Two-Stage Air Compressor Internal Duct Base Block
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Solution Overview
Problem
Existing two-stage air compressors face challenges in compact design, inadequate lubricant oil refrigeration, temperature differentials between compression stages, and inefficient heat distribution, often requiring external ducts and additional components.
Innovation Solution
A two-stage air compressor design with V-cylinder blocks integrated on a base block, featuring internal compressed air ducts that connect the stages directly, eliminating external ducts and enhancing lubricant oil refrigeration through direct contact with the crankcase, while using ventilation chambers for efficient heat transfer and refrigeration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If external air ducts are used to connect the two compression stages, then the compressor can be assembled with separate components, but the device complexity increases and the compaction degree is reduced
Solution Approach 1:
The patent merges the air duct function into the base block by creating internal passages within the base block structure. This integration eliminates the need for separate external ducts and reduces the total number of component parts while maintaining the ability to connect the two compression stages effectively.
Solution Approach 2:
The base block is designed to serve multiple functions: it provides structural support, houses the crankshaft, and contains internal passages for air ducting. This multi-functionality reduces the need for additional dedicated components and improves overall compaction.
2Ease of manufacture
If external air ducts are used to connect the two compression stages, then the components can be manufactured separately, but the compaction degree is reduced
Solution Approach 1:
The air duct passages are merged into the base block structure, eliminating external ducts and reducing the overall compressor volume. The internal passages are formed directly within the base block material, creating a more compact design.
Solution Approach 2:
The air duct passages are nested within the base block structure, with the passages contained inside the solid material of the base block. This nesting approach minimizes the external dimensions of the compressor while maintaining functional air flow paths.
3Reliability
If the compressor uses lubricant oil, then the lubrication function is provided, but the refrigeration degree of the lubricant oil is limited
Solution Approach 1:
The base block acts as an intermediary heat transfer medium between the compressed air and the lubricant oil. The internal passages allow compressed air to flow through the base block, transferring heat to the lubricant oil in the crankcase, thereby providing refrigeration to the lubricant oil while maintaining lubrication function.
4Device complexity
If the cylinder blocks are limited in refrigeration degree, then the structure is simplified, but the air temperature differential between stages increases
Solution Approach 1:
The base block with internal passages serves as an intermediary cooling system that pre-cools the compressed air from the first stage before it enters the second stage cylinder. This intermediary cooling reduces the temperature differential between stages without requiring complex cylinder block structures.
5Productivity
If external ducts are used, then the air flow path is established, but the homogeneous distribution of heat through the compressor body is difficult to obtain
Solution Approach 1:
The air flow path is merged with the base block structure, allowing the compressed air to flow through internal passages that are distributed throughout the base block. This distribution of flow paths through the base block promotes homogeneous heat distribution across the compressor body.
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 achieves a compact, efficient compressor with reduced external dimensions and improved heat distribution, maintaining energetic efficiency and adequate lubricant oil refrigeration, thereby enhancing the operational performance of the compressor.
Implementation Method 1
maintaining energetic efficiency and adequate lubricant oil refrigeration
Implementation Method 2
using ventilation chambers for efficient heat transfer and refrigeration
Implementation Method 3
two stage air compressor design with V-cylinder blocks integrated on a base block
Data Source
AI summary
The compressor presents a first and a second cylinder block arranged in V and defining, respectively, a first and a second cylinder, and being affixed on a base block, each cylinder housing a respective piston driven by a crankshaft which is housed and supported on the base block. The first and the second cylinder block incorporate, respectively, a first and a second duct portion having an outer end open to the interior of the cylinder head of the respective cylinder, and an inner end open to a third duct portion incorporated to the base block, said duct portions forming a compressed air duct connecting the first cylinder to the second cylinder.