An integrated compressor core assembly method

Abstract

The application relates to the field of integrated compressors, in particular to an integrated compressor core component assembling method, which comprises the following steps: reserving an expansion gap, that is, reserving a thermal compensation gap between key matching surfaces when high-temperature components in a shell are heated and expanded; measuring the expansion gap and adjusting the measured expansion gap according to the reserved expansion gap to realize control of the shell expansion gap; protecting a matching surface of a rotor and a radial electromagnetic bearing stator; fixing and protecting a cable led out from the radial electromagnetic bearing stator; assembling the radial electromagnetic bearing stator; calculating the thickness Z of a gasket on the rotor and making protection preparation for the rotor and the radial electromagnetic bearing; assembling an auxiliary bearing; adjusting the gap of the auxiliary bearing; adjusting a thrust gap; and completing the installation. The application has the effect of assembling the electromagnetic bearing of the integrated compressor.

Description

Technical Field

[0001] This application relates to the field of integrated compressors, and more particularly to a method for assembling integrated compressor core components. Background Technology

[0002] An integrated compressor is a device that integrates the compressor body, drive motor, control system, and related auxiliary equipment into a highly integrated design and manufacturing process. By optimizing the layout and connection methods of each component, it integrates these originally relatively independent parts into a compact structure, achieving a high degree of functional integration and efficient system operation. It features a compact structure, small footprint, convenient installation, stable operation, high energy efficiency, and a high degree of intelligent control. It is widely used in industrial production, energy transmission, air conditioning and refrigeration, automobiles, and other fields, meeting the needs for gas compression and refrigeration in various scenarios. It is one of the important devices for achieving high-efficiency and low-energy-consumption operation in modern industry and daily life.

[0003] Integrated compressors combine a high-speed motor and compressor into one unit. The unit uses electromagnetic bearings instead of the oil film bearings of traditional units, eliminating the need for lubrication systems, dry gas sealing systems, and other auxiliary systems. The unit is completely shielded from the outside environment, resulting in a lighter, more integrated structure and higher usability. The unit requires no external cooling medium; the process gas used cools the motor rotor, stator, and electromagnetic bearings. The high-speed motor and compressor housing share the pressure, thus providing greater operational flexibility. However, currently, there is no domestic method for assembling electromagnetic bearings in integrated compressors, and the domestic technological reserves are lacking. Summary of the Invention

[0004] In order to assemble the electromagnetic bearing of an integrated compressor, this application provides a method for assembling integrated compressor core components.

[0005] This application provides an integrated compressor core component assembly method, which adopts the following technical solution: An assembly method for integrated compressor core components includes the following steps: Reserved expansion gap, which is the thermal compensation gap reserved between key mating surfaces when high-temperature components inside the casing expand due to heat; The expansion gap is measured and adjusted according to the reserved expansion gap to achieve control of the housing expansion gap; Protect the mating surfaces of the rotor and the radial electromagnetic bearing stator; Secure and protect the cables leading out from the radial electromagnetic bearing stator. Assemble the radial electromagnetic bearing stator; Calculate the thickness Z of the shims on the rotor and prepare protective measures for the rotor and radial electromagnetic bearing; Assemble auxiliary bearings; Adjust the clearance of the auxiliary bearing; Adjust the thrust clearance; Installation complete.

[0006] By adopting the above technical solutions, and through the reserved expansion gap and actual measurement adjustment mechanism, dynamic thermal compensation of key mating surfaces under high-temperature conditions is achieved, avoiding component jamming or wear caused by thermal expansion, and significantly improving the operating stability and lifespan of the compressor under extreme conditions. Protective measures for the mating surfaces of the rotor and radial electromagnetic bearing stator prevent damage from impacts during assembly, ensuring the geometric accuracy of the precision mating surfaces and reducing frictional losses and vibration noise during operation. The cable fixing and protection design prevents loosening or wear of electrical connections, ensuring the stability of control system signal transmission. Precise control of the auxiliary bearing housing clearance adjustment and thrust clearance ensures the dual positioning accuracy of the rotor in both the axial and radial directions, improving the bearing system's load-bearing capacity and impact resistance, and reducing mechanical failures caused by clearance deviations. The dynamic compensation mechanism and high-precision assembly process together ensure the reliability of the equipment during long-term operation and reduce the failure rate.

[0007] Preferably, the reserved expansion gap includes the following steps: Install fastening bolts on the right end cover and measure the distance A from the stop at the nut of each fastening bolt to the end face of the end cover; Use a measuring tool to measure the thickness B at the location corresponding to the bolt hole on the outlet partition; The expansion gap is calculated using A and B. If the expansion gap is uneven, too small, or too large, the expansion gap is adjusted.

[0008] By adopting the above technical solution, the expansion gap corresponding to each bolt position can be accurately calculated by measuring the relevant dimensions (A and B) of the bolt holes of the end cap and the partition, so as to realize the quantitative control of thermal expansion, avoid the error of traditional experience estimation, ensure that the key mating surfaces can still maintain a reasonable gap under high temperature conditions, and prevent seizing or leakage caused by thermal expansion. By measuring and calculating each bolt hole separately, local gap deviations can be found and corrected.

[0009] Preferably, the expansion gap is AB; If the expansion gap is uneven or too large, adjust the expansion gap by adding adjusting shims; If the expansion gap is too small, it can be adjusted by grinding the inner end face of the screw of the fastening bolt at the corresponding point.

[0010] By adopting the above technical solution, the reserved gap automatically compensates for temperature changes during operation, preventing bolt breakage due to thermal expansion. If the expansion gap is uneven or too large, local deviations can be quickly corrected by adding adjusting shims. If the expansion gap is too small, the inner end face of the screw of the fastening bolt is ground to accurately expand the gap, avoiding the need to replace the entire component, reducing costs, eliminating local stress concentration caused by gap deviation, and preventing end cover deformation. By using shims or grinding, gap correction can be achieved without complex tooling. Single-point gap problems can be adjusted individually, avoiding the need for disassembly of the entire machine.

[0011] Preferably, the expansion gap is adjusted to ensure that it is within the design range and the deviation is no greater than 0.05 mm.

[0012] By adopting the above technical solutions, precise expansion gaps can make the gas compression process inside the compressor more stable and efficient. Excessive gaps can lead to increased gas leakage and reduced compression efficiency; insufficient gaps can increase friction and resistance between components, also affecting compression efficiency. The various components of the compressor transmit power through precise cooperation. Appropriate expansion gaps ensure smooth power transmission between key components such as the rotor and bearings, reducing energy loss. At the same time, excessive gaps may cause components to shake and collide during operation, accelerating wear; insufficient gaps may cause components to squeeze together after thermal expansion, leading to jamming. Appropriate expansion gaps help reduce vibration and noise during compressor operation.

[0013] Preferably, the measured expansion gap includes the following steps: After cleaning the mating surfaces of the movement and the outlet partition, assemble them. After tightening the bolts, there should be no gap between the outlet partition and the movement. Clean the right end cover, assemble the right end cover and the outlet partition, ensuring there is no gap between the right end cover and the outlet partition; Assemble the movement. After the movement is assembled, measure the gap C between the outer end face of the right end cover and the housing. C is the measured expansion gap. Based on A, B, and C, determine the conditions that the measured expansion gap must meet, and adjust the measured expansion gap accordingly.

[0014] By adopting the above technical solution, the actual effect of the reserved gap AB after assembly is directly verified by measuring the gap C between the outer end face of the right end cover and the housing (i.e., the measured expansion gap). This ensures that the final gap deviates from the theoretical value by ≤0.05mm, meets the gapless assembly requirements between the outlet partition and the core, and between the right end cover and the outlet partition, and ensures that the mating surfaces fit tightly in the cold state. This avoids misalignment caused by machining burrs or foreign objects, detects machining defects in advance, and avoids stress concentration caused by initial gap deviation in the hot state. By measuring the C value, the axial positioning of the core in the housing is verified to be accurate. At the same time, by adjusting the C value, the compressor maintains a suitable gap under different operating conditions such as start-up, full load, and shutdown.

[0015] Preferably, the measured expansion gap must satisfy AB-2mm < C < AB-0.5mm; If the measured expansion gap C ≥ AB - 0.5 mm, then adjust the expansion gap by grinding the inner end face of the screw of the fastening bolt according to the numerical difference; If the measured expansion gap C ≤ AB - 2 mm, then the expansion gap should be adjusted using shims.

[0016] By adopting the above technical solution, a safety margin is accurately set. The reasonable range of cold assembly gap is clarified by the formula AB-2mm<C<AB-0.5mm. When C≥AB-0.5mm (i.e. the cold gap is too small), the expansion of the component at high temperature may cause the gap to disappear and cause seizing. The safety margin is restored by increasing the value of C by grinding the inner end face of the screw of the fastening bolt. When C≤AB-2mm, the expansion at high temperature may cause the seal to fail or the vibration to increase. The value of C is reduced by adding a gasket to ensure that there is still sufficient contact pressure in the hot state.

[0017] Preferably, the assembly of the radial electromagnetic bearing stator includes the following steps: Adjust the clearance between the inner bore of the radial electromagnetic bearing and the laminated sleeve; Install the radial electromagnetic bearing and fastening bolts; Measure the distance between the outer axial end face of the laminated sleeve and the position sensor ring; Select a shim of appropriate thickness and add it between the radial electromagnetic bearing and the end cover. The shim thickness should be adapted to the distance between the outer axial end of the lamination sleeve and the position sensor after the radial electromagnetic bearing stator is assembled.

[0018] By adopting the above technical solution and adjusting the gap between the inner hole of the radial electromagnetic bearing and the laminated sleeve, the rotor can maintain a stable rotation center during operation, reducing eccentricity and vibration. A suitable gap can avoid excessive friction and wear between the radial electromagnetic bearing and the laminated sleeve. If the gap is too large, it will cause the rotor to wobble during operation, increasing collisions and wear between components; if the gap is too small, it will increase the friction between the two, which will also accelerate wear. The radial electromagnetic bearing relies on electromagnetic force to support the rotor. The size of the gap will affect the distribution and effect of the electromagnetic force. A suitable gap can ensure the uniform distribution of electromagnetic force, allowing the radial electromagnetic bearing to better perform its supporting and control functions and improve the overall performance of the compressor. The position sensor is used to monitor the position and status of the rotor. By measuring the distance between the axial outer end face of the laminated sleeve and the position sensor ring, the installation position of the radial electromagnetic bearing stator can be ensured to be accurate. The compressor generates heat during operation, causing thermal expansion of components. The gasket can play a certain compensating role. When the components change size due to thermal expansion, the gasket can absorb some of the deformation, ensuring that the relative position between the radial electromagnetic bearing and other components remains unchanged, thereby maintaining the normal operation of the compressor.

[0019] Preferably, calculating the thickness Z of the shim on the rotor includes the following steps: Measure the length X of the rotor auxiliary bearing sleeve; Measure the total width Y of the inner ring of the auxiliary bearing; The thickness of the shim on the rotor is Z = Y + auxiliary bearing clearance - X.

[0020] By adopting the above technical solution and accurately calculating the shim thickness Z, it is possible to ensure that the auxiliary bearing has a suitable axial clearance after installation. A suitable axial clearance can ensure that the bearing can rotate flexibly during operation while effectively limiting the axial displacement of the rotor. This avoids rotor movement due to excessive axial clearance or excessive axial force on the bearing due to insufficient axial clearance, thereby improving the working accuracy and stability of the bearing. The precise shim thickness can achieve a good fit between the inner ring of the auxiliary bearing and related components, allowing the bearing to distribute stress evenly when bearing load.

[0021] Preferably, the assembly of the auxiliary bearing includes the following steps: Adjust the clearance between the inner bore of the auxiliary bearing and the sleeve of the auxiliary bearing. Align the inner bore of the auxiliary bearing with the cable outlet of the radial electromagnetic bearing, and then fix the radial electromagnetic bearing and the auxiliary bearing in place. Remove the outer gasket assembly of the auxiliary bearing sleeve, fix the auxiliary bearing sleeve to the auxiliary bearing, and ensure that the circumferential distance is consistent; Assemble a shim, pin, pad, washer, and lock nut of thickness Z on the rotor, and tighten the lock nut.

[0022] By adopting the above technical solution, precise adjustment of the clearance can ensure that the rotor maintains a stable central position during rotation, effectively reducing eccentricity and vibration problems caused by unreasonable clearance. If the clearance is too large, the rotor will wobble significantly during high-speed operation, reducing compression efficiency; if the clearance is too small, it will increase frictional resistance and may even cause component wear or jamming. A suitable clearance can avoid excessive friction and wear between the auxiliary bearing and the auxiliary bearing sleeve, reduce heat generation, reduce the risk of component damage due to overheating, and ensure that the distance between the auxiliary bearing sleeve and the auxiliary bearing is consistent in the circumferential direction, so that the force between them is evenly distributed, avoiding component damage caused by excessive local force, improving the load-bearing capacity and service life of the auxiliary bearing. At the same time, assembling a shim with a thickness of Z can precisely control the axial clearance of the auxiliary bearing, ensuring the accurate position of the rotor in the axial direction.

[0023] Preferably, the adjustment of the thrust clearance includes the following steps: Protect all components; Install thrust disc adjustment pads; The lifting bridge is assembled with the auxiliary bearing and aligned with the cable outlet of the radial electromagnetic bearing; Assemble the inner axial electromagnetic bearing; Assemble the outer axial electromagnetic bearing.

[0024] By adopting the above technical solutions, protective measures are taken for precision components such as thrust discs and bearings during the assembly process to avoid bumps and scratches. By adjusting the shim thickness, the thrust clearance is controlled within the design range, and a clearance margin is reserved under hot conditions to prevent bearing seizure under high-temperature conditions. The precise matching of the lifting bridge and auxiliary bearings can distribute axial loads and avoid single-point stress concentration. It ensures that the cable outlet is aligned and avoids cable twisting or excessive stretching during assembly. The inner bearing bears the main axial force, and its precise assembly can ensure uniform load distribution. The active control characteristics of the electromagnetic bearing can compensate for axial displacement in real time and adapt to fluctuations in operating conditions.

[0025] In summary, this application includes at least one of the following beneficial technical effects: 1. By reserving expansion gaps and implementing a measured adjustment mechanism, dynamic thermal compensation is achieved for key mating surfaces under high-temperature conditions, preventing component jamming or wear caused by thermal expansion and significantly improving the compressor's operational stability and lifespan under extreme conditions. Protective measures for the rotor-radial electromagnetic bearing stator mating surfaces prevent damage during assembly, ensuring the geometric accuracy of precision mating surfaces and reducing frictional losses and vibration noise during operation. Cable fixing and protection design prevents loosening or wear of electrical connections, ensuring the stability of control system signal transmission. Precise control of auxiliary bearing housing clearance adjustment and thrust clearance ensures dual axial and radial positioning accuracy of the rotor, improving the bearing system's load-bearing capacity and impact resistance, and reducing mechanical failures caused by clearance deviations. The dynamic compensation mechanism and high-precision assembly process jointly ensure the equipment's reliability during long-term operation and reduce the failure rate. This method, through systematic process optimization, effectively solves the performance degradation problem of traditional compressors caused by thermal expansion and assembly errors. Attached Figure Description

[0026] Figure 1 This is a schematic diagram illustrating the distance A from the screw end face to the right end cap end face in an embodiment of this application; Figure 2 This is a schematic diagram illustrating the thickness of the outlet partition; Figure 3 Structural entity diagram for adjusting the expansion gap section; Figure 4 This is a diagram showing the positional relationship of each component during the actual measurement of the expansion gap; Figure 5 A schematic diagram of a structure for measuring the distance between the outer end face of the laminated sleeve and the position sensor ring; Figure 6 This is a schematic diagram showing the distance X between the two end faces of the auxiliary bearing sleeve; Figure 7 This is a schematic diagram showing the width Y of the inner ring of the auxiliary bearing stator; Figure 8 This is a schematic diagram showing the position of the auxiliary bearing adjustment shims; Figure 9 This diagram illustrates the determination of the thickness of the inner axial electromagnetic bearing adjustment pad. Figure 10 This diagram illustrates how to determine the thickness of the adjusting shim for the outer axial electromagnetic bearing.

[0027] Explanation of reference numerals in the attached drawings: 1. Right end cover; 2. Outlet partition; 3. Screw; 301. Screw inner end face; 4. Washer; 5. Housing; 6. Laminate sleeve; 7. Electromagnetic bearing stator; 8. Auxiliary bearing stator; 9. Auxiliary bearing; 10. Adjusting shim; 11. Auxiliary bearing sleeve; 12. Pad; 13. Rotor; 14. Inner axial electromagnetic bearing; 15. Bridge; 16. Thrust disc; 17. Adjusting shim; 18. Outer axial electromagnetic bearing. Detailed Implementation

[0028] The following is in conjunction with the appendix Figure 1-10 This application will be described in further detail.

[0029] This application discloses an assembly method for an integrated compressor core component. The assembly method for the integrated compressor core component includes the following steps: S1 is a reserved expansion gap, which is a thermal compensation gap reserved between key mating surfaces when the high-temperature components inside the housing 5 are heated and expanded.

[0030] The process of reserving an expansion gap includes the following steps: S1.1 Install fastening bolts on the right end cover 1, and measure the distance A from the stop at the nut of each fastening bolt to the end face of the end cover. Refer to [reference needed] for details. Figure 1 .

[0031] S1.2 Use a measuring tool to measure the thickness B at the corresponding bolt hole location on the outlet partition 2, referring to the following for details. Figure 2 .

[0032] S1.3 Calculate the expansion gap using A and B. If the expansion gap is uneven, too small, or too large, adjust the expansion gap accordingly.

[0033] Expansion gap = AB. If the expansion gap is uneven or too large, adjust the expansion gap by adding adjusting shims 10; refer to Figure 3 If the expansion gap is too small, it can be adjusted by grinding the inner end face 301 of the screw at the corresponding point of the fastening bolt. By calculating the expansion gap, the amount of thermal expansion can be quantitatively controlled, avoiding estimation errors and ensuring that a reasonable gap is maintained under high-temperature conditions. If the expansion gap is uneven or too large, it can be adjusted by adding adjusting shims 10. If the expansion gap is too small, the inner end face 301 of the screw at the fastening bolt needs to be ground to accurately widen the gap, avoiding the need to replace the entire component. At the same time, adjusting the expansion gap can eliminate local stress concentration caused by gap deviation, preventing end cover deformation. Using shims 4 or grinding, gap correction can be achieved without complex tooling, allowing for individual adjustment of single-point gap problems and avoiding disassembly of the entire machine.

[0034] In a preferred embodiment, the expansion gap is adjusted to ensure it is within the design range and the deviation is no greater than 0.05 mm. A precise expansion gap makes the gas compression process inside the compressor more stable and efficient. An excessively large gap leads to increased gas leakage and reduced compression efficiency; an excessively small gap may increase friction and resistance between components, also affecting compression efficiency. The compressor's various components transmit power through precise cooperation. A suitable expansion gap ensures smooth power transmission between key components such as the rotor 13 and bearings, reducing energy loss. Simultaneously, an excessively large gap may cause components to shake and collide during operation, accelerating wear; an excessively small gap may cause components to squeeze against each other after thermal expansion, leading to jamming. A suitable expansion gap helps reduce vibration and noise during compressor operation.

[0035] S2 measures the expansion gap and adjusts the measured expansion gap according to the reserved expansion gap to control the expansion gap of the housing 5.

[0036] The measured expansion gap includes the following steps: S2.1 After cleaning the mating surfaces of the movement and the outlet partition 2, assemble them. After tightening the bolts, there should be no gap between the outlet partition 2 and the movement.

[0037] S2.2 Clean the right end cover 1, assemble the right end cover 1 and the outlet partition 2, with no gap between the right end cover 1 and the outlet partition 2.

[0038] Optionally, due to the expansion gap that exists when using product bolts, the product bolts can be replaced with tooling bolts.

[0039] S2.3 Assemble the movement. After the movement is assembled, measure the gap C between the outer end face of the right end cover 1 and the housing 5. C is the measured expansion gap. Refer to [reference needed] for details. Figure 4 .

[0040] S2.4 Determine the conditions that the measured expansion gap must meet based on A, B, and C, and adjust the measured expansion gap accordingly.

[0041] Optionally, the measured expansion gap must satisfy AB-2mm < C < AB-0.5mm. If the measured expansion gap C ≥ AB-0.5mm, the expansion gap is adjusted by grinding the inner end face 301 of the screw of the fastening bolt according to the numerical difference. If the measured expansion gap C ≤ AB-2mm, the expansion gap is adjusted by using the shim 4. When C ≥ AB-0.5mm (i.e., the cold-state gap is too small), the expansion of the component at high temperature may cause the gap to disappear, leading to seizing. The value of C is increased by grinding the inner end face 301 of the screw of the fastening bolt to restore the safety margin. When C ≤ AB-2mm, high-temperature expansion may lead to sealing failure or increased vibration. The value of C is reduced by adding the shim 4 to ensure sufficient contact pressure under hot conditions.

[0042] S3 protects the mating surfaces of rotor 13 and radial electromagnetic bearing stator 7.

[0043] Specifically, this includes: wrapping Nomex paper around the rotor 13 shaft diameter to prevent scratching the shaft diameter when assembling the electromagnetic bearing stator 7; applying a thin layer of silicone grease to the mating surfaces of the radial electromagnetic bearing stator 7 for lubrication and to facilitate assembly and disassembly; and securing and protecting the power cables and sensor cables leading out from the radial electromagnetic bearing stator 7.

[0044] S4 secures and protects the cable leading out from the radial electromagnetic bearing stator 7, ensuring it will not be pulled or damaged during assembly.

[0045] S5 assembles the radial electromagnetic bearing stator 7.

[0046] The specific steps include: S5.1 Adjust the gap between the inner hole of the radial electromagnetic bearing and the laminated sleeve 6 to avoid scratching the rotor 13 disc sleeve.

[0047] S5.2 Install the radial electromagnetic bearing and fasten the bolts.

[0048] S5.3 measures the distance between the outer end face of the stacked sleeve 6 and the position sensor ring.

[0049] S5.4 Select a shim 4 of appropriate thickness and add it between the radial electromagnetic bearing and the end cover. The thickness of the shim 4 is adapted to the distance between the outer axial end of the laminated sleeve 6 and the position sensor after the radial electromagnetic bearing stator 7 is assembled.

[0050] Reference Figure 5 The radial electromagnetic bearing is ejected using a set screw. A shim 4 is added between the radial electromagnetic bearing and the end cover. The electromagnetic bearing is then reinstalled, and the bolts are tightened evenly diagonally to the specified torque. The distance between the axial outer end face of the laminated sleeve 6 and the position sensor ring is measured using a depth gauge. Optionally, because there is an expansion gap between the drive-side end cover and the housing 5, this expansion gap must be considered when assembling the radial electromagnetic bearing stator 7. The actual expansion gap value must be added when calculating the thickness of the shim 10 to ensure that the distance between the axial outer end face of the laminated sleeve 6 and the position sensor ring meets the drawing requirements after the electromagnetic bearing stator 7 is assembled.

[0051] Optionally, adjusting the clearance between the inner bore of the radial electromagnetic bearing and the laminated sleeve 6 can ensure that the rotor 13 maintains a stable rotation center during operation, reducing eccentricity and vibration. A suitable clearance can prevent excessive friction and wear between the radial electromagnetic bearing and the laminated sleeve 6. If the clearance is too large, the rotor 13 will wobble during operation, increasing collisions and wear between components; if the clearance is too small, the friction between the two will increase, similarly accelerating wear. The radial electromagnetic bearing relies on electromagnetic force to support the rotor 13, and the size of the clearance affects the distribution and effect of the electromagnetic force. A suitable clearance can ensure the uniform distribution of the electromagnetic force, enabling the radial electromagnetic bearing to better perform its supporting and control functions, and improving the overall performance of the compressor.

[0052] Optionally, a position sensor is used to monitor the position and status of the rotor 13. By measuring the distance D between the outer end face of the laminated sleeve 6 and the position sensor ring, the installation position of the radial electromagnetic bearing stator 7 can be ensured to be accurate. During the operation of the compressor, heat is generated, which causes the components to expand thermally. The gasket 4 can play a certain compensating role. When the components change size due to thermal expansion, the gasket 4 can absorb some of the deformation, ensuring that the relative position between the radial electromagnetic bearing and other components remains unchanged, thereby maintaining the normal operation of the compressor.

[0053] S6 calculates the thickness Z of the shim 4 on rotor 13 and prepares protection for rotor 13 and radial electromagnetic bearing.

[0054] Reference Figure 6 and Figure 7 The calculation of the thickness Z of the shim 4 on rotor 13 includes the following steps: S6.1 Measure the length X of the auxiliary bearing sleeve 11 of rotor 13.

[0055] S6.2 Measure the total width Y of the inner ring of auxiliary bearing 9.

[0056] The thickness of the shim 4 on rotor 13 of S6.3 is Z = Y + clearance of auxiliary bearing 9 - X.

[0057] Optionally, by accurately calculating the thickness Z of the shim 4, it can be ensured that the auxiliary bearing 9 has a suitable axial clearance after installation. A suitable axial clearance can ensure that the bearing can rotate flexibly during operation while effectively limiting the axial displacement of the rotor 13. This avoids the rotor 13 moving due to excessive axial clearance, or the bearing bearing bearing excessive axial force due to insufficient axial clearance, thereby improving the working accuracy and stability of the bearing. The precise thickness of the shim 4 can achieve a good fit between the inner ring of the auxiliary bearing 9 and related components, allowing the bearing to distribute stress evenly when bearing load, reducing the phenomenon of local stress concentration, reducing the risk of premature wear and fatigue failure of the bearing, and extending the service life of the bearing. At the same time, a suitable thickness of the shim 4 can keep the rotor 13 in a stable position in both the axial and radial directions, reducing vibration and impact caused by improper clearance, thereby improving the smoothness of the entire equipment operation.

[0058] The specific protective preparations for rotor 13 and radial electromagnetic bearing are as follows: wrap Nomex paper around the shaft diameter of rotor 13 to avoid scratching the shaft diameter when assembling auxiliary bearing 9; apply a thin layer of silicone grease to the mating surface of auxiliary bearing 9 to lubricate and facilitate disassembly and assembly; and secure and protect the power cable and sensor cable leading out from stator 7 of radial electromagnetic bearing to ensure that they are not pulled or damaged during the assembly of auxiliary bearing 9.

[0059] S7 is equipped with auxiliary bearing 9.

[0060] The specific steps include: S7.1 Adjust the clearance between the inner hole of the auxiliary bearing 9 and the auxiliary bearing sleeve 11 to avoid scratching the auxiliary bearing sleeve 11, and then install the auxiliary bearing 9.

[0061] S7.2 Align the inner hole of the auxiliary bearing 9 with the cable outlet of the radial electromagnetic bearing, and fix the radial electromagnetic bearing and the auxiliary bearing 9.

[0062] S7.3 Remove the four sets of outer gaskets of the auxiliary bearing bushing 11, fix the auxiliary bearing bushing 11 and the auxiliary bearing 9 and ensure that the circumferential distance is consistent.

[0063] S7.4 Assemble a shim 4 of thickness Z, a pin, a pad 12, a washer, and a lock nut on the rotor 13, and tighten the lock nut.

[0064] Optionally, precisely adjusting this clearance allows the rotor 13 to maintain a stable central position during rotation, effectively reducing eccentricity and vibration problems caused by improper clearance. If the clearance is too large, the rotor 13 will wobble significantly during high-speed operation, reducing compression efficiency; if the clearance is too small, it will increase frictional resistance and may even cause component wear or jamming. A suitable clearance can prevent excessive friction and wear between the auxiliary bearing 9 and the auxiliary bearing sleeve 11, reduce heat generation, reduce the risk of component damage due to overheating, ensure that the distance between the auxiliary bearing sleeve 11 and the auxiliary bearing 9 is consistent in the circumferential direction, and enable the force between them to be evenly distributed, avoiding component damage caused by excessive local force, improving the load-bearing capacity and service life of the auxiliary bearing 9. At the same time, assembling a shim 4 with a thickness of Z can precisely control the axial clearance of the auxiliary bearing 9, ensuring the accurate axial position of the rotor 13.

[0065] S8 adjusts the clearance of auxiliary bearing 9.

[0066] The specific steps include: S8.1 Adjust rotor 13 to the center position.

[0067] S8.2 Install a rotor axial movement measuring tool on the non-drive side and set up dial indicators on both sides of the rotor 13 to record the axial movement value of the rotor 13.

[0068] S8.3 uses a rotor 13 axial force measuring fixture to record the minimum torque and axial displacement when the rotor 13 moves axially, the force and axial displacement when the rotor 13 moves axially to the farthest position, and the value of the axial displacement remaining unchanged after the force is applied, thereby providing data support for future dynamic debugging.

[0069] S8.4 Remove the fastening bolts of the auxiliary bearing bushing 11 and measure the thickness of the axial shim 4.

[0070] S8.5 Adjust the thickness of the shim 10 according to the maximum displacement of the rotor 13's axial reciprocating movement and the distance between the auxiliary bearing bushing 11 and the auxiliary bearing 9. See details below. Figure 8 Install four sets of shims and tighten the bolts to ensure that after the rotor 13 is centered, the distance from the auxiliary bearing 9 to the auxiliary bearing sleeves 11 on both sides is the same.

[0071] S9 adjusts the thrust clearance.

[0072] The specific steps include: S9.1 provides protection for all components.

[0073] Optionally, a thin layer of silicone grease can be applied to the mating surfaces of each component to provide lubrication and facilitate assembly and disassembly; the power cables and sensor cables leading out from the radial electromagnetic bearing stator 7 should be fixed and protected to ensure that they are not pulled or damaged during the assembly of bridge 15, inner electromagnetic bearing, and outer electromagnetic bearing.

[0074] S9.2 is equipped with thrust plate 16 and adjusting pad 17.

[0075] The S9.3 lifting bridge 15 is assembled with the auxiliary bearing 9 and aligned with the cable outlet of the radial electromagnetic bearing.

[0076] S9.4 is equipped with an inner axial electromagnetic bearing 14.

[0077] The specific steps include: S9.4.1 Measure the distance a from the outer end face of the adjustment shim 17 to the end face of the bridge 15.

[0078] S9.4.2 Measure the distance b from the inner electromagnetic bearing end face (where it mates with the thrust plate 16) to the inner electromagnetic bearing end face (where it mates with the bridge 15).

[0079] S9.4.3 Measure the distance c from the thrust surface of thrust disk 16 to the axial end face.

[0080] S9.4.4 Based on the data from S9.4.1, S9.4.2, and S9.4.3, and the required thrust clearance, calculate the thickness of the shim 4 between the inner axial electromagnetic bearing 14 and the bridge 15. Adjust the shim 10 thickness = cb - a + inner thrust clearance. Refer to [reference needed] for details. Figure 9 .

[0081] S9.4.5 Install gasket 4, and assemble the inner axial electromagnetic bearing 14 with bridge 15 by hoisting.

[0082] S9.4.6 Clean the inner hole of the thrust plate 16 and the outer surface of the rotor 13 of debris, and install the thrust plate 16, gasket 4 and lock nut.

[0083] S9.4.7 Use a long feeler gauge to measure the axial clearance between the thrust plate 16 and the inner axial electromagnetic bearing 14.

[0084] S9.5 is equipped with an outer axial electromagnetic bearing 18.

[0085] The specific steps include: S9.5.1 Measure the distance f between the outer end face of the thrust disk 16 and the inner axial electromagnetic bearing 14 (the mating surface with the outer electromagnetic bearing).

[0086] S9.5.2 Measure the distance e between the end face of the outer axial electromagnetic bearing 18 (the mating surface with the inner axial electromagnetic bearing 14) and the inner end face of the outer axial electromagnetic bearing 18 (be careful not to damage the appearance quality of the inner end face of the outer electromagnetic bearing).

[0087] S9.5.3 Based on S9.5.1, S9.5.2, and the required axial clearance, calculate the thickness of the shim 4 between the inner axial electromagnetic bearing 14 and the bridge 15: e - f + outer thrust clearance. Refer to [reference needed] for details. Figure 10.

[0088] S9.5.4 Install shim 4, hoist the outer axial electromagnetic bearing 18 and assemble it with the inner axial electromagnetic bearing 14, align it with the cable outlet on the inner axial electromagnetic bearing 14, and tighten the bolts.

[0089] S9.5.5 The axial clearance between the thrust plate 16 and the inner axial electromagnetic bearing 14 is measured using a long feeler gauge.

[0090] S10 installation complete.

[0091] The implementation principle of this application embodiment is as follows: By reserving expansion gaps and using a measured adjustment mechanism, dynamic thermal compensation of key mating surfaces under high-temperature conditions is achieved, avoiding component jamming or wear caused by thermal expansion, and significantly improving the operating stability and lifespan of the compressor under extreme conditions; the protection measures for the mating surfaces of the rotor 13 and the radial electromagnetic bearing stator 7 can prevent collision damage during assembly, ensure the geometric accuracy of the precision mating surfaces, and reduce friction loss and vibration noise during operation; the cable fixing and protection design avoids loosening or wear of electrical connections, ensuring the stability of signal transmission in the control system; the precise control of the clearance adjustment of the auxiliary bearing 9 seat and the thrust clearance ensures the dual positioning accuracy of the rotor 13 in both the axial and radial directions, improves the bearing system's load-bearing capacity and impact resistance, and reduces mechanical failures caused by clearance deviations; the dynamic compensation mechanism and high-precision assembly process together ensure the reliability of the equipment during long-term operation and reduce the failure rate; this method effectively solves the performance degradation problem of traditional compressors caused by thermal expansion and assembly errors through systematic process optimization.

[0092] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A method for assembling integrated compressor core components, characterized in that, Including the following steps: Reserved expansion gap, which is the thermal compensation gap reserved between key mating surfaces when high-temperature components inside the casing expand due to heat; The expansion gap is measured and adjusted according to the reserved expansion gap to achieve control of the housing expansion gap; Protect the mating surfaces of the rotor and the radial electromagnetic bearing stator; Secure and protect the cables leading out from the radial electromagnetic bearing stator. Assemble the radial electromagnetic bearing stator; Calculate the thickness Z of the shims on the rotor and prepare protective measures for the rotor and radial electromagnetic bearing; Assemble auxiliary bearings; Adjust the clearance of the auxiliary bearing; Adjust the thrust clearance; Installation complete.

2. The method for assembling integrated compressor core components according to claim 1, characterized in that, The reserved expansion gap includes the following steps: Install fastening bolts on the right end cover and measure the distance A from the stop at the nut of each fastening bolt to the end face of the end cover; Use a measuring tool to measure the thickness B at the location corresponding to the bolt hole on the outlet partition; The expansion gap is calculated using A and B. If the expansion gap is uneven, too small, or too large, the expansion gap is adjusted.

3. The method for assembling integrated compressor core components according to claim 2, characterized in that, The expansion gap = AB; If the expansion gap is uneven or too large, adjust the expansion gap by adding adjusting shims; If the expansion gap is too small, adjust the expansion gap by grinding the inner end face of the screw of the fastening bolt at the corresponding point.

4. The method for assembling integrated compressor core components according to claim 3, characterized in that, By adjusting, ensure that the expansion gap is within the design range and the deviation is no greater than 0.05mm.

5. The method for assembling integrated compressor core components according to claim 2, characterized in that, The measured expansion gap includes the following steps: After cleaning the mating surfaces of the movement and the outlet partition, assemble them. After tightening the bolts, there should be no gap between the outlet partition and the movement. Clean the right end cover, assemble the right end cover and the outlet partition, ensuring there is no gap between the right end cover and the outlet partition; Assemble the movement. After the movement is assembled, measure the gap C between the outer end face of the right end cover and the housing. C is the measured expansion gap. Based on A, B, and C, determine the conditions that the measured expansion gap must meet, and adjust the measured expansion gap accordingly.

6. The method for assembling integrated compressor core components according to claim 5, characterized in that, The measured expansion gap must satisfy AB-2mm < C < AB-0.5 mm; If the measured expansion gap C ≥ AB - 0.5 mm, then adjust the expansion gap by grinding the inner end face of the screw of the fastening bolt according to the numerical difference; If the measured expansion gap C ≤ AB-2 mm, then the expansion gap should be adjusted using shims.

7. The method for assembling integrated compressor core components according to claim 1, characterized in that, The assembly of the radial electromagnetic bearing stator includes the following steps: Adjust the clearance between the inner bore of the radial electromagnetic bearing and the laminated sleeve; Install the radial electromagnetic bearing and fastening bolts; Measure the distance between the outer axial end face of the laminated sleeve and the position sensor ring; Select a shim of appropriate thickness and add it between the radial electromagnetic bearing and the end cover. The shim thickness should be adapted to the distance between the outer axial end of the laminated sleeve and the position sensor ring after the radial electromagnetic bearing stator is assembled.

8. The method for assembling integrated compressor core components according to claim 1, characterized in that, The calculation of the rotor shim thickness Z includes the following steps: Measure the length X of the rotor auxiliary bearing sleeve; Measure the total width Y of the inner ring of the auxiliary bearing; The thickness of the shim on the rotor is Z = Y + auxiliary bearing clearance - X.

9. The method for assembling integrated compressor core components according to claim 8, characterized in that, The assembly of the auxiliary bearing includes the following steps: Adjust the clearance between the inner bore of the auxiliary bearing and the sleeve of the auxiliary bearing; Align the inner bore of the auxiliary bearing with the cable outlet of the radial electromagnetic bearing, and then fix the radial electromagnetic bearing and the auxiliary bearing in place. Remove the outer gasket assembly of the auxiliary bearing sleeve, fix the auxiliary bearing sleeve to the auxiliary bearing, and ensure that the circumferential distance is consistent; Assemble a shim, pin, pad, washer, and lock nut of thickness Z on the rotor, and tighten the lock nut.

10. The method for assembling integrated compressor core components according to claim 1, characterized in that, The adjustment of the thrust clearance includes the following steps: Protect all components; Assemble the thrust plate and adjusting shims; The lifting bridge is assembled with the auxiliary bearing and aligned with the cable outlet of the radial electromagnetic bearing; Assemble the inner axial electromagnetic bearing; Assemble the outer axial electromagnetic bearing.

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