Brushless Claw Compressor for Diesel Filter Regeneration
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Solution Overview
Problem
Existing devices for applying compressed air to diesel soot particle filters to overcome filter resistance during regeneration fail to meet requirements of wide control range, high control quality, long service life, robustness, efficiency, and operational versatility across varying conditions, including temperature and tilt angles.
Innovation Solution
A two-shaft, dry-running rotary compressor with a claw design, featuring overhung pistons and a brushless synchronous motor, is used to generate compressed air, allowing for efficient and controlled air flow over a wide range, with a compact design and adaptable to varying ambient temperatures and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional compressed air generating device is used, then the device structure is simple, but it cannot achieve wide control range (300-6000 rpm) and high control quality
Solution Approach 1:
The patent employs a brushless synchronous motor with permanent magnets that enables dynamic speed control from 300 to 6000 rpm through electronic commutation. The motor's rotor magnetic field synchronizes with the stator's rotating magnetic field, allowing precise speed adjustment without mechanical commutators, thus achieving wide adaptability while maintaining structural integrity.
Solution Approach 2:
The invention replaces traditional mechanical compression systems with an electrically-driven claw compressor. The brushless motor substitutes mechanical linkages and commutators with electromagnetic fields, enabling electronic control of compression ratios and air flow while reducing mechanical complexity and improving reliability across the 300-6000 rpm range.
2Reliability
If the device is designed for high efficiency and long service life, then the control accuracy is improved, but the installation space and cost increase
Solution Approach 1:
The patent integrates the brushless synchronous motor directly into the claw compressor assembly, with the motor rotor forming the compressor shaft. The permanent magnets are embedded in the rotor, and the stator windings are positioned concentrically around the rotor. This nested configuration eliminates separate drive mechanisms and reduces overall installation space while maintaining high efficiency and long service life through direct coupling.
Solution Approach 2:
The invention merges the motor drive system with the compression mechanism into a single integrated unit. The brushless motor's rotor shaft directly drives the compressor claws, combining power generation and compression functions in one compact assembly. This integration reduces installation space, minimizes mechanical linkages for improved reliability, and lowers overall system cost.
3Adaptability or versatility
If the device must operate over a wide temperature range (-40°C to 100°C), then the operational versatility is improved, but the control accuracy and efficiency decrease
Solution Approach 1:
The patent employs a brushless synchronous motor with permanent magnets that maintains synchronous operation across the -40°C to 100°C temperature range. The electronic control system adjusts the stator firing angles and current magnitudes to compensate for temperature-induced changes in magnetic field strength and motor impedance, preserving control accuracy while adapting to extreme thermal conditions.
4Strength
If the device is designed to be vibration and shock resistant with tilt capability, then the robustness is improved, but the device complexity and installation space increase
Solution Approach 1:
The patent segments the compressor into modular components: the brushless motor assembly, the claw compressor housing, and the mounting flange. Each segment is independently optimized for vibration resistance, with the motor secured to the housing via vibration-dampening mounts and the entire assembly designed to accommodate 45° tilt angles. This segmentation allows robustness without excessive structural 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 solution enables reliable and efficient regeneration of diesel soot particle filters across diverse operating conditions, ensuring consistent performance and longevity while meeting stringent requirements for control accuracy and resilience.
Implementation Method 1
brushless, permanently excited synchronous motor
Implementation Method 2
two-shaft, dry-running rotary compressor with the claw design... generate compressed air
Data Source
Figure 1
Figure 2
AI summary
The device has two claw pistons (10, 11) shifting against each other in a cylinder housing (1). An air outlet opening (13) is provided with a cross section for obtaining a small geometrical compression ratio of a small internal compression. The claw pistons and/or shafts (14, 15) are provided with a fixed bearing (16) and a movable bearing (17). An axial distance between the bearings is smaller such that a claw compressor is inclined up to 45 degrees without the bearings with oil. The claw compressor exhibits a brushless permanent-moved synchronous motor (18) as a drive.