

[0031] from Figure 5 (4) From (1), when the cylinder cavity and plunger 6 have rotated 180°, the crankshaft diameter 7 rotates 360° at double speed, driving the plunger 6 to the end point of cylinder cavity B. At this point, the graph returns to its previous state. Figure 5 (1) Shape. The difference is that the B end of the plunger 6 reaches the top dead center, the B end cavity reaches the end of the discharge, and the A end cavity reaches the maximum volume.

[0032] Working process of rotary piston air compressor: See Figure 4 , Figure 6 Sleeve 2 has two internal inlet holes on one side and only one internal outlet hole on the other side, directly connecting to the discharge port. Gas is compressible, and the output air pressure depends on the compression ratio. The air compressor operates by compressing to a certain pressure before discharging. One cylinder chamber is filled with air before compression begins, and air is only discharged near the end of the compression cycle.

[0033] Figure 6 (1) As shown, when the cylinder cavity is in the vertical position, end A of the plunger 6 is at top dead center, the volume of end A is at its minimum, and the volume of end B is at its maximum. At top dead center, the crankshaft diameter 7 is directly above the center of the circle.

[0034] Figure 6 (1) to (2) to (3), as shown, when the cylinder chamber and plunger 6 rotate through 45° and 90° angles, the crankshaft diameter 7 rotates through 90° and 180° angles at double speed. At this time, the crankshaft diameter 7 rotates to directly below the center, driving the plunger 6 to move towards end B. End A chamber continuously draws in air, while end B chamber continues to compress air.

[0035] Figure 6 (3) to (4) show that when the cylinder chamber and plunger 6 have rotated 135°, the crankshaft diameter 7 rotates 270° at double speed, driving the plunger 6 to move towards end B. The end B chamber begins to exhaust air. The end A chamber continues to draw in air.

[0036] from Figure 6 (4) When the cylinder chamber and plunger 6 rotate 180° from (1), the crankshaft diameter 7 rotates 360° at double speed, driving the plunger 6 to the end point B. At this time, the graph returns to the previous state. Figure 6 (1) Shape. The difference is that the B end of the plunger 6 reaches the top dead center, the B end cavity reaches the exhaust end, and the A end cavity reaches the maximum volume.

[0037] Advantages of this product: The rotary piston compression mechanism of this invention has the following advantages when applied to hydraulic pumps and air compressors: 1. Compact structure, small size, high power, high efficiency and energy saving. 2. Large compression stroke, large compression ratio, and high output pressure. 3. Large volumetric efficiency, high speed, and large output flow. 4. Continuous pressure output without interruption, with no pressure fluctuation. 5. Wide-area sliding seal, good sealing performance, wear resistance, and long service life. 6. No complex curved surfaces, easy to manufacture and low cost.

[0038] Specific Applications: This invention's rotary plunger compression mechanism solves all the problems of existing high-pressure plunger pumps, significantly increasing output pressure and flow rate. This invention features a novel structure where a rotating plunger performs continuous pressure output within a rotating cylinder chamber. Its superior performance places it in the high-end segment of plunger pumps. It comes in two models: one is a hydraulic pump with ultra-high pressure, ultra-large flow rate, high efficiency, low energy consumption, and low cost, capable of replacing various existing high-pressure pumps. It is suitable for large-scale engineering machinery and weapon systems requiring high pressure and large flow rates. Its small size, light weight, and high efficiency make it suitable for aircraft hydraulic systems. The other model is an air compressor with high pressure, large flow rate, and high energy efficiency, capable of replacing existing low-efficiency reciprocating, low-pressure screw-type, and poorly sealed rotor-type air compressors. It is used in large-scale, high-speed pneumatic machinery, pneumatic catapult machinery, and vacuum pumps requiring high-pressure air.

Claims

1. A rotary plunger compression mechanism, characterized in that: It includes: The assembly consists of an outer cylinder, front and rear end caps (3), a cylinder (5), a plunger (6), and an assembly crankshaft. The outer cylinder is composed of a sleeve (2) inserted into the outer shell (1). The assembly crankshaft includes a crankshaft diameter (7) with a cylindrical middle section. Flat shafts of the main shaft diameter gear shaft (8) are inserted into the eccentric flat holes on both ends of the crankshaft diameter (7). A suction inlet (10) is provided on one side of the middle section of the outer shell (1), and a discharge outlet (11) is provided on the other side. Two internal inlet holes (12, 13) are provided on one side of the middle section of the sleeve (2), and two internal outlet holes (15, 16) are provided on the other side. The outer shell and the sleeve of the assembly are provided on both sides. There is an inner channel, which includes: an inner suction channel (14) that connects two inner inlet holes to the suction inlet, and an inner discharge channel (17) that connects two inner outlet holes to the discharge outlet. There are two front and rear end caps (3) with the same structure. There are two levels of bosses on the inner plane of the front and rear end caps (3). There is an eccentric hole in the center of the boss plane. There is a concave platform on the outer plane of the front and rear end caps (3). The inner cavity of the concave platform is a counterweight chamber. There is a rectangular radial cylinder cavity hole with rounded corners in the middle of the cylinder (5). There are concave platforms at both ends of the cylinder cylinder that cooperate with the bosses. There is an identical internal gear hole at the center of the concave platform plane at both ends of the cylinder cylinder.

2. The rotary plunger compression mechanism according to claim 1, characterized in that, The plunger (6) is a rectangular cuboid with rounded corners. Its two ends are cylindrical, and its two sides have central holes with copper sleeve sliding bearings installed inside.

3. The rotary plunger compression mechanism according to claim 1, characterized in that, The cylindrical shaft end of the main shaft radial gear shaft (8) has a spline.

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