Compressor including end cap having internal features and methods of assembling the same

Abstract

A compressor includes a compressor shell having an upper and lower end defining an internal volume, the upper end includes an annular axial ledge. A main bearing housing is positioned in engagement with the axial ledge. A scroll assembly is positioned in engagement with a top surface of the main bearing housing. The scroll assembly includes an orbiting scroll and a non-orbiting scroll. An end cap is attached to the compressor shell at the upper end thereof and includes an internal feature to seat the scroll assembly into engagement with the main bearing housing. At least one of the non-orbiting scroll and the main bearing housing is compressed between the axial ledge of the compressor shell and the internal feature of the end cap when the end cap is attached to the compressor shell.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 756,086, filed on February 8, 2025, entitled COMPRESSOR HAVING INTERNAL FEATURES ON THE ENDCAP AND METHODS OF ASSEMBLING THE SAME, which is incorporated herein by reference in its entirety.FIELD

[0002] The field relates generally to scroll compressors, and more particularly, to scroll compressors including a subassembly that facilitates installing compressor components (e.g., scrolls, bearing housing, driveshaft) within the compressor as a single unit and aligning the compressor components in the compressor.BACKGROUND

[0003] Scroll compressors compress refrigerant using a non-orbiting scroll member and an orbiting scroll member that cooperate to form sealed pockets therebetween. During operation of the scroll compressor, motion of the orbiting scroll member relative to the non-orbiting scroll member continuously changes the volume of the sealed pockets to compress refrigerant within.

[0004] Scroll compressors typically include one or more bearings which support rotation of a driveshaft and a drive bearing for transmitting rotational motion of the driveshaft to the orbiting motion of the scroll member.

[0005] During operation, mis-alignment between the compressor components may create the opportunity for the driveshaft to deflect excessively under applied loads, which may lead to wear of compressor components (e.g., bearings). As demand increases for efficient and reliable operation of the compressor to ensure that the climate-control system in which the compressor is installed is capable of effectively and efficiently providing a cooling and / or heating effect on demand, the tolerances for mis-alignment between the main bearing housing and the scroll members continue to shrink. Furthermore, there is ongoing demand for ways to reduce the opportunity for wear on components, such as bearing assemblies, of the scroll compressor and increase the longevity of the compressor and the climate-control system.

[0006] Compressors are operable to rotate compressor components during operation. Aligning the compressor components along the axial direction of rotation ensures efficient operation of the compressor and minimizes wear on the compressor components. When not aligned, the compressor experiences additional wear that degrades the lifespan of the compressor.SUMMARY

[0007] In one aspect, a compressor includes a compressor shell having an upper and lower end defining an internal volume, the upper end includes an annular axial ledge. A main bearing housing is positioned in engagement with the axial ledge. A scroll assembly is positioned in engagement with a top surface of the main bearing housing. The scroll assembly includes an orbiting scroll and a non-orbiting scroll. An end cap is attached to the compressor shell at the upper end thereof and includes an internal feature to seat the scroll assembly into engagement with the main bearing housing. At least one of the non-orbiting scroll and the main bearing housing is compressed between the axial ledge of the compressor shell and the internal feature of the end cap when the end cap is attached to the compressor shell.

[0008] Another aspect is a method of assembling a compressor. The method includes positioning a main bearing housing into engagement with an annular axial ledge of an upper end of a compressor shell. The method also includes positioning a scroll assembly into engagement with a top surface of the main bearing housing, wherein the scroll assembly comprises an orbiting scroll and a non-orbiting scroll. The method further includes engaging at least one of the main bearing housing and the non-orbiting scroll with an internal feature of an end cap. The method also includes compressing at least one of the main bearing housing and the non-orbiting scroll between the internal feature of the end cap and the axial ledge of the compressor shell, and attaching the end cap to the upper end of the compressor shell while the at least one of the main bearing housing and the non-orbiting scroll is compressed between the internal feature of the end cap and the axial ledge, such that the attachment of the end cap to the compressor shell retains a compressive force against the at least one of the main bearing housing and the non-orbiting scroll.

[0009] Various refinements exist of the features noted in relation to the above-mentioned aspects. Further features may also be incorporated in the above-mentioned aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to any of the illustrated embodiments may be incorporated into any of the above-described aspects, alone or in any combination.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The following figures illustrate various aspects of the disclosure.

[0011] FIG. 1 is a perspective view of an example compressor.

[0012] FIG. 2 is a cross-sectional view of the compressor shown in FIG. 1 taken along line 2-2.

[0013] FIG. 3A is a perspective view of a bayonet fitting between the main bearing housing and the scroll assembly.

[0014] FIG. 3B is a perspective view of a bayonet fitting engaged between the main bearing housing and the scroll assembly.

[0015] FIG. 3C is a cross-sectional view of the compressor including a main bearing housing attached to a scroll assembly attached by a bayonet fitting.

[0016] FIG. 4A is a perspective view of an example end cap including an internal feature.

[0017] FIG. 4B is a side cross-sectional view of a compressor including the example end cap shown in FIG. 4A.

[0018] FIG. 4C is a top cross-sectional view of a compressor including the example end cap shown in FIG. 4A.

[0019] FIG. 5A is a perspective view of another example end cap including an internal feature.

[0020] FIG. 5B is a side cross-sectional view of a compressor including the example end cap shown in FIG. 5A.

[0021] FIG. 5C is a top cross-sectional view of a compressor including the example end cap shown in FIG. 5A.

[0022] FIG. 6A is a perspective view of yet another example end cap including an internal feature.

[0023] FIG. 6B is a side cross-sectional view of a compressor including the example end cap shown in FIG. 6A.

[0024] FIG. 6C is a top cross-sectional view of a compressor including the example end cap shown in FIG. 6A.

[0025] Corresponding reference numerals indicate corresponding parts throughout the drawings.DETAILED DESCRIPTION

[0026] Referring to FIG. 1, a view of an example compressor is indicated generally at 100. The compressor 100 includes a compressor housing 102 forming at least one sealed cavity within which refrigerant compression is accomplished. The compressor housing 102 includes a shell 104, an end cap 106 positioned at a first end 118 of the shell 104, and a base 108 positioned at an opposing second end 120 of the shell 104. In the illustrated example, the shell 104 is cylindrical in shape and the end cap 106 and the base 108 are each generally dome-shaped, such that the compressor housing 102 has a generally oval-shaped profile. The shell 104, the end cap 106, and / or the base 108 may be differently shaped depending on a desired shape and profile of the compressor housing 102. The end cap 106 and / or the base 108 may be attached at the respective ends 118, 120 of the shell 104 using any suitable means to join components. For example, the end cap 106 and / or the base 108 may be welded or bolted to the shell 104. In the example compressor, the end cap 106 includes one or more internal features (discussed later). The internal feature 107 positions and aligns one or more compressor components within the compressor housing 102. The attachment between the end cap 106 and the compressor housing 102 applies a clamping force to secure the compressor component within the compressor housing 102. The attachment applies the clamping force to the compressor component between the internal feature 107 of the end cap 106 and an upper axial portion of the compressor housing 102. The clamping force orients the compressor component within the compressor housing 102. Orienting the compressor component includes axially aligning and / or seating the compressor component within the compressor housing 102. Orienting the compressor components for axial alignment reduces the wear on compressor components during operation of the compressor. For example, the compressor component includes a main bearing housing, or a scroll assembly and is oriented by the clamping force between the end cap 106 and the shell 104. In some embodiments, the internal feature 107 on the end cap 106 seats the scroll assembly 204 into engagement with a top surface of the main bearing housing 208, and the attachment of the end cap 106 to the shell 104 compresses at least one of the non-orbiting scroll 228 and the main bearing housing 208 between the internal feature 107 and an annular axial ledge of the shell 104.

[0027] The compressor 100 includes an inlet fitting 110 attached to the compressor housing 102 at an inlet opening (not shown) through which working fluid (e.g., refrigerant) enters the at least one sealed cavity formed by the compressor housing 102. For example, the working fluid is drawn into the compressor 100 via the inlet fitting 110 and compressed in the at least one sealed cavity. After the working fluid is compressed, the compressed working fluid exits the compressor 100 through a tube 112. A discharge fitting 114 may be attached to the compressor housing 102 at the tube 112. In the example compressor 100, the tube 112 is located on the base 108, and the discharge fitting 114 is attached to the base 108 at the tube 112, enabling compressed working fluid to exit a second chamber 117 (FIG. 2) defined by the base 108. In the example compressor 100, the working fluid in the second chamber 117 is at discharge pressure, and the second chamber 117 may alternatively be referred to as a discharge chamber. A discharge valve assembly (not shown) may be disposed within the discharge fitting 114 to prevent a reverse flow condition. A hermetic electric terminal 115 may also be attached to the compressor housing 102, for example, to the shell 104.

[0028] FIG. 2 is a cross-section of the compressor 100. The compressor 100 includes the compressor housing 102 including the shell 104, the end cap 106 positioned at the first end 118 of the shell 104 and defining the first chamber 116, and the base 108 positioned at the second end 120 of the shell 104 and defining the second chamber 117. The compressor 100 also includes a motor assembly 122 and a compression mechanism (e.g., a scroll assembly), indicated generally at 204, installed in the compressor housing 102 and operably connected to the motor assembly 122.

[0029] The motor assembly 122 includes a motor stator 124 and a rotor 126. The rotor 126 may be press fit on a driveshaft 128 positioned within the compressor housing 102 and may transmit rotational power to the driveshaft 128. The motor assembly 122 may be a variable-speed motor for rotating the driveshaft 128 at any of a plurality of speeds. In the illustrated embodiment, the motor assembly 122 is disposed within the shell 104. In some other embodiments, the compressor 100 may be an open drive compressor driven by a motor assembly 122 that is disposed outside of the compressor housing 102.

[0030] The driveshaft 128 is rotatably supported within a first bearing housing assembly 206 and second bearing housing assembly 130. The first bearing housing assembly 206 and the second bearing housing assembly 130 are axially displaced and located on opposite sides of the motor assembly 122. The first bearing housing assembly 206 is located proximate the first end 118 of the shell 104 and the second bearing housing assembly 130 is located proximate the second end 120 of the shell 104 (e.g., within the base 108). The driveshaft 128 extends through the first bearing housing assembly 206 and includes an eccentric body 132 extending axially beyond the first bearing housing assembly 206.

[0031] The first bearing housing assembly 206 includes a primary bearing 134 and the second bearing housing assembly 130 includes a secondary bearing 136. The primary and secondary bearings 134, 136 rotationally support the driveshaft 128 within the respective bearing housing assembly 206, 130. The first bearing housing assembly 206 includes the primary bearing 134 and a main bearing housing 208. The primary bearing 134 and / or the secondary bearing 136 may be rolling element bearings having an inner ring defining a bearing surface and bearing opening for receiving the driveshaft 128, an outer ring spaced radially outward from the inner ring, and a plurality of balls or rollers disposed between the inner ring and the outer ring. Alternatively, in some embodiments, the primary bearing 134 and / or secondary bearing 136 are journal bearings, and the driveshaft 128 rotationally supported by the journal bearings 134 and / or 136 within a bearing opening and relative to a stationary bearing inner surface. The primary bearing 134 and / or the secondary bearing 136 may be any suitable bearing type. In the embodiment illustrated in FIG. 3C, the internal feature 107 on the interior of the end cap 106 and the upper axial portion of the shell 104 to secure the main bearing housing 208 within the compressor housing 102. When the end cap 106 is attached, the engagement between the internal feature 107 and the shell 104 seats the main bearing housing 208 on the annular axial ledge of the shell 104 and axially aligns the driveshaft 128 with the secondary bearing 136, such that the main bearing housing 208 and the secondary bearing 136 are aligned by the clamp established between the internal feature 107 and the shell 104.

[0032] The scroll assembly 204 is in engagement with a top surface of the main bearing housing 208. The scroll assembly 204 includes an orbiting scroll 226 and a non-orbiting scroll 228. The orbiting scroll 226 includes a generally disk-shaped orbiting plate 230 defining opposing radial surfaces. An orbiting spiral wrap 232 extends axially from one of the surfaces of the orbiting plate 230, and the surface opposite the orbiting spiral wrap 232 includes a cylindrical hub 236 extending axially therefrom. A drive bushing 239 is disposed in the cylindrical hub 236 and receives the eccentric body 132 of the driveshaft 128 that extends through the main bearing housing 208. The eccentric body 132 drivingly engages the drive bushing 239 in the cylindrical hub 236 of the orbiting scroll 226 and facilitates transmitting rotational motion of the driveshaft 128 to orbiting motion of the orbiting scroll 226 relative to the main bearing housing 208 and / or the non-orbiting scroll 228. A coupling (e.g., an Oldham coupling), not labeled, may be engaged with the orbiting scroll 226 and the main bearing housing 208 and / or the non-orbiting scroll 228 to limit or prevent relative rotation therebetween.

[0033] The non-orbiting scroll 228 includes a non-orbiting body 238 defining an upper surface 241 and an opposing lower surface 242. In some embodiments, the non-orbiting scroll 228 may include an annular wall 244. A non-orbiting spiral wrap 240 extends, generally axially, from the lower surface 242 and faces the orbiting spiral wrap 232. In the embodiment illustrated in FIG. 2, the non-orbiting scroll 228 also includes a raised portion 246 extending axially from the upper surface 241 of the non-orbiting body238. The non-orbiting scroll 228 further includes a plurality of circumferentially spaced flanges on a radial outer surface of the non-orbiting scroll 228 for bayonet connection to the main bearing housing 208, and a scroll alignment hole 312 defined by and extending through the scroll assembly 204.

[0034] The non-orbiting spiral wrap 240 engages, or meshes, with the orbiting spiral wrap 232 of the orbiting scroll 226, defining a series of fluid pockets. Orbiting motion of the orbiting scroll 226 translates to movement of the fluid pockets defined by the spiral wraps 232 and 240, whereby the fluid pockets decrease in volume to compress working fluid in the fluid pockets. During a compression cycle of the scroll assembly 204, the fluid pockets defined by the spiral wraps 232 and 240 decrease in volume as orbiting motion of the orbiting scroll 226 translates to movement of the fluid pockets from a radially outer position 250 (at a suction pressure) to a radially intermediate position (at an intermediate pressure) to a radial inner position 252 (at a discharge pressure).

[0035] FIGS. 4A-6C illustrate an example compressor 100 including one or more internal features 107 on the end cap 106. Each internal feature 107 is shaped to orient and secure at least one compressor component between the end cap 106 and the compressor shell 104. The one or more internal features 107 may be positioned on the internal surface relative to the suction inlet 109 on the end cap 106. The position of the one or more internal features 107 on the end cap 106 facilitates both gas flow in high side compressors and for the implementation of a direct suction tube with rotolock fitting to the non-orbiting scroll 228. In the example compressor 100, the at least one compressor component is positioned on the upper axial ledge of the compressor shell 104. The end cap 106 encloses the at least one compressor component and attaches to the compressor shell 104. In the example compressor 100, the end cap 106 is attached to the compressor shell 104 with a weld 111.

[0036] The at least one compressor component includes the main bearing housing 208 and / or the scroll assembly 204. One or more bolts 901 may attach the scroll assembly 204 to the main bearing housing 208. In the embodiment illustrated in FIGS. 3A-3C the scroll assembly 204 and the main bearing housing 208 are attached by a bayonet fitting 300. The bayonet fitting 300 includes a scroll retainment feature 302 and a main bearing retainment feature 304. The bayonet fitting 300 prevents axial separation between the scroll retainment feature 302 and the main bearing retainment feature 304 during the operation of the compressor 100. In some embodiments, the bayonet fitting 300 comprises a plurality of circumferentially-extending slots formed on a main bearing retainment feature that extends radially from a radial outer surface of the main bearing housing 208, each slot configured to receive a corresponding flange on the non-orbiting scroll 228.

[0037] A main bearing alignment hole 314 extends from a top surface of the main bearing housing 208 and terminates within the main bearing housing 208. With the bayonet fitting 300 engaged, an alignment pin 310 extends through the scroll alignment hole 312 and into the main bearing alignment hole 314 to maintain angular alignment between the scroll assembly 204 and the main bearing housing 208 and to maintain the axial connection between the plurality of flanges and the plurality of slots, thereby preventing unintended disengagement of the bayonet connection.

[0038] The scroll retainment feature 302 includes at least one radially projecting flange 306 configured to engage a corresponding slot 308 formed in the main bearing retainment feature 304. The main bearing retainment feature 304 is seated on and engaged with the annular axial ledge of the compressor shell 104. To engage the bayonet fitting 300, the scroll retainment feature 302 is axially positioned to align with the main bearing retainment feature 304, as shown in FIG. 3A. The scroll assembly 204 is rotated to engage the flange 306 with the corresponding slot 308 of the main bearing retainment feature 304, as shown in the embodiment illustrated in FIG. 3B. The bayonet fitting 300 is secured by an alignment pin 310 to maintain the axial connection between the scroll assembly 204 and the main bearing housing 208 and prevent unintended disengagement. As shown in the embodiment illustrated in 3C, the alignment pin 310 is inserted through a scroll alignment hole 312 formed on the scroll assembly 204 and a corresponding main bearing housing alignment hole 314 formed on the main bearing housing 208. The scroll alignment hole 312 and the main bearing housing alignment hole 314 align when the bayonet fitting 300 is engaged to angularly align the scroll assembly 204 and the main bearing housing 208. For example, the main bearing alignment hole 314 is formed on the top surface of the main bearing 208. The alignment pin 310 prevents rotational movement between the scroll assembly 204 and the main bearing housing 208 to maintain the axial connection of the bayonet fitting 300 to prevent disengagement. In some embodiments, a portion of the internal feature 107 and a portion of the main bearing retainment feature 304 cooperatively define a vent that facilitates working-fluid flow from the scroll assembly 204 toward the end cap 106.

[0039] As shown in the embodiment illustrated in FIG. 3C, the main bearing retainment feature 304 and the scroll retainment feature 302 are secured between the internal feature 107 and the compressor shell 104. The main bearing retainment feature 304 extends radially from the main bearing housing 208 and is positioned on the shell 104. The scroll retainment feature 302 extends radially from the scroll assembly 204 and supports the internal feature 107 of the end cap 106. The end cap 106 is attached to the shell 104 by a weld 111 to secure scroll assembly 204 and the main bearing housing 208 between the internal feature 107 and the compressor shell 104. Accordingly, the cooperation of the internal feature 107 and the shell 104 axially constrains the scroll assembly 204 and the main bearing housing 208 between the internal feature 107 and the axial ledge of the shell 104, and inhibits axial movement of the non-orbiting scroll 228 within the compressor 100. The applied clamping force is retained by the attachment of the end cap 106.

[0040] The attachment between the scroll assembly 204 and the main bearing housing 208 further maintains the relative axial alignment within the compressor housing 102. For example, the attachment between the scroll assembly 204 and the main bearing housing 208 including one or more internal features 107 formed on the interior surface of the end cap 106, which interior surface defines a radial inner surface of the end cap 106. The attachment between the shell 104 and the end cap 106 applies a clamping force on the at least one compressor component. For example, the attachment between the end cap 106 and the shell 104 maintains a preload and the radial alignment of the at least one compressor component positioned between the internal feature 107 of the end cap 106 and the shell 104. The preload between the end cap 106 and the shell 104 primarily serves to seat the at least one compressor component against the compressor housing 102. Alignment of the at least one compressor component with the compressor 100 results from the cooperation of the internal feature 107 and the shell 104. In the example embodiment, the internal features 107 include four machine pads on the radial inner surface of the end cap 106. The weld 111 secures the attachment between the end cap 106 and the shell 104 to maintain the position and axial alignment of the at least one compressor component.

[0041] FIGS. 4A-4C illustrate an embodiment of the example compressor 100 including an internal feature 107 formed on the interior surface of the end cap 106. FIG. 4A illustrates an embodiment of the end cap 106 including one or more internal features 107 formed on the internal surface of the end cap 106. For example, the internal features 107 include four machine pads on the interior surface of the end cap 106. In the embodiment shown in FIGS. 4A-4C, the internal feature 107 is formed with additional material on the internal portion of the end cap 106. As shown in FIG. 4B, the internal feature 107 includes additional material that defines a machine pad with a smaller internal diameter than the interior surface of the end cap 106. The bottom of the machine pad may be formed as a ledge that contacts the compressor component. The ledge extends inwards along the length of the internal diameter of the internal feature 107. As shown in FIG. 4B, the bottom of the machine pad and the upper axial ledge of the compressor shell 104 orient each of the compressor components within the compressor housing 102. The main bearing housing 208 is clamped between the bottom of the machine pad and the upper end of the compressor shell 104.

[0042] FIG. 4C illustrates a top cutaway view of the compressor components within the compressor 100 depicting the one or more vents 940 within the compressor housing between the end cap 106 and the compressor shell 104. One or more vents 940 are defined cooperatively by the internal feature(s) 107 of the end cap 106 and portions of the at least one compressor component, including the main bearing housing 208 and / or the non-orbiting scroll 228. The vents 940 may be positioned on the portions of the end cap 106 between the internal features 107. The vents 940 facilitate the gas flow in high side compressors, such as compressor 100.

[0043] FIGS. 5A-5C illustrate an embodiment of the example compressor 100 including internal features 107 formed by stamping the end cap 106. FIG. 5A illustrates an embodiment of the end cap 106 including one or more internal features 107 formed by stamping the end cap 106. For example, the end cap 106 may be stamped to decrease the internal diameter of a portion of the end cap 106. In some embodiments, a portion of the end cap 106 is first stamped to form a shoulder and is subsequently machined to form the internal feature 107 as one or more machine pads. In one example, four machine pads are formed on the interior portion of the end cap 106. The interior surface of the shoulder defines the internal feature 107 on the interior surface of the end cap 106. The interior surface of each internal feature may include a ledge. The ledge is positioned to interface with the one or more compressor components. As shown in FIG. 5B, the ledge of the internal feature 107 seats the scroll assembly 204 into engagement with the top surface of the main bearing housing 208 and positioned on the upper axial ledge of the compressor shell 104. In some embodiments, the scroll assembly 204 and the main bearing housing 208 may be attached by one or more bolts 901. In other embodiments, the scroll assembly 204 and the main bearing housing 208 are attached by the bayonet fitting 300. The clamping force between the internal feature 107 and the compressor shell 104 transfers through the scroll assembly 204 and the main bearing housing 208 to orient the at least one compressor component. FIG. 5C illustrates a top cutaway view of the compressor components within the compressor 100. The one or more vents 210 extend beyond the top of the scroll assembly 204 to provide fluid communication between the scroll assembly 204 and the end cap 106.

[0044] FIG. 6A illustrates an embodiment of the example compressor 100 including an internal feature 107 that is a groove on the interior surface of the end cap 106. The groove may be continuous or discontinuous along the internal surface of the end cap 106. The internal feature 107 extends along an axial length on the interior surface of the end cap 106. As illustrated in FIG. 6B, the internal feature 107 is machined to have a larger internal diameter than the interior surface of the end cap 106. For example, the interior surface includes an undercut extending from the bottom of the end cap 106 to the location where the at least one compressor component contacts the internal feature 107. The change in diameter between the internal feature 107 and the interior surface of the compressor 100 forms a ledge that contacts the at least one compressor component. FIG. 6C illustrates a top cutaway view of the at least one compressor component within the compressor 100. One or more vents 210 are formed between the interior surface of the end cap 106 and the at least one compressor component.

[0045] A method of assembling a compressor includes positioning a main bearing housing into engagement with an annular axial ledge at an upper end of a compressor shell, and positioning a scroll assembly into engagement with a top surface of the main bearing housing, the scroll assembly including an orbiting scroll and a non-orbiting scroll. The method further includes aligning an internal feature on an end cap with at least one of the main bearing housing or the non-orbiting scroll and engaging the internal feature with that component. An axial clamping force is then applied so that at least one of the main bearing housing or the non-orbiting scroll is compressed between the internal feature of the end cap and the annular axial ledge of the compressor shell, thereby axially retaining the main bearing housing and the non-orbiting scroll. While the components are compressed, the end cap is attached to the upper end of the compressor shell such that the attachment retains the compressive force after the external force is removed, for example by a weld. In some embodiments, forming the internal feature on the end cap includes stamping a portion of the end cap and machining the stamped portion to form the internal feature, for example as four machine pads on an interior portion of the end cap. In other embodiments, forming the internal feature includes machining a continuous groove along an interior surface of the end cap. In some embodiments, attaching the scroll assembly to the upper surface of the main bearing housing includes using one or more fasteners.

[0046] Another method of assembling a compressor includes positioning a main bearing housing into engagement with an annular axial ledge at an upper end of a compressor shell, engaging a slot on the main bearing housing with a flange on a scroll assembly to connect the main bearing housing to the scroll assembly, aligning a main bearing alignment hole on the main bearing housing with a scroll alignment hole on the scroll assembly, and inserting an alignment pin through the scroll alignment hole and into the main bearing alignment hole to maintain angular alignment between the main bearing housing and the scroll assembly and to maintain their axial connection. The method further includes aligning an internal feature on an end cap with the scroll assembly, compressing the main bearing housing and the scroll assembly between the internal feature formed on the end cap and the annular axial ledge of the compressor shell, and attaching the end cap to the upper end of the compressor shell while the main bearing housing and the scroll assembly are compressed so that the attachment retains a compressive force against the main bearing housing and the scroll assembly. In some embodiments, the connected main bearing housing and scroll assembly are positioned on the axial ledge of the compressor shell so that the main bearing housing contacts the upper end of the compressor shell, and the scroll assembly is attached to the main bearing housing with a bayonet fitting. In some embodiments, positioning the end cap on the compressor shell includes contacting an upper surface of the scroll assembly and radially contacting the compressor shell.

[0047] As used herein, the terms “about,”“substantially,”“essentially” and “approximately” when used in conjunction with ranges of dimensions, concentrations, temperatures or other physical or chemical properties or characteristics is meant to cover variations that may exist in the upper and / or lower limits of the ranges of the properties or characteristics, including, for example, variations resulting from rounding, measurement methodology or other statistical variation.

[0048] When introducing elements of the present disclosure or the embodiment(s) thereof, the articles "a", "an", "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," "containing," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements. The use of terms indicating a particular orientation (e.g., "top," "bottom," "side," etc.) is for convenience of description and does not require any particular orientation of the item described.

[0049] As various changes could be made in the above constructions and methods without departing from the scope of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawing(s) shall be interpreted as illustrative and not in a limiting sense.

Claims

1. A compressor comprising:a compressor shell having an upper end and a lower end, the compressor shell defining an internal volume, wherein the upper end comprises an annular axial ledge;a main bearing housing positioned in engagement with the axial ledge;a scroll assembly positioned in engagement with a top surface of the main bearing housing, the scroll assembly comprising an orbiting scroll and a non-orbiting scroll; andan end cap attached to the compressor shell at the upper end thereof, the end cap comprising an internal feature to seat the scroll assembly into engagement with the main bearing housing, wherein at least one of the non-orbiting scroll and the main bearing housing is compressed between the axial ledge of the compressor shell and the internal feature of the end cap when the end cap is attached to the compressor shell.

2. The compressor of claim 1, wherein the end cap is attached to the compressor shell by one or more welds.

3. The compressor of claim 1, wherein the internal feature of the end cap comprises one or more machine pads formed on an interior surface of the end cap, and wherein the one or more machine pads engage at least one of the main bearing housing or the non-orbiting scroll.

4. The compressor of claim 3, wherein the internal feature comprises four machine pads.

5. The compressor of claim 3, wherein each of the one or more machine pads is a machined portion of a stamped feature on the end cap.

6. The compressor of claim 1, wherein the internal feature extends from a radial inner surface of the end cap.

7. The compressor of claim 1, wherein the internal feature includes a ledge that axially seats at least one of the main bearing housing and the non-orbiting scroll against the axial ledge of the compressor shell.

8. The compressor of claim 1, wherein the main bearing housing and the scroll assembly are axially constrained by the end cap and the compressor shell.

9. The compressor of claim 1, wherein the internal feature of the end cap aligns a scroll suction inlet and an end cap suction inlet.

10. The compressor of claim 1, wherein the internal feature of the end cap and the main bearing housing cooperatively form a vent to facilitate flow of a working fluid from the scroll assembly to the end cap.

11. The compressor of claim 1, wherein the non-orbiting scroll is attached to the main bearing housing by one or more fasteners.

12. The compressor of claim 1, wherein the main bearing housing and a secondary bearing are aligned by the engagement between the internal feature of the end cap and the compressor shell when at least one of the non-orbiting scroll and the main bearing housing is compressed between the axial ledge of the compressor shell and the internal feature of the end cap.

13. The compressor of claim 1, the main bearing housing is seated into the axial ledge of the compressor shell when the end cap is attached to the compressor shell.

14. A method of assembling a compressor, the method comprising:positioning a main bearing housing into engagement with an annular axial ledge of an upper end of a compressor shell;positioning a scroll assembly into engagement with a top surface of the main bearing housing, wherein the scroll assembly comprises an orbiting scroll and a non-orbiting scroll;engaging at least one of the main bearing housing and the non-orbiting scroll with an internal feature of an end cap;compressing at least one of the main bearing housing and the non-orbiting scroll between the internal feature of the end cap and the axial ledge of the compressor shell; andattaching the end cap to the upper end of the compressor shell while the at least one of the main bearing housing and the non-orbiting scroll is compressed between the internal feature of the end cap and the axial ledge, such that the attachment of the end cap to the compressor shell retains a compressive force against the at least one of the main bearing housing and the non-orbiting scroll.

15. The method of claim 14, wherein compressing at least one of the main bearing housing and the non-orbiting scroll further comprises applying a clamping force between the upper end of the compressor shell and the internal feature of the end cap.

16. The method of claim 15, wherein applying the clamping force axially retains the main bearing housing and the non-orbiting scroll between the internal feature of the end cap and the axial ledge of the compressor shell.

17. The method of claim 14, further comprising forming the internal feature on the end cap by:stamping a portion of the end cap; andmachining the stamped portion of the end cap to form the internal feature.

18. The method of claim 17, wherein forming the internal feature comprises forming four machine pads on an interior portion of the end cap.

19. The method of claim 14, further comprising forming the internal feature on the end cap by machining a continuous groove along an internal surface of the end cap.

20. The method of claim 14, further comprising attaching the scroll assembly to an upper surface of the main bearing housing, wherein attaching the scroll assembly to the main bearing housing comprises using one or more fasteners.

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