Air Compressor Pulley-Flywheel Transmission for High-Load Torque
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Solution Overview
Problem
Traditional two-stage compressors face high load conditions that increase motor torque requirements, leading to increased costs due to the need for more powerful motors.
Innovation Solution
A two-cylinder piston compressor design with a pulley and flywheel configuration, where the pulley diameter is smaller than the flywheel, and a gear ratio of 27:104, along with a drive belt and crankshaft mechanism, allows for efficient torque transmission and reduced rotational speed to enhance torque without increasing motor cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the motor torque is increased to meet high load conditions, then the torque output is improved, but the motor cost and whole machine cost are greatly increased
Solution Approach 1:
The patent introduces a pulley-flywheel transmission mechanism as an intermediary between the motor and the compressor crankshaft. The pulley (with smaller diameter) connected to the motor shaft and the flywheel (with larger diameter) connected to the crankshaft form a torque multiplication system. This intermediary transmission system allows the motor to operate at lower torque while still delivering high torque to the compressor during high load conditions, thereby resolving the contradiction between torque output and motor cost.
Solution Approach 2:
The patent changes the rotational speed parameter of the motor through the pulley-flywheel transmission system. By using a smaller pulley diameter on the motor shaft and a larger flywheel diameter on the crankshaft, the system reduces the motor's rotational speed and multiplies the torque output. This parameter transformation allows the motor to operate in a more efficient range while providing the necessary high torque for compression, thus avoiding the need for an expensive high-torque motor.
2Force
If the pulley diameter is made smaller than the flywheel diameter with a ratio of 27:104, then the torque multiplication is improved, but the device complexity is increased
Solution Approach 1:
The flywheel in this patent serves multiple functions simultaneously: it acts as the larger diameter pulley for torque multiplication, it stores rotational energy to smooth out the cyclic loading of the compressor, and it provides the mounting interface for the crankshaft. By making the flywheel serve these multiple purposes, the patent avoids adding separate components for each function, thereby limiting the increase in device complexity while achieving torque multiplication.
Solution Approach 2:
The patent merges the torque transmission function with the energy storage function by combining the flywheel and the pulley into a single integrated component. The large-diameter flywheel that provides torque multiplication is the same component that stores rotational energy and smooths the compressor's cyclic operation. This merging of functions achieves the desired torque output without proportionally increasing the number of parts or system complexity.
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
The design achieves high-pressure air output with increased torque, improving efficiency and reducing the need for more powerful motors under high load conditions.
Implementation Method 1
The drive belt transmits torque from the output shaft to the flywheel so as to rotate the flywheel about the axis upon rotation of the output shaft
Implementation Method 2
The diameter of the pulley is smaller than that of the flywheel... The pulley transmits torque from the output shaft to the flywheel so as to rotate the flywheel
Implementation Method 3
The crankshaft interconnects the flywheel with the piston so as to reciprocate the piston in the cylinder upon rotation of the flywheel
Data Source
AI summary
The patent application discloses an air compressor. The air compressor comprises a pair of pistons, a motor, a flywheel, a pulley, a crankshaft. Each piston is reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder. The motor comprise an output shaft. The pulley transmits torque from said output shaft to said flywheel so as to rotate said flywheel about said axis upon rotation of said output shaft. The crankshaft interconnects said flywheel with said piston so as to reciprocate said piston in said cylinder upon rotation of said flywheel. The diameter of the pulley is smaller than that of said flywheel.