Compressor Balancing via Motor-Drive Imbalance Compensation
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Solution Overview
Problem
Existing diaphragm pumps in compressors generate vibrations due to dynamic imbalance, which are not effectively mitigated by traditional balancing methods, leading to increased weight, housing size, and cost when using springs to reduce these vibrations, especially in applications like vehicle seats.
Innovation Solution
A compressor design where the motor and drive unit are configured with specific imbalances, generated by milled grooves or weights, to achieve static and dynamic balance, eliminating the need for additional suspensions and reducing vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional balancing methods are used for the motor and drive unit separately, then each component can be balanced individually, but the overall compressor generates dynamic imbalance and vibrations
Solution Approach 1:
The patent combines the balancing considerations of the motor and drive unit into a single integrated balancing process. Instead of balancing each component separately, the invention balances the complete assembly (motor + drive unit + coupling) as one system, allowing the imbalances to compensate for each other and achieve overall static and dynamic balance.
Solution Approach 2:
The patent introduces counterweights (balancing masses) strategically positioned on the motor shaft or drive unit components. These counterweights are calculated to offset the combined imbalance of the motor and drive unit, creating a statically and dynamically balanced system that eliminates vibrations during operation.
2Object-generated harmful factors
If springs are added to reduce vibrations, then pump vibrations can be reduced, but the weight, housing size, and cost increase
Solution Approach 1:
The patent converts the harmful effect of imbalances into a beneficial solution by deliberately designing controlled imbalances in the motor and drive unit that compensate for each other. Instead of adding vibration-reducing components like springs, the invention uses calculated imbalance compensation to eliminate vibrations, thereby avoiding the penalty of increased weight, size, and cost.
3Object-generated harmful factors
If springs are added to reduce vibrations, then pump vibrations can be reduced, but the housing size increases
Solution Approach 1:
The patent eliminates the need for additional vibration-reducing components by implementing imbalance compensation within the existing motor and drive unit assembly. This approach avoids the need for enlarged housing to accommodate springs or other vibration isolation components, maintaining a compact design.
4Object-generated harmful factors
If springs are added to reduce vibrations, then pump vibrations can be reduced, but the cost increases
Solution Approach 1:
The patent avoids the additional cost of springs and vibration isolation components by implementing a balancing solution that uses the existing motor and drive unit components. The balancing weights and adjustment mechanisms are integrated into the manufacturing process, eliminating the need for expensive vibration reduction add-ons.
Data Source
AI summary
A compressor includes a housing with a first and second area; a motor incorporated into the first area and a diaphragm pump unit incorporated into the second area; the diaphragm pump unit including at least one diaphragm body and a drive unit; an armature of the motor being operatively connected to the drive unit through a drive axle; and the diaphragm pump unit having a first imbalance U1 and the motor having a second imbalance U2, wherein the size of the second imbalance U2 is designed in such a way that the sum of the first imbalance U1 and the second imbalance U2 in the system consisting of the motor and the drive unit coupled with the drive axle statically and dynamically results in zero. A related method for manufacturing the compressor is also disclosed.