Compressor manufacturing method and compressor life prediction method

Abstract

A method for manufacturing a compressor includes preparing a used compressor (step S2). In addition, the manufacturing method of the compressor includes estimating the deterioration state of the sliding part of the used compressor (step S4). The method for manufacturing the compressor further includes manufacturing a new compressor by changing the first refrigerator oil contained in the used compressor of which the deterioration state satisfies a predetermined reference into a new second refrigerator oil (step S8).

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a manufacturing method of a compressor and a life prediction method of a compressor. BACKGROUND

[0002] For example, a refrigeration cycle device using a refrigerant is disclosed in Japanese Patent Application Publication No. 2009-156504 (Patent Literature 1). The refrigeration cycle device is provided with an indoor unit, an outdoor unit, and a refrigerant pipe connecting the indoor unit and the outdoor unit. In Japanese Patent Application Publication No. 2009-156504, a method of reusing an existing refrigerant pipe in a refrigeration cycle device in a case where a refrigerant is changed from a conventional refrigerant to a different refrigerant is disclosed.

[0003] PRIOR ART DOCUMENTS

[0004] PATENT LITERATURE

[0005] Patent Literature 1: Japanese Patent Application Publication No. 2009-156504 SUMMARY

[0006] PROBLEMS TO BE SOLVED BY THE INVENTION

[0007] Generally, a compressor deteriorates as a refrigeration cycle device is used, but it is preferable to reuse a deteriorated compressor from the viewpoint of environmental protection and the like.

[0008] The present disclosure was made to solve the above problem, and aims to reuse a used compressor to manufacture a new compressor and predict the life of the manufactured new compressor.

[0009] MEANS FOR SOLVING THE PROBLEMS

[0010] The manufacturing method of a compressor of the present disclosure includes preparing a used compressor. In addition, the manufacturing method includes estimating a deterioration state of a sliding portion of the used compressor. The manufacturing method further includes manufacturing a new compressor by replacing first refrigerant oil housed in the used compressor, in which the deterioration state satisfies a prescribed reference, with new second refrigerant oil.

[0011] EFFECTS OF THE INVENTION

[0012] According to the present disclosure, it is possible to reuse a used compressor to manufacture a new compressor and predict the life of the manufactured new compressor. BRIEF DESCRIPTION OF DRAWINGS

[0013] Figure 1 is a drawing showing a configuration example of a refrigeration cycle device.

[0014] Figure 2 is a drawing showing a configuration example of a compressor.

[0015] Figure 3 is an example of a flowchart of a manufacturing method.

[0016] Figure 4 is a flowchart showing the process of step S4 of Figure 3

[0017] Figure 5 is a graph for explaining use data.

[0018] Figure 6 is a graph showing an example of a relationship between a good parameter and an added material.

[0019] Figure 7 is a graph showing an example of a relationship between a good parameter and an added material.

[0020] Figure 8 is a flowchart showing a life prediction method of a new compressor.

[0021] Figure 9 is a graph showing an example of related information.

[0022] Figure 10 is a graph showing an example of a relationship between a good parameter and an added material of another embodiment.

[0023] Figure 11 is a graph showing an example of a relationship between a good parameter and an added material of another embodiment.

[0024] Figure 12 is a flowchart of a life prediction method. DETAILED DESCRIPTION

[0025] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Note that, in the drawings, the same or corresponding portions will be denoted by the same reference signs, and a description thereof will not be repeated. Also, it is initially intended that at least a part of the structure in each embodiment be used in combination as appropriate.

[0026] Embodiment 1.

[0027] [Structure Example of Refrigeration Cycle Device]

[0028] In the present disclosure, a manufacturing method of a compressor is disclosed. As an example, the compressor is used for a refrigeration cycle device. Figure 1 is a graph showing a structure example of a refrigeration cycle device 100 of the present embodiment. The refrigeration cycle device 100 is provided with a compressor 200, a condenser 2, an expansion valve 3, and an evaporator 4. The compressor 200 is typically a hermetic type compressor for refrigerant.

[0029] ​The compressor 200 and the condenser 2 are connected by a pipe 5a. The condenser 2 and the expansion valve 3 are connected by a pipe 5b. The expansion valve 3 and the evaporator 4 are connected by a pipe 5c. The evaporator 4 and the compressor 200 are connected by a pipe 5d. The refrigerant circuit 5 is formed by the pipe 5a, the pipe 5b, the pipe 5c, and the pipe 5d. The refrigerant is enclosed in a manner to circulate within the refrigeration cycle device 100 (the refrigerant circuit 5).

[0030] When the refrigerant is sucked into the compressor 200, the compressor 200 compresses the refrigerant. The condenser 2 cools the refrigerant in a gaseous state after being compressed by the compressor 200, and the refrigerant becomes a high-pressure liquid refrigerant or a refrigerant in a gas-liquid two-phase state. The expansion valve 3 decompresses the high-pressure liquid refrigerant or the refrigerant in a gas-liquid two-phase state. The evaporator 4 heats the decompressed refrigerant, and the refrigerant becomes a low-pressure gaseous refrigerant. The compressor 200 sucks the refrigerant in a low-pressure gaseous state and compresses it again. In this way, the refrigerant circulates within the refrigeration cycle device 100.

[0031] The blower 6 blows air to the condenser 2. By the blowing of the blower 6, heat exchange between the refrigerant flowing in the condenser 2 and air is promoted, and heat is absorbed or released. In addition, the blower 7 blows air to the evaporator 4. By the blowing of the blower 7, heat exchange between the refrigerant flowing in the evaporator 4 and air is promoted, and heat is absorbed or released.

[0032] Note that the refrigeration cycle device 100 can be any one of a device capable of performing both refrigeration and heating, a device capable of performing refrigeration without heating, and a device capable of performing heating without refrigeration.

[0033] [Structure Example of Compressor]

[0034] Figure 2 is a diagram showing a structure example of the compressor 200. Figure 2 is an example of a rotary compressor. As shown in Figure 2 , the compressor 200 includes a housing 8, a compression mechanism 9, a suction pipe 10, a discharge pipe 11, a shaft 12, an oil reservoir 13, an oil supply hole 14, a bearing 16, a rotor 17, and a stator 18.

[0035] The compression mechanism 9 is disposed inside the housing 8. The suction pipe 10 and the discharge pipe 11 are connected to the compression mechanism 9. The suction pipe 10 is a pipe for flowing the refrigerant into the inside of the compressor 200. The discharge pipe 11 is a pipe for discharging the refrigerant to the outside of the compressor 200. The compression mechanism 9 compresses the refrigerant that has entered the housing 8 from the suction pipe 10 and discharges it from the discharge pipe 11.

[0036] The compressor 200 has a motor portion. The motor portion includes the shaft 12, the rotor 17, and the stator 18. The compressor 200 is driven by the motor portion.

[0037] The compressor 200 has at least one sliding portion. The sliding portion is a portion where a part of the compressor 200 contacts with another part. Typically, one part is metal, and the other part is metal or organic material. The sliding portion is, for example, a contact portion of the shaft and the bearing (a contact portion of the shaft 12 and the bearing 16), a contact portion of the vane and the piston, a portion of the tip of the orbiting scroll, and the like. The compressor 200 can include a plurality of sliding portions. In Figure 2 In the present embodiment, as an example of the sliding portion 30, the contact portion of the shaft 12 and the bearing 16 is shown.

[0038] The oil reservoir portion 13 stores refrigerant oil. The refrigerant oil is supplied to the sliding portion inside the compression mechanism 9 by the pump (not shown) through the oil supply hole 14. Since the refrigerant oil is in contact with the refrigerant in the compressor 200, a part of the refrigerant is dissolved in the refrigerant oil. The refrigerant oil is, for example, polyvinyl ether-based refrigerant oil.

[0039] [Reuse of Compressor]

[0040] Generally, due to the high reliability of the refrigeration cycle device 100 (for example, an air conditioner), even after the durable years (for example, the statutory durable years) of the compressor 200, the compressor 200 is mostly in a reusable state. In addition, even after the durable years of the refrigeration cycle device 100, the occurrence of sludge is rare. On the other hand, depending on the usage state of the refrigeration cycle device 100 by the user or the like, the wear of the sliding portion or the like is large, and there is a case where the compressor fails or is about to fail.

[0041] When such a refrigeration cycle device 100 is recycled, even if the compressor 200 is normally operated, the compressor 200 sometimes fails due to further use before reaching the statutory life. Such a compressor that fails before reaching the statutory life is also referred to as a "defective compressor". From the viewpoint of environmental protection or the like, such a defective compressor can extract a metal portion or the like and reuse the metal portion.

[0042] On the other hand, there is a compressor that can be used before reaching the statutory life by reusing. In the past, such a compressor was extracted a metal portion or the like as with the defective compressor, and the metal portion was reused. However, such a compressor is preferably reused to become a state where it can be used again as a new compressor.

[0043] The inventors found that, in determining whether the compressor can be reused, it is preferable to determine the state of the sliding portion. Furthermore, the inventors disassembled and observed the sliding portion of a compressor recovered from the market. Through this observation, the inventors found various sliding portions, including a sliding portion having no damage, i.e., a sliding portion to be sintered, and the like, in the compressor.

[0044] Thus, for example, if the operator disassembles the compressor and confirms the state of the sliding portion by visual inspection or the like, it is possible to determine whether the compressor can be reused. However, in the case where the compressor is disassembled in order to determine whether the compressor can be reused, the disassembly and the process of inspection of the compressor or the like are increased. Therefore, in the case where the compressor is disassembled to manufacture a new compressor, the cost can be larger compared to the case where the compressor is manufactured from new parts. Therefore, in order to determine whether the compressor can be reused, it is preferable that the state of the sliding portion can be evaluated definitely without disassembling the compressor. The manufacturing method of the compressor of the present embodiment is a method of manufacturing a new compressor using a used compressor without disassembling the used compressor.

[0045] [Manufacturing method of compressor]

[0046] Figure 3 is an example of a flowchart of the manufacturing method of the present embodiment of manufacturing a new compressor. Figure 3 and the entire processes of the flowcharts of Figure 4 , Figure 8 , Figure 12 may be performed by the operator. That is, the entire processes of the flowcharts can also be performed by the operator. In addition, part of the processes of the flowcharts can also be performed by the operator, and the remaining processes can also be performed by the manufacturing device (robot or the like). In addition, the entire processes of the flowcharts can also be performed by the manufacturing device. Hereinafter, an example in which the entire processes are performed mainly by the operator will be described.

[0047] First, in step S2, a used compressor 200 is prepared. Next, in step S4, the deterioration state of the sliding portion of the compressor 200 is estimated. The deterioration state of the sliding portion is typically the "wear state" of the sliding portion.

[0048] Next, in step S6, it is determined whether the estimated deterioration state satisfies a prescribed criterion. In step S6, in the case where it is determined that the deterioration state satisfies the prescribed criterion (YES in step S6), in step S8, it is determined that the used compressor 200 can be reused.

[0049] Hereinafter, the refrigerant oil accommodated in the used compressor 200 is also referred to as "first refrigerant oil". In step S8, the first refrigerant oil accommodated in the used compressor 200 is discarded. After the first refrigerant oil of the used compressor 200 is discarded, a new refrigerant oil is accommodated in the oil storage portion 13 (refer to Figure 2 ). Thus, a new compressor 200 is manufactured. The new refrigerant oil is also referred to as "second refrigerant oil". In the second refrigerant oil, a prescribed additive (antioxidant, etc.) is mixed in advance.

[0050] On the other hand, in step S6, in a case where it is judged that the deterioration state does not satisfy the prescribed criterion (NO in step S6), it is judged that the used compressor 200 is not reusable. Note that the metal portion of the used compressor 200 judged to be not reusable can be reused.

[0051] Figure 4 is a flowchart of details of the process of step S4 (estimation of deterioration state) of Figure 3 . In step S22, a good parameter is calculated. The good parameter is a parameter indicating the goodness of the sliding portion of the compressor 200. In the present embodiment, the larger the good parameter, the better the sliding portion of the compressor 200 is indicated to be. The calculation method of the good parameter will be described later.

[0052] Next, it is judged whether or not the good parameter calculated in step S24 belongs to a normal range (prescribed range). The normal range is a range decided in advance, and the method of deciding the normal range will be described later. In a case where the good parameter belongs to the normal range (YES in step S24), in step S26, it is judged that the deterioration state of the sliding portion satisfies the prescribed criterion. Then, the flowchart of Figure 3 is returned to, and YES is judged in step S6 of Figure 3 . On the other hand, in a case where the good parameter does not belong to the normal range (NO in step S24), in step S26, it is judged that the deterioration state of the sliding portion does not satisfy the prescribed criterion. Then, the flowchart of Figure 3 is returned to, and NO is judged in step S6 of Figure 3 .

[0053] [Good Parameter]

[0054] Next, usage data used in the calculation of the good parameter described later is explained. Figure 5 is a graph for explaining the usage data. As Figure 5As shown in the example of FIG. 6, the use data can include a first data group, a second data group, a third data group, and a fourth data group. The first data group and the second data group together correspond to "refrigerant oil data" of the present disclosure. The "refrigerant oil data" is data related to the first refrigerant oil. The first data group corresponds to "first data" of the present disclosure. The second data group corresponds to "second data" of the present disclosure. The third data group corresponds to "compressor data" of the present disclosure.

[0055] The first data group is data related to the goodness of the sliding portion. In other words, the first data group is data indicating the goodness of the sliding portion. As shown in FIG. 6, the first data group includes at least one of the amount of the first refrigerant oil and the amount of an additive of the first refrigerant oil. The additive is a substance added to the first refrigerant oil. The additive is, for example, an anti-wear agent. The anti-wear agent is, for example, tricresyl phosphate. In addition, as the first refrigerant oil, a polyvinyl ether-based refrigerant oil to which tricresyl phosphate is added as an anti-wear agent is used. Figure 5

[0056] The inventor found that the more the amount of the first refrigerant oil and the amount of the additive, the more the sliding portion tends to be good. Therefore, as the first data group, the amount of the first refrigerant oil and the amount of the additive of the first refrigerant oil are adopted.

[0057] As a method of obtaining the amount of the first refrigerant oil, for example, the operator cuts off the pipe (e.g., the suction pipe 10 and the discharge pipe 11 of the compressor 200) and recovers the first refrigerant oil from the cut-off portion. Then, the operator measures the amount of the recovered first refrigerant oil. Figure 2

[0058] In addition, as a method of obtaining the amount of the first refrigerant oil, a sensor can also be used. As the sensor, for example, an ultrasonic sensor is used. As a first method using the ultrasonic sensor, the ultrasonic sensor measures the time until an ultrasonic wave, which is incident from the bottom surface of the used compressor 200 and is reflected at the liquid surface, is received by the ultrasonic sensor. Then, the ultrasonic sensor calculates the distance based on the time. The distance is a value corresponding to the liquid level height of the housed first refrigerant oil. Based on the distance, the amount of the first refrigerant oil is obtained. The first method is disclosed in Japanese Patent No. 4123764.

[0059] In addition, as a second method using the ultrasonic sensor, the side surface of the compressor is palpated with the ultrasonic sensor, and the height of the first refrigerant oil is obtained from the signal shape. Specifically, in the second method, an ultrasonic wave is incident in the horizontal direction from the ultrasonic sensor to the side surface of the used compressor 200. Then, based on the difference in propagation characteristics of the gas refrigerant and the liquid refrigerant in which the first refrigerant oil is dissolved, and the like, the liquid level height of the first refrigerant oil is obtained. The second method is disclosed, for example, in Japanese Patent No. 6808039. ​​

[0060] As a method using an electrostatic capacity sensor, an electrostatic capacity sensor is provided to the side surface of the used compressor 200. In general, the dielectric constant of a gas refrigerant gas is different from the dielectric constant of the refrigerant oil (including also a state in which refrigerant is dissolved). Based on the difference in the dielectric constant, the liquid level height of the first refrigerant oil is obtained. The method using an electrostatic capacity sensor is disclosed, for example, in Japanese Patent Application Publication No. 2021-56134.

[0061] As a method using a spectrometer, the absorbance of at least one of the first refrigerant oil discharged from the used compressor 200 and the first refrigerant oil sucked into the used compressor 200 is measured by a spectrometer. Then, based on an absorbance characteristic representing the relationship between a predetermined absorbance and the amount of the first refrigerant oil and the measured absorbance, the amount of the first refrigerant oil is measured. The method using a spectrometer is disclosed, for example, in Japanese Patent Application Publication No. Sho 62-043523.

[0062] As for the amount of the additive included in the first data group (refer to Figure 5 ), for example, an analysis device is used. The analysis device includes a gas chromatograph or a liquid chromatograph.

[0063] The second data group is data related to the deterioration of the sliding portion. In other words, the second data group is data indicating the deterioration property of the sliding portion. Note that the second data group can also be referred to as a data group related to the deterioration of the refrigerant oil. As shown in Figure 5 , the second data group includes at least one of the total acid number of the first refrigerant oil and the hue value of the first refrigerant oil.

[0064] The total acid number of the first refrigerant oil is measured, for example, in accordance with "JIS K2501". The total acid number is measured, for example, by an indicator titration method or a potentiometric titration method, or the like.

[0065] The hue value of the first refrigerant oil is measured, for example, by a hue sensor (absorptiometer or the like). More specifically, the absorbance of at least one of the primary colors (RGB) of the first refrigerant oil is measured as the hue value. Note that at least one of the viscosity and the moisture concentration of the first refrigerant oil can also be included in the second data group.

[0066] The third data group is data related to the deterioration of the used compressor 200. In other words, the third data group is data indicating the deterioration property of the used compressor 200. As shown in Figure 5 , the third data group includes at least one of the noise of the used compressor 200 being driven, the amount of vibration of the used compressor 200 being driven, and the amount of foreign matter mixed in the first refrigerant oil.

[0067] As for the acquisition of the noise of the used compressor 200, for example, the used compressor 200 is driven before the piping is cut off, and in this driving, the acquisition is made by the measurement of the noise meter. As for the acquisition of the amount of vibration of the used compressor 200, for example, the used compressor 200 is driven, and in this driving, the acquisition is made by the measurement of the vibration sensor. In addition, the input current of the used compressor 200 can also be included in the third data group. The measurement method of the vibration or the input current of the used compressor 200 is disclosed in, for example, WO2019 / 239549.

[0068] The fourth data group is data about which it is unclear whether or not it is related to the degree of deterioration of the sliding portion. The fourth data group includes at least one of the residual amount of the antioxidant and the moisture amount. The antioxidant is added to the refrigerant oil. The moisture amount is the moisture amount of the refrigerant oil. In addition, the fourth data group can also include the viscosity or the like of the first refrigerant oil.

[0069] [Method of determining good parameter]

[0070] Next, the method of determining the calculation method of the good parameter will be described in stages. First, in the first stage, for example, the operator classifies the data that can be acquired. The classification example is shown in, for example, FIG. 6. Figure 5

[0071] Next, as the second stage, the operator selects at least one data from the first to fourth data groups. For example, the operator selects the data from the data group of at least one of the first data group and the second data group. In addition, for the data group from which the data is not selected, the data selected from the data group can also be an arbitrary fixed value.

[0072] Next, as the third stage, the operator calculates the product or the sum of the amounts represented by the data selected from the first data group as the first value. Likewise, the operator calculates the product or the sum of the amounts represented by the data selected from the second data group, the third data group, and the fourth data group as the second value.

[0073] Next, as the fourth stage, the operator calculates the parameter by dividing the first value by the second value. Next, as the fifth stage, the operator compares the calculated parameter with the state of the sliding portion and considers whether or not the correlation between the parameter and the amount of wear (wear state) of the sliding portion can be obtained. As a result thereof, in the case where the desired correlation is not obtained, the parameter is discarded, and in the case where the desired correlation is obtained, the calculation method (calculation formula) of the parameter is determined as the calculation method of the good parameter.

[0074] [Calculation formula of good parameter]

[0075] Next, the calculation formula of the good parameter will be described. Figure 4 ​A specific example of the calculation formula of the good parameter of step S22 will be described. Here, as data for calculating the good parameter, the first refrigerant oil amount V of the (selected) first data group, the additive amount A of the additive of the refrigerant oil of the first data group, the total acid number C of the first refrigerant oil of the second data group, and the hue value D of the first refrigerant oil of the second data group are used. Note that the additive of the refrigerant oil of the first data group is a phosphorus-based anti-wear agent, and more specifically, a tritolyl phosphate. In addition, the hue value D of the first refrigerant oil is a blue absorbance.

[0076] Next, with respect to the good parameter W, calculation is performed by the following formula (1).

[0077] W = (V x A) / (C x D) (1)

[0078] The numerator on the right side of formula (1) is a "product value of the first refrigerant oil amount V and the amount A of the phosphorus-based anti-wear agent (first product value)". In addition, the denominator on the right side of formula (1) is a "product value of the total acid number C of the first refrigerant oil and the blue absorbance D of the first refrigerant oil (second product value)". Furthermore, in the example of formula (1), the good parameter W is calculated by dividing the first product value by the second product value.

[0079] The value of the numerator of formula (1) is a product value of data values belonging to the first data group related to the good property of the sliding portion. Therefore, the value of the numerator is a value that has a good influence on the sliding portion. The value of the denominator of formula (1) is a product value of data values belonging to the second data group related to the deterioration property of the sliding portion. Therefore, the value of the denominator is a value that has a bad influence on the sliding portion. Therefore, it is clear that the greater the good parameter W, the better the sliding portion.

[0080] Note that the calculation of the good parameter W using formula (1) can be performed, for example, by mental calculation by an operator, or using an information processing device (PC: Personal Computer).

[0081] Next, a modification example of the calculation formula of the life parameter will be described. For example, it can be set that the good parameter W = A. In addition, it can be set that the good parameter W = V x A. In addition, it can be set that the good parameter W = A / C.

[0082] In addition, in the example of formula (1), the value related to the good property of the sliding portion is the numerator, and the value related to the deterioration of the first refrigerant oil is the denominator. However, the numerator and the denominator of formula (1) can be reversed. The smaller the parameter calculated by such a formula, the more it becomes a parameter indicating the good property of the sliding portion. Above, with respect to the calculation formula of the parameter and the normal range, design is appropriately performed based on the analysis result of the recovered compressor.

[0083] [Setting of Normal Range]

[0084] Next, the setting method of the normal range will be described. First, a plurality of used compressors 200 are prepared. The used compressors 200 can be recovered from the market. Alternatively, the used compressors 200 can be manufactured under certain market acceleration conditions simulated for new compressors.

[0085] The operator calculates the value of the use data (here, the additive amount A) and the above-mentioned good parameter W for each of the prepared plurality of used compressors 200. Then, the operator disassembles the used compressors 200 and observes the condition of the sliding portion. The observation of the sliding portion can be performed only by the operator's visual observation. In the case where the observation of the sliding portion is only the operator's visual observation, an empirical relative evaluation such as an additional multi-stage (for example, 3 stages) evaluation is performed for each of the observed plurality of used compressors. Alternatively, at least one of the wear amount of the sliding portion and the surface roughness of the sliding portion can be obtained through the observation of the sliding portion. By obtaining the correlation between the condition of the sliding portion obtained through the operator's observation and the good parameter W, the operator can predict the condition of the sliding portion from the good parameter W based on the correlation.

[0086] Figure 6 is a graph for explaining the correlation. In addition, Figure 6 is also a graph for setting the normal range. In Figure 6 , an example of the relationship between the amount A of the phosphorus-based anti-wear agent (additive amount A) and the good parameter W is shown. In Figure 6 , the vertical axis represents A and the horizontal axis represents W. Note that the amount A of the phosphorus-based anti-wear agent is a relative value of the amount of the phosphorus-based anti-wear agent mixed in the new refrigerant oil being "1". That is, the amount A of the phosphorus-based anti-wear agent is a value of 0 or more and 1 or less.

[0087] Figure 6 The white circle of indicates normal wear of the sliding portion. The normal wear is wear that is judged to be a degree that can be used when the second refrigerant oil (new refrigerant oil) is enclosed in the compressor. The can be used, for example, means that the compressor can be used to a degree that can reach a product life that is acceptable in the market.

[0088] Figure 6 The black circle of indicates abnormal wear of the sliding portion. The abnormal wear is wear that is judged to be a degree that cannot be used even when the second refrigerant oil is enclosed in the compressor. The cannot be used, for example, means that the compressor cannot be used to a degree that can reach a product life that is acceptable in the market.

[0089] Further, the determination of normal wear and abnormal wear is made by the observation of the sliding portion described above. Further, the compressor including the sliding portion of normal wear is also referred to as "normal compressor", and the compressor including the sliding portion of abnormal wear is also referred to as "abnormal compressor". Note that the definitions of the white circle and the black circle are the same as those described later in Figure 10 and Figure 11 .

[0090] In Figure 6 , there is a compressor indicated by the black circle (refer to the point S1 of Figure 6 , although the good parameter W is large. This compressor has a high possibility of becoming a failure mode due to the mixing-in of foreign matter (the biting-in of foreign matter). The foreign matter is, for example, a cutting chip or the like generated at the time of cutting of the piping in the case where the refrigeration cycle device 100 is installed.

[0091] In this failure mode, the refrigeration oil is not deteriorated. Therefore, although the good parameter W is large, it becomes abnormal wear. As a reason for this abnormal wear, there is a compressor that is hardly used, in which the good parameter W is large although the sliding portion is hardly deteriorated, but in which foreign matter is mixed in. Note that this foreign matter can be discharged to the outside by the use of the compressor.

[0092] As shown in Figure 6 , in the case where the sliding portion of abnormal wear is included in the compressor in which the good parameter W is extremely small and the compressor in which the good parameter W is extremely large, the state of the sliding portion can also be determined based on the average value and the standard deviation of the good parameter W of the normal compressor.

[0093] Figure 6 The solid line L1 indicates the average value Wa of the good parameter W of the normal compressor. The broken line L2 indicates a value Wb obtained by adding the standard deviation to the average value Wa. The broken line L3 indicates a value Wc obtained by subtracting the standard deviation from the average value Wa. In other words, the broken lines L2, L3 are upper and lower boundary lines in the case where n = 1 in "average value Wa ± nσ". Note that σ indicates the standard deviation. Further, the range with Wb as the lower limit value and Wc as the upper limit value corresponds to the "normal range" of step S24 of Figure 4 .

[0094] Further, as to the value of n, for example, the operator can make Figure 6 n so as to set n in such a manner that the abnormal compressor is not included in the normal range. Note that in the example of Figure 6 , n = 1 is appropriate. If n is larger than 1, there is a case where the abnormal compressor is determined to be the normal compressor. Further, if n is smaller than 1, there is a case where the normal compressor is determined to be the abnormal compressor.

[0095] Thus, by defining the normal range of the good parameter W, the operator can clearly distinguish between the normal compressor and the abnormal compressor. In other words, the operator can judge whether the sliding state is normal or abnormal based on Figure 6 the analysis of the first refrigerant oil and the calculation of the good parameter W. Also, the operator can judge whether the second refrigerant oil can achieve a market-allowable life if enclosed in the used compressor 200. In addition, when the biting-in of foreign matter has occurred in the used compressor 200, there is a case where the sliding portion is abnormal even if the good parameter W is large. In order to judge the used compressor 200 having such a sliding portion as an abnormal compressor, it is preferable to set an upper limit value Wb to the good parameter W. By thus setting the upper limit value, the operator can judge, for example, the compressor into which the foreign matter has been mixed as an abnormal compressor. Note that, as for the normal range, it can also be determined by the operator's visual observation, etc. without using the average and the standard deviation. Thus, in the example of Figure 6 , the range (the range between the broken line L3 and the broken line L2) including the normal compressor of the white circle but not including the abnormal compressor of the black circle is set as the normal range.

[0096] As described above, as for the calculation formula of the good parameter W, it can also be set as good parameter W = A, but the following describes an inappropriate example where it is set as good parameter W = A. Figure 7 is a graph for explaining such an example. In the example of Figure 7 , the vertical axis represents the phosphorus-based anti-wear agent amount A, and the horizontal axis represents the good parameter W. Note that the good parameter W is calculated by formula (1).

[0097] In the example of Figure 7 , as shown by the white circle, the phosphorus-based anti-wear agent amount A of the normal compressor is distributed in the range of about 0.4 to 1.0. In addition, the phosphorus-based anti-wear agent amount A of the abnormal compressor is widely distributed to 0 to 1.0.

[0098] In the example of Figure 7 , if the phosphorus-based anti-wear agent amount A is 0.4 or less, the used compressor 200 can be judged as an abnormal compressor. However, even if the phosphorus-based anti-wear agent amount A is 0.4 to 1.0, since the abnormal compressor is included in the range of 0.4 to 1.0, the used compressor 200 cannot be judged as a normal compressor.

[0099] That is, in this Figure 7 example, the operator cannot judge whether the used compressor 200 is a normal compressor or an abnormal compressor based on the good parameter set as good parameter W = A. Therefore, the operator cannot judge whether the used compressor 200 is reusable. Therefore, in the example of Figure 7In the case where the good parameter W=A is set, it is not appropriate. Note that in the following Figure 11 the case where the good parameter W=A is set is appropriate.

[0100] What kind of data value is appropriate as a data value used in the calculation of the good parameter depends on the category of the used compressor 200. The category of the used compressor 200 is defined by the kind of the used compressor 200, the kind of the first refrigerant oil contained in the used compressor 200, the use purpose of the device having the used compressor 200, and the like.

[0101] The kind of the used compressor 200 includes, for example, scroll compressors, rotary compressors, and screw compressors. The kind of the first refrigerant oil includes polyol ester oil, polyvinyl ether oil, polyalkylene glycol oil, and mineral oil. The use purpose of the device having the used compressor 200 includes commercial use, home use, air conditioning use, and refrigeration use.

[0102] For example, it is preferable that the operator prepares the correlation chart and the like of the above-mentioned each category in advance, and determines the data value and the normal range used for the calculation of the good parameter W. Figure 6 Figure 7

[0103] [Life prediction of new compressor]

[0104] Next, a method of life prediction of a new compressor manufactured by the method of Figure 3 will be described. Figure 8 is a flowchart showing the method of life prediction of a new compressor. First, in step S32, a good parameter is prepared. The good parameter is a parameter calculated by the formula (1) or the like at the time of the state of the used compressor 200 before the new compressor which is the object of life prediction.

[0105] Next, in step S34, the life of the new compressor is predicted on the basis of the correlation information prepared in advance and the calculated good parameter.

[0106] Figure 9 is a chart showing an example of the correlation information. In the example of Figure 9 , the horizontal axis shows the good parameter W, and the vertical axis shows a quantity having a correlation with the life. Note that as a modification, the vertical axis can not be the quantity having a correlation with the life, but the value of the life itself. In the example of Figure 9 , a positive correlation is shown.

[0107] When the good parameter W is calculated in step S34, the operator refers to Figure 9 ​​The relevant information is used to determine the quantity that is correlated with the lifespan corresponding to the optimal parameter W. Then, the operator determines the lifespan based on the quantity that is correlated with this lifespan.

[0108] It should be noted that the processing in step S34 can also be performed manually by the operator. Alternatively, the processing in step S34 can also be performed by the operator inputting a favorable parameter W into the information processing device, which then outputs (predicts) the lifespan by executing a predetermined calculation. This predetermined calculation could be, for example, using AI (Artificial Intelligence) computation.

[0109] Next, the explanation Figure 9 This is an example of a method for producing relevant information. The operator assembles a compressor with calculated optimal parameters W. Then, the operator confirms the lifespan of multiple compressors, each with different conditions of the sliding parts, through accelerated testing, etc. The accelerated testing time is preferably converted into market usage time. It should be noted that, since the intention is to use a new compressor, new refrigeration oil is sealed in during compressor assembly.

[0110] Then, the operator plots the calculated optimal parameter W against the corresponding compressor lifespan. Based on this plot, a... Figure 9 Related information.

[0111] Additionally, the required lifespan of the new compressor is set as a lifespan threshold. Then, the operator can manufacture a new compressor with a lifespan longer than the lifespan threshold from a used compressor 200 that has obtained good parameters that are greater than the good parameters corresponding to the lifespan threshold.

[0112] [Summary of this implementation method]

[0113] In this embodiment, such as Figure 3 As shown, the operator estimates the deterioration state of the sliding part (step S4). Next, the operator determines whether the deterioration state meets the prescribed criteria (step S6). Then, for a used compressor 200 whose deterioration state meets the prescribed criteria, a new compressor is manufactured by replacing the first refrigeration oil contained in the used compressor 200 with new second refrigeration oil. Therefore, through the manufacturing method of this embodiment, the operator can reuse a used compressor to manufacture a new compressor at low cost.

[0114] In addition, the estimation of the deterioration state (step S4) includes refrigeration oil data related to the first refrigeration oil ( Figure 5 The first and second data sets were used to calculate good parameters. Figure 4the deterioration state is estimated (step S4) includes estimating the deterioration state based on the good parameter (step S24). Therefore, the operator can estimate the deterioration state of the sliding portion from the viewpoint of the first refrigerant oil. In addition, for example, even if the used compressor 200 is a compressor for a sealed refrigerant, the operator can estimate the deterioration state of the sliding portion without opening and closing the sealed container.

[0115] In addition, the refrigerant oil data includes a first data group related to the goodness of the sliding portion and a second data group related to the deterioration of the first refrigerant oil. Therefore, the operator can estimate the deterioration state of the sliding portion from the viewpoint of the goodness of the sliding portion and the deterioration of the first refrigerant oil.

[0116] In addition, the first data includes at least one of the amount of the first refrigerant oil and the amount of an additive of the first refrigerant oil. Therefore, the operator can estimate the deterioration state of the sliding portion from the viewpoint of at least one of the amount of the first refrigerant oil and the amount of the additive of the first refrigerant oil.

[0117] In addition, the second data includes at least one of the total acid number of the first refrigerant oil and the hue value of the first refrigerant oil. Therefore, the operator can estimate the deterioration state of the sliding portion from the viewpoint of at least one of the total acid number of the first refrigerant oil and the hue value of the first refrigerant oil.

[0118] In addition, estimating the deterioration state can include estimating the deterioration state based on the refrigerant oil data and compressor data related to the deterioration of the used compressor. Therefore, the operator can estimate the deterioration state of the sliding portion from the viewpoint of the deterioration of the used compressor 200.

[0119] In addition, as shown in Figure 5 the compressor data includes at least one of the noise of the driven used compressor, the vibration amount of the driven used compressor, and the amount of foreign matter mixed in the first refrigerant oil. Therefore, the operator can estimate the deterioration state of the sliding portion from the viewpoint of at least one of the noise of the driven used compressor, the vibration amount of the driven used compressor, and the amount of foreign matter mixed in the first refrigerant oil.

[0120] In addition, the good parameter is calculated by, for example, the above-described equation (1). Therefore, the operator can estimate the deterioration state of the sliding portion by a simple operation of comparison.

[0121] In addition, the life estimation method according to the present embodiment, as shown in Figure 8As shown, the life of the new compressor can be predicted based on the good parameter calculated in step S22. In other words, the operator can predict the life of the new compressor using the good parameter calculated in step S22. Therefore, the operator can predict the life of the new compressor without disassembling the new compressor or the like.

[0122] Embodiment 2

[0123] In Embodiment 1, as the anti-wear agent, an example in which tricresyl phosphate is mainly used as the anti-wear agent is described. In Embodiment 2, an example in which triphenyl phosphate is used as the anti-wear agent is described. Note that, in Embodiment 2, the used compressor is a scroll type hermetic compressor, which is recovered after an acceleration test is performed under various conditions.

[0124] The calculation formula of the good parameter W of Embodiment 2 is the following formula (2).

[0125] W = (V x A) / C (2)

[0126] Figure 10 is a graph for explaining the determination method of the normal range of Embodiment 2. In Figure 10 is a graph showing the relationship between the anti-wear agent amount (additive amount A) of tricresyl phosphate and the good parameter W calculated by formula (2). Figure 10 The vertical axis of indicates the additive amount A, and the horizontal axis indicates the good parameter W. By Figure 10 The broken line L4 of indicates the value Wd. The value Wd is a value obtained by adding n (n = 3 here) times the standard deviation of the good parameter W to the average value of the good parameter W of the abnormal compressors. As Figure 10 indicated, in a case where the abnormal compressors are concentrated in a range where the good parameter W is small, the operator can not set the upper limit value and not set the lower limit value as the normal range.

[0127] Note that the above n = 3 is a value set in order to separate the abnormal compressors and the normal compressors, and is a value adjusted according to the separation state of the two. Also, in a case where the purpose is to determine the normal compressors, it is preferable to set the normal range so that the abnormal compressors are not mixed into the normal compressors, and even if the normal compressors are mixed into the abnormal compressors, there is no particular problem. In addition, the good parameter W can be used for the judgment of the abnormal compressors.

[0128] As described above, as in Embodiment 2, the normal range can be defined by only the lower limit threshold value without being defined by the upper limit threshold value. Note that, although not particularly illustrated, the normal range can be defined by only the upper limit threshold value without being defined by the lower limit threshold value.

[0129] Embodiment 3

[0130] Figure 11 is a graph showing another example of the relationship between the additive amount A and the good parameter W. In the case where the result of the analysis is Figure 11 In that case, for example, the good parameter W=A can be set. Also, the normal range (lower threshold value) of the good parameter W (additive amount A) is set to the value We shown by the straight line L5. In this way, the good parameter W can also be Figure 5 one data (if this embodiment, the additive amount A of the first data).

[0131] Embodiment 4.

[0132] If the good parameter described in Figure 3 and Figure 4 is used, the operator can determine the state of the sliding portion of the compressor without disassembling the compressor. Therefore, the operator can determine the state of the sliding portion of the compressor 200 by using the good parameter of the compressor 200 connected to the refrigeration cycle device 100 of Figure 1

[0133] Therefore, in this embodiment, the life prediction of the compressor 200 connected to the refrigeration cycle device 100 is described. Figure 12 is an example of a flowchart of the life prediction method of this embodiment.

[0134] In step S42, the compressor 200 that is the object of the life prediction is prepared. Note that in the case where the compressor 200 is connected to the refrigeration cycle device 100, the refrigeration cycle device 100 is prepared.

[0135] Next, in step S44, the good parameter of the compressor is calculated. The calculation formula uses, for example, formula (1) or the like. Note that as a modification, another formula can be used. Then, in step S46, the life of the compressor 200 is predicted based on the good parameter and the relevant information prepared in advance.

[0136] Next, an example of the method of obtaining the data used in the calculation of the good parameter W is described. For example, the operator extracts a small amount of the first refrigerant oil of the compressor 200 from the valve or the like that extracts the first refrigerant oil. Then, the operator obtains the use data by the above-described method. Note that the amount of the extracted first refrigerant oil is preferably an amount that does not affect the operation of the refrigeration cycle device 100.

[0137] In addition, the relevant information used in step S46 uses, for example, the relevant information shown in Figure 9 . In this way, the relevant information is information indicating the correspondence between the good parameter W and the life.

[0138] ​That is, the life prediction method disclosed in Embodiment 4 is expressed as follows. The life prediction method includes: preparing a compressor (a compressor of which life is to be predicted); calculating a parameter (a good parameter) based on refrigerant oil data related to first refrigerant oil of the compressor; and predicting life of the compressor based on the parameter.

[0139] In particular, with respect to the calculation of the good parameter, the above-described formula (1) or the like is used. In addition, with respect to the calculation of the good parameter, in order to improve the life prediction accuracy, it is also possible to use not only the first refrigerant oil amount of the first data set but also other data. The other data is, for example, at least one of an additive amount of the first refrigerant oil, a total acid number of the first refrigerant oil, and a color phase value of the first refrigerant oil. According to the life prediction method of the present embodiment, for example, even if the compressor 200 of which life is to be predicted is not separated from the refrigeration cycle device 100, it is possible to predict the life of the compressor 200.

[0140] The embodiments disclosed this time are to be considered as illustrative and not restrictive in all aspects. The scope of the disclosure is not shown by the above description but by the claims, and is intended to include all modifications equivalent in meaning and scope to the claims.

[0141] Explanation of Reference Signs

[0142] 2 condenser, 3 expansion valve, 4 evaporator, 5 refrigerant circuit, 5a, 5b, 5c, 5d pipe, 6, 7 blower, 8 housing, 9 compressor mechanism, 10 suction pipe, 11 discharge pipe, 12 shaft, 13 oil storage portion, 14 oil supply hole, 16 bearing, 17 rotor, 18 stator, 30 sliding portion, 100 refrigeration cycle device, 200 compressor.

Claims

1. A manufacturing method of a compressor, wherein, A manufacturing method of the compressor includes: preparing a used compressor; estimating a deterioration state of a sliding portion of the used compressor; and manufacturing a new compressor by replacing a first refrigerant oil housed in the used compressor, in which the deterioration state satisfies a prescribed criterion, with a new second refrigerant oil.

2. The manufacturing method of the compressor according to claim 1, wherein the estimating of the deterioration state includes: calculating a parameter based on refrigerant oil data related to the first refrigerant oil; and estimating the deterioration state based on the parameter.

3. The manufacturing method of the compressor according to claim 2, wherein the refrigerant oil data includes estimating the deterioration state based on at least one of first data related to a soundness of the sliding portion and second data related to a deterioration of the first refrigerant oil.

4. The manufacturing method of the compressor according to claim 3, wherein the first data includes at least one of an amount of the first refrigerant oil and an amount of an additive of the first refrigerant oil.

5. The manufacturing method of the compressor according to claim 3 or 4, wherein the second data includes at least one of a total acid number of the first refrigerant oil and a color phase value of the first refrigerant oil.

6. The manufacturing method of the compressor according to any one of claims 2 to 5, wherein the estimating of the deterioration state includes estimating the deterioration state based on the refrigerant oil data and compressor data related to a deterioration of the used compressor.

7. The manufacturing method of the compressor according to claim 6, wherein the compressor data includes at least one of a noise of the used compressor driven, an amount of vibration of the used compressor driven, and an amount of foreign matter mixed in the first refrigerant oil.

8. The manufacturing method of the compressor according to claim 2, wherein the refrigerant oil data is an amount of the first refrigerant oil, an amount of a phosphorus-based anti-wear agent mixed in the first refrigerant oil, a total acid number of the first refrigerant oil, and a blue light absorbance of the first refrigerant oil, the parameter is calculated by dividing a product value of the amount of the first refrigerant oil and the amount of the phosphorus-based anti-wear agent by a product value of the total acid number and the blue light absorbance.

9. A method of life prediction of a compressor, wherein, A life prediction method of the compressor includes: based on the parameter, predicting a life of the new compressor manufactured by the manufacturing method of the compressor according to any one of claims 2 to 8.

Images