Axial foil bearing assembly and spacer

Abstract

The invention relates to an air compressor (100) comprising at least one axial air bearing location comprising a first foil bearing assembly (312) and a second foil bearing assembly (314), a rotor and a high speed fuel cell air compressor, a spacer element (306), a first device part (322) and a second device part (316), the invention relates to an axial air bearing assembly for forming an axial air bearing point, which comprises at least one cover foil with one or more clip geometries (310.1, 310.2) and at least one spring foil with one or more cutouts.

Description

Technical Field

[0001] The invention relates to an air compressor, the air compressor comprising at least one axial air bearing part, a rotor, a high-speed fuel cell air compressor, a spacing element, a first equipment part and a second equipment part, wherein the axial air bearing part comprises a first foil bearing assembly and a second foil bearing assembly for constructing the axial air bearing part. In addition, the invention also relates to a method for assembling the axial air bearing part and the use of the air compressor. Background Art

[0002] DE 202022102710 U1 relates to a compressor having a compressor wheel, a shaft, an electric motor for driving the shaft, and an axial air bearing, the compressor wheel being fastened to the shaft, the axial air bearing having a spring leaf and a cover leaf fastened to a bracket. The spring leaf and the cover leaf are fastened to the bracket by a clamp.

[0003] DE 112012002901 T5 relates to an air delivery device for a fuel cell, the air delivery device having a shaft, a compressor wheel arranged in a compressor housing and fastened at one of the ends of the shaft, a bearing arranged in a bearing housing for supporting the shaft, and an electric motor arranged in the bearing housing for driving the shaft, wherein the shaft has two shaft bearing sections configured as separate components, a magnetic section arranged between the shaft bearing sections and forming a separate component, and a magnetic section forming a rotor of the electric motor. The shaft bearing section and the magnetic section are braced against each other. In addition, the shaft bearing section and the magnetic section are centered with each other via a centering component acting on the outer edge, wherein the shaft bearing section and the magnetic section are respectively in contact with each other in the axial direction. Summary of the invention

[0004] According to a first aspect of the present invention, an air compressor is proposed, which includes at least one axial air bearing part, a rotor, a spacer element, a first equipment part and a second equipment part, wherein the axial air bearing part includes a first foil bearing assembly and a second foil bearing assembly for constructing the axial air bearing part, and the axial air bearing part includes at least one covering foil with one or more clamping geometric structures and at least one spring foil with one or more recesses.

[0005] The invention particularly comprises an advantageous configuration of at least one, preferably at least two, pre-assembled structural groups, which improves the axial air bearing configuration. The pre-assembled structural group comprises the pre-assembly of the foil assembly on the spacing element, the joining of the pre-assembled structural group, the joining of the rotor and the joining of the second pre-assembled structural group. Optionally, the pre-assembly structural group comprises the pre-assembly of the rotor, optionally the pre-assembly of one or two device parts. In the sense of the invention, the pre-assembly structural group can be understood as the first foil bearing assembly and / or the second foil bearing assembly.

[0006] An air compressor, also known as a compressor, is a device for compressing gas, which increases the pressure of gas, such as air, by reducing the gas volume. Such an air compressor is used, for example, for the operation of a fuel cell. Typically, an air compressor has a compressor impeller, which is driven by a motor via a shaft, and the motor includes a rotor and a stator. The rotor is a rotating component that ensures that the gas or air sucked into the compressor is compressed, wherein the gas or air moves through the compression space of the compressor. Another major component of the air compressor is an axial air bearing portion, which enables the rotor to move axially in the longitudinal direction inside the compressor. The advantage of the axial air bearing is that the rotor can move axially to receive thermal expansion or other movements that occur during operation. Therefore, friction and wear can be significantly limited and the service life of the compressor can be greatly improved. Typically, the axial air bearing portion is implemented in the compressor so that a free space volume is provided for the axial movement of the rotor and a stable position is ensured inside the air compressor at the same time. For example, the axial air bearing can be realized by a spacer element and a foil assembly. For example, a notch that is left empty as an annular ring can be implemented on the second device part.

[0007] A spacer element in the sense of the present invention is a spacer element for the axial air bearing region, which is used to provide a spacing between device parts, with the aim of promoting efficient and precise component positioning between individual elements of the axial air bearing region. For example, the spacer element can advantageously contribute to reducing friction. For example, the spacer element can be configured as an annular spacer.

[0008] The first and second device parts are understood to be those components of the air compressor which at least partially surround the foil arrangement including the axial air bearing point on both sides.

[0009] A foil bearing assembly within the meaning of the present invention relates to the arrangement and positioning of foil elements, such as cover foils and / or spring foils, for forming an axial air bearing point, wherein the foil bearing assembly via these foil elements advantageously influences the functionality and operating capacity of the axial air bearing point.

[0010] According to the invention, the axial air bearing region comprises at least one spring foil and at least one cover foil, wherein the cover foil rests on the spring foil. The spring foil rests on the spacing element, so that during a substantially rotational movement of the rotor an air cushion is formed via the cover foil, via which the rotor flange or the spacing element of the rotor is guided.

[0011] A cover foil is understood to be a component of a foil bearing assembly, wherein the cover foil has a material, for example, made of a nickel-chromium alloy or spring steel, which is particularly provided with a friction-reducing coating. The cover foil is designed so that it is fixed to the spacing element by means of at least one clamping geometry in combination with the spring foil. Within the scope of the present invention, the cover foil has at least one clamping geometry. A clamping geometry is understood, for example, to be a fastening element or a tab for fastening the spring foil and / or the cover foil to the spacing element. For example, the clamping geometry can be designed as a spring clamp and can provide a form-locking connection between the axial air bearing parts.

[0012] A spring foil is understood to be a component of a foil bearing assembly, wherein the spring foil has a mass, for example made of a nickel-chromium alloy or spring steel, which in particular has a friction-reducing coating, wherein the spring foil is designed such that it is fixed to the spacing element in combination with the cover foil. For example, the spring foil can have one or more recesses, through which, for example, a clamping geometry passes.

[0013] In an advantageous development of the air compressor proposed according to the invention, the cover foil is provided with one or more clamping geometries which have at least one section which is designed in an angled manner.

[0014] Furthermore, the cover foil advantageously has one or more clipping geometries in the sense of the invention, which have at least one section that is embodied in an angled manner. For example, the clipping geometry can be designed as a rectangular tab, wherein the majority of the clipping geometry is a rectangle with straight sides, but at the ends, that is to say at the angled section, a portion is bent, for example, at an angle of 45 degrees, thereby forming an inclined edge.

[0015] In an advantageous embodiment of the air compressor proposed according to the invention, the cover foil with one or more clamping geometries has at least one guide geometry.

[0016] A guide geometry in the sense of the invention is a formation and / or structure, wherein the formation and / or structure is formed, for example, on a cover foil and / or a spring foil, for example to influence the movement, orientation and / or positioning of a component, for example the positioning of a spacer.

[0017] In an advantageous embodiment of the air compressor proposed according to the invention, the spring foil has at least one recess through which the clamping geometry and / or at least one guide geometry can be guided.

[0018] In a further advantageous embodiment of the air compressor according to the invention, the second device part has a recess for receiving the clamping geometry.

[0019] In the scope of the present invention, a notch is a recess in a material, for example in a second device part. The second device part with a notch makes it possible to receive at least one clamping geometry, wherein the structure of the notch is configured, for example, so that when the clamping geometry is introduced into the notch, the section of the clamping geometry implemented at an angle is first compressed. For example, the notch can have an introduction section with an inclined slope, wherein the introduction section makes it possible to introduce the clamping geometry. During the introduction of the clamping geometry into the notch, the section implemented at an angle is compressed due to the slope. After the introduction of the clamping geometry, the notch can constitute a straight section with a straight slope. In this area, the compressed section of the clamping geometry is released and has its original shape. Since this section of the clamping geometry is no longer compressed at this time, the geometry of this section of the clamping geometry combined with the straight slope prevents the tab of the clamping geometry from sliding out of the notch, thereby generating a permanent connection between the clamping geometry and the second device part. Furthermore, the notch can also have, for example, a wedge-shaped notch, a dovetail notch, a conical notch, a T-shaped notch or also a circular notch. For example, the notch can be formed by a punch or a milling machine. As an alternative, the notch can be implemented in the material, for example in the second device part, by drilling.

[0020] In another advantageous embodiment of the air compressor according to the invention, the first foil bearing assembly has at least one spring foil and at least one cover foil.

[0021] In another advantageous embodiment of the air compressor according to the invention, the second foil bearing assembly has at least one spring foil.

[0022] In a further advantageous embodiment of the air compressor proposed according to the invention, the air compressor has a housing part which comprises a housing part guide geometry, so that the housing part can be guided around the foil bearing arrangement and / or the spacer element.

[0023] In a further advantageous embodiment of the air compressor proposed according to the invention, the spring foil and / or the cover foil comprises a material consisting of a nickel-chromium alloy or spring steel, in particular with a friction-reducing coating.

[0024] A friction-reducing coating is understood to be a thin layer applied to the surface of a material, for example a cover foil and / or a spring foil, in order to reduce the friction between moving elements. The friction-reducing coating can be applied as a solid coating (for example a Teflon nitride layer), as a paste-like coating or as a liquid coating corresponding to the coated element (such as a cover foil and / or a spring foil).

[0025] According to a second aspect of the present invention, a method for assembling an axial air bearing portion is provided, wherein the method comprises at least the following steps:

[0026] i. fastening the first foil bearing assembly to the spring foil on the first spacing element side by means of a clip-on geometry, thereby enabling pre-assembly, and

[0027] ii. Fastening the second foil bearing assembly on the second spacing element side by means of a clip-on geometry.

[0028] In an advantageous development of the method according to the invention for mounting an axial air bearing station, step ii. is carried out after the rotor has been installed.

[0029] The method for assembly can be performed, for example, as follows: Produce a first and a second foil bearing assembly; pre-assemble the first foil bearing assembly onto the spacer element; join the rotor; assemble the second foil bearing assembly or completely pre-assemble all foil bearing assemblies including the rotor, wherein the assembly is pre-assembled only once so that all tolerances are detected and compensated during assembly. Optionally, further device parts can be integrated, for example, laminations on the housing side and / or on the motor side, into the pre-assembled assembly.

[0030] In an advantageous development of the method according to the invention for mounting an axial air bearing point, according to step ii., the clamping geometry is guided by a groove of the second device part and a positive connection is achieved by the angled section.

[0031] Furthermore, the invention relates to the use of an air compressor for rotating a rotor at high speeds.

[0032] Typical speed ranges for high speed rotor rotation are between 20,000 and 120,000 to 140,000 rpm.

[0033] The present invention discloses a very efficient solution for configuring the axial air bearing area of ​​an air compressor, because the proposed axial air bearing area enables the air compressor to run with low friction. The wear of the components of the air compressor is minimized by a special foil bearing assembly, thereby extending the service life of the air compressor and reducing maintenance costs. The minimized wear and the resulting reduced friction make it possible to achieve efficient rotational speeds, which is particularly advantageous for extremely efficient compression of air or gas. In addition, the present invention enables precise positioning of the bearing parts of the axial air bearing area relative to the rotor and the assembly of at least one, particularly preferably two, pre-assembled structural groups to enable rapid and reliable assembly. During assembly, parts of the axial air bearing area are held or guided with a defined bearing clearance.

[0034] Furthermore, the proposed invention enables a simple, fast and reliable assembly of the first and second foil bearing assemblies, wherein the foils, cover foils and / or spring foils are preassembled in at least two preassembled structural groups for simple and fast assembly.

[0035] Furthermore, by minimizing energy losses due to targeted friction reduction, the energy efficiency of the air compressor is increased and the operating costs are advantageously reduced.

[0036] Besides this, the friction reduction also leads to a very beneficial heat development in the air compressor, which prevents overheating and maintains compression efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Embodiments of the present invention are explained in more detail with reference to the drawings and the following description.

[0038] The accompanying drawings show:

[0039] Figure 1 Schematic diagram of a partial view of an air compressor,

[0040] Figure 2 Schematic diagram of cover foil and spring foil,

[0041] Figure 3.1-Figure 3.3 A detailed view of the axial air bearing section of an air compressor, and

[0042] Figure 4 Schematic diagram of a method for assembling an axial air bearing station.

[0043] In the following description of embodiments of the invention, identical or similar elements are marked with the same reference numerals, wherein a repeated description of these elements is omitted in individual cases. The figures only schematically illustrate the subject matter of the invention. DETAILED DESCRIPTION

[0044] Figure 1 A schematic diagram of a partial view of an air compressor 100 is shown, which has a rotor 106 and an axial air bearing region 102. The axial air bearing region 102 is responsible for the efficient movement of the rotor 106. For example, the axial air bearing region 102 is composed of multiple components, and has a spacing element 306 and at least one first and second foil bearing assembly 312, 314. Here, the foil bearing assembly 312, 314 is formed by at least one spring foil 200.1 and / or at least one cover foil 200.2.

[0045] Figure 2 A schematic diagram of such a spring foil 200.1 and a cover foil 200.2 is shown. Figure 2 , the spring foil 200 . 1 has a plurality of recesses 202 , and the cover foil 200 . 2 has two clamping geometries 204 and two guide geometries 206 .

[0046] The recess 202 of the spring foil 200.1 and the clamping geometry 204 of the cover foil 200.2 as well as the two guide geometries 206 are constructed on the cover foil 200.2 and the spring foil 200.1 in such a way that when the cover foil 200.2 and the spring foil 200.1 are combined into the first and second foil bearing assemblies 312, 314, they are superimposed on each other so that the clamping geometry 204 and the guide geometry 206 pass through the recess 202.

[0047] The clamping geometry 204 of the cover foil 200.2 has an angled section 324, and the guide geometry 206 has a straight section. In the joined state of the spring foil 200.1 and the cover foil 200.2, the clamping geometry 204 and the guide geometry 206 pass through the cutout 202 of the associated spring foil 200.1 into the notch 308 of the second device part 316, wherein a form-fitting connection is achieved.

[0048] Figure 3.1 to Figure 3.3 A detailed view of the axial air bearing region 102 of the air compressor 100 is shown. Figure 3.1 The detailed view in FIG. 1 shows the first device part 322 and the second device part 316. The axial air bearing region 102 is located between the first device part 322 and the second device part 316. Figure 3.1It can be seen that the axial air bearing region 102 is formed by the first foil bearing assembly 312, the spacing element 306 and the second foil bearing assembly 314. The first foil bearing assembly 314 is positioned on the first spacing element side 302 and the second foil bearing assembly 312 is positioned on the second spacing element side 304. Here, the first foil bearing assembly 312 has at least a spring foil 200.1 and a cover foil 200.2 according to the invention, wherein the cover foil 200.2 comprises at least a clamping geometry 204. Here, Figure 3.1 2 shows a clamping geometry 204 having an angled section 324 and a clamping geometry shape 310.1. Figure 3.1 It can also be seen that the second device part 316 has a recess 202 in the form of a slot 308, wherein the clamping geometry 204 inserted into the slot 308 is shown. Figure 3.1 3. A detailed view of the housing part 320 can be seen in the partial view. The housing part 320 has a housing part guide geometry 318, wherein the housing part guide geometry 318 surrounds the first device part 322, the first foil bearing assembly 312 and partially surrounds the spacer element 306. Alternatively, the housing part guide geometry 318 can have an alternative shape and other surrounding shapes of the components of the configured axial air bearing region 102.

[0049] Figure 3.2 The detailed view in Figure 2 shows an alternative to Figure 3.1 204, wherein the clip-on geometry 204 has an alternative clip-on geometry shape 310.2. Figure 3.2 It can also be seen that the clip-on geometry 204 having the clip-on geometry shape 310 . 2 is introduced into the recess 308 .

[0050] Figure 3.3 The detailed view in FIG. 2 shows the guide geometry 206 inserted into the notch 308. The guide geometry 206 is an integral part of the cover foil 200.2 and serves to position the first foil bearing assembly 312, the spacing element 306 and the second foil bearing assembly 314 stably and efficiently.

[0051] Different from the Figures 3.1 to 3.3 , the notch 308 can have a notch shape different from these notch shapes. For example, the notch 308 can be implemented as a wedge-shaped notch 308, a dovetail notch 308, a conical notch 308, a T-shaped notch 308 or also a circular notch 308. Suitably, the notch 308 is designed in such a way that after being introduced or positioned in the notch 308, the at least one clamping geometry 204 of the cover foil 200.2 achieves a form-locking connection.

[0052] Figure 4 A method 400 is shown for assembling an axial air bearing station 102. The method 400 has the following steps: fastening 402 a first foil bearing assembly 312 on a spring foil 200.1 on a first spacing element side 302 by means of a clip-on geometry 204, thereby performing a pre-assembly; and fastening 404 a second foil bearing assembly 314 on a second spacing element side 304 by means of a clip-on geometry 204.

[0053] In addition, according to Figure 4 The method 400 for assembling the axial air bearing station 102 comprises installing 406 the rotor 106 . Here, suitably, the rotor 106 is installed 406 directly before the second foil bearing assembly 314 is fastened 404 on the second spacing element side 304 by means of the clip-on geometry 204 .

[0054] In an advantageous manner, a positive-locking connection is achieved after fastening 404 of the second foil bearing assembly 314 on the second spacing element side 304 by means of the clip geometry 204 .

[0055] The present invention is not limited to the embodiments described herein and the aspects emphasized therein. Rather, there are many possible variations within the scope provided by the present invention, which are within the scope that can be operated by a person skilled in the art.

Claims

1. An air compressor (100), comprising at least one axial air bearing portion (102), a rotor (106), a spacing element (306), a first equipment part (322) and a second equipment part (316), wherein: An axial air bearing section (102) comprises a first foil bearing assembly (312) and a second foil bearing assembly (314) for constructing an axial air bearing section (102) comprising at least one cover foil (200.2) with one or more clip-on geometries (204) and at least one spring foil (200.1) with one or more cutouts (202).

2. The air compressor (100) according to claim 1, wherein: The cover foil (200.2) is provided with one or more clamping geometries (204), wherein the clamping geometry (204) has at least one section (324) which is embodied in an angled manner.

3. The air compressor (100) according to any one of the preceding claims, wherein: The cover foil (200.2) with one or more clamping geometries (204) has at least one guide geometry (206).

4. The air compressor (100) according to any one of the preceding claims, wherein: The spring foil (200.1) has at least one recess (202) through which the clamping geometry (204) and at least one guide geometry (206) can be guided.

5. The air compressor (100) according to any one of the preceding claims, wherein: The second device portion (316) has a notch (308) for receiving the clip-on geometry (204).

6. The air compressor (100) according to any one of the preceding claims, wherein: The first foil bearing assembly (312) has at least one spring foil (200.1) and at least one cover foil (200.2).

7. The air compressor (100) according to any one of the preceding claims, wherein: The second foil bearing assembly (314) has at least one spring foil (200.1).

8. The air compressor (100) according to any one of the preceding claims, wherein: The air compressor (100) has a housing portion (320) including a housing portion guide geometry (318) such that the housing portion (320) can surround the foil bearing assembly (312, 314) and / or the spacing element (306) are guided.

9. The air compressor (100) according to any one of the preceding claims, wherein: The spring foil (200.1) and / or the cover foil (200.2) comprises a material consisting of a nickel-chromium alloy or spring steel, in particular with a friction-reducing coating.

10. A method (400) for assembling an axial air bearing station (102) according to one of the preceding claims, wherein: The method (400) comprises at least the following steps: i. fastening (402) the first foil bearing assembly (312) to the spring foil (200.1) on the first spacing element side (302) by means of a clip-on geometry (204), thereby enabling pre-assembly, and ii. Fastening (404) the second foil bearing assembly (314) on the second spacing element side (304) by means of a clip-on geometry (204).

11. The method (400) for assembling an axial air bearing station (102) of claim 8, wherein: Step ii. is performed after installing (406) the rotor (106).

12. The method (400) for assembling an axial air bearing station (102) according to claim 9 or 10, wherein: After step ii., the clamping geometry (204) is guided through the recess (308) of the second device part (316) and a positive connection is achieved via the angled section (324).

13. Use of an air compressor (100) according to claims 1 to 9 for rotating a rotor (106) at high speed.

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