Air Compressor Flow Channel Layout for Axial Force Relief
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Solution Overview
Problem
Existing air compressors for fuel cell engines face challenges in managing axial force, leading to increased power consumption, complexity, and reduced efficiency, due to the need for oil-free lubrication and large thrust bearings, which can result in bearing wear and increased costs.
Innovation Solution
The air compressor design incorporates a controlling flow channel that redirects high-pressure gas from the wheel-back side to the gas-intake side of the pressure wheel, converting pressure energy into kinetic energy to reduce axial force, and features a simple structure with a cooling flow channel to enhance efficiency and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a balance board is installed to offset axial force, then the axial force is reduced, but the device complexity and power consumption increase
Solution Approach 1:
The patent extracts the axial force balancing function from a separate balance board component and integrates it into the thrust bearing's loading region. By increasing the area of the loading region of the thrust bearing, the axial force is directly counteracted without requiring additional balance board components, thereby reducing device complexity while maintaining force balance
Solution Approach 2:
The patent merges the axial force balancing function with the thrust bearing by expanding its loading region. This combines what would traditionally be separate functions (thrust bearing for radial support and balance board for axial force) into a single integrated component, reducing overall device complexity
2Force
If a grease-lubricated ball bearing is used to tolerate large axial force, then the axial force capacity is improved, but the reliability decreases due to grease leakage risk
Solution Approach 1:
The patent replaces the grease-lubricated ball bearing mechanical system with an air bearing system. The air bearing uses a gas film (typically air) for lubrication instead of grease, eliminating the risk of grease leakage that would pollute the fuel cell system. The air bearing maintains reliability while providing sufficient axial force capacity through its design
3Force
If the area of the loading region of the thrust bearing is increased to increase loading capacity, then the axial force capacity is improved, but the power consumption and rotational inertia increase
Solution Approach 1:
The patent optimizes the parameters of the thrust bearing's loading region area to achieve the necessary loading capacity while minimizing power consumption and rotational inertia. By carefully selecting and adjusting the loading region area parameter, the design balances axial force capacity with energy efficiency, avoiding excessive power consumption and rotational inertia that would result from simply maximizing the area
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively reduces axial force, prolongs the service life of the air compressor, improves efficiency, and enhances the field surging characteristic of the air compressor, while maintaining a low cost and simple structure.
Implementation Method 1
the high-pressure gas on the wheel-back side of the pressure wheel is guided to the gas-intake side of the pressure wheel, to convert a part of the pressure energy of the gas into kinetic energy, thereby effectively reducing the pressure on the wheel-back side of the pressure wheel, and reducing the axial force
Data Source
AI summary
The air compressor includes: a housing assembly, wherein the housing assembly has a first installation cavity, a second installation cavity and a rotation-shaft cooperating cavity, and the first installation cavity has a gas inlet and a gas outlet; a rotor shaft, wherein the rotor shaft is rotatably fitted inside the rotation-shaft cooperating cavity, and extends into the first installation cavity and the second installation cavity; a pressure wheel, wherein the pressure wheel is nested to the rotor shaft and is located inside the first installation cavity, and the housing assembly is provided with a controlling flow channel for communicating the gas-intake side and the wheel-back side of the pressure wheel; and a driving assembly, wherein the driving assembly is nested to the rotor shaft and is located inside the second installation cavity.