Air Compressor Transmission Mechanism for Stable Bearing Engagement
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Solution Overview
Problem
Conventional air compressors experience reduced air compressing efficiency and shortened service life due to deformation of plastic bases at high temperatures and improper engagement between the piston and bearing, leading to idle rotation and friction issues.
Innovation Solution
A transmission mechanism where the piston is rotatably connected to a torque gear with a screw bolt that engages with the bearing, ensuring the bearing remains in place and the piston moves reciprocally within the cylinder without friction, using a design with a central orifice and internal ring configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the base is made of plastic material, then the manufacturing cost is reduced and ease of manufacture is improved, but the base softens at high temperature causing deformation and reduced reliability
Solution Approach 1:
The base structure is segmented into two distinct parts: a plastic base body (30) for cost-effective manufacturing and a metal reinforcement plate (33) for thermal stability. The metal plate is positioned at the bearing support area to prevent deformation under high temperature, while the plastic base maintains ease of manufacture and cost advantages.
Solution Approach 2:
The base combines plastic and metal materials to create a composite structure that leverages the advantages of both materials. The plastic provides cost-effectiveness and ease of manufacture, while the metal reinforcement plate provides high-temperature resistance and structural stability at critical load-bearing areas.
2Device complexity
If the piston is directly connected to the bearing, then the structure is simplified, but the piston causes idle rotation and friction leading to deformation and reduced service life
Solution Approach 1:
A torque gear (57) is introduced as an intermediary component between the piston (54) and the bearing (6). The torque gear converts the reciprocating motion of the piston into rotational motion and transmits it to the bearing through proper engagement, eliminating idle rotation and friction while maintaining a relatively simple overall structure.
Solution Approach 2:
The direct mechanical connection between piston and bearing is replaced with a gear-mediated mechanical system. This substitution transforms the motion transmission mechanism to eliminate harmful idle rotation and friction, thereby extending service life while maintaining acceptable structural complexity.
3Ease of operation
If the bearing is allowed to move freely, then the operation is smoother, but the bearing gets removed from the screw bolt causing deformation and reduced air compressing efficiency
Solution Approach 1:
The bearing's movement is made dynamic and controlled through proper engagement with the torque gear and positioning by the screw bolt. The bearing can rotate smoothly during operation but is prevented from being removed or displaced axially, maintaining both operational smoothness and structural integrity.
Solution Approach 2:
The bearing's own rotational movement during operation is utilized to achieve proper engagement with the torque gear teeth. The bearing's rotation itself serves to maintain the engagement relationship, eliminating the need for additional complex retention mechanisms while preventing removal.
Data Source
AI summary
A transmission mechanism of an air compressor contains: a piston, a torque gear, a connection rod rotatably connected with the piston, a cylinder configured to accommodate the piston, wherein a central orifice of the torque gear corresponds to an internal ring of a bearing in a second positioning orifice of a base, and a screw bolt is inserted through the torque gear to screw with the central orifice from the internal ring of the bearing, such that the torque gear matingly contacts with the bearing along the screw bolt, and the bearing is not broken, thus moving the piston in the cylinder stably.