Air Compressor Bearing Support Structure for Stable Piston Motion
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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 of the piston and bearing, leading to idle rotation and torque imbalance, which affects the piston's vertical movement and bearing loading.
Innovation Solution
The air compressor design incorporates a screw bolt mechanism that securely engages the torque gear with the bearing, preventing removal and allowing the piston to move reciprocally within the cylinder while maintaining a non-frictional distance between the torque gear and the base, ensuring stable operation and reduced deformation.
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: an aluminum alloy base body (301) that provides structural support and heat resistance, and a separate plastic cover (302) that provides insulation and aesthetic functions. This segmentation allows each material to be optimized for its specific function - the aluminum base maintains reliability at high temperatures while the plastic cover can be easily manufactured and molded.
Solution Approach 2:
The base assembly uses a composite structure combining aluminum alloy and plastic materials. The aluminum alloy base body provides thermal stability and structural strength, while the plastic cover provides insulation and cost-effective manufacturing. This composite approach resolves the contradiction by leveraging the advantages of both materials without the disadvantages of either used alone.
2Productivity
If the piston moves reciprocally in the cylinder, then the air compressing function is achieved, but the piston pulls the bearing causing idle rotation and deformation
Solution Approach 1:
A dedicated bearing support structure (303) is introduced as an intermediary element between the piston assembly and the base. This support structure provides a stable mounting position for the bearing (304), preventing the bearing from being pulled or displaced during piston reciprocation. The intermediary structure absorbs and distributes the mechanical loads, preventing direct transmission of harmful forces to the bearing.
Solution Approach 2:
The bearing support structure is pre-configured with proper positioning features and mounting mechanisms that ensure the bearing is correctly positioned before operation begins. This preliminary arrangement prevents idle rotation and misalignment during operation, ensuring the bearing maintains its proper orientation and function throughout the air compressing cycle.
3Stability of the object's composition
If the post is locked in the bearing by screw element, then the bearing position is fixed, but the receiving orifice is fractioned and broken by the driven gear and post
Solution Approach 1:
The bearing support structure extracts and isolates the bearing mounting function from the main base body. By providing a dedicated support structure (303) with its own integrated bearing mounting features, the design eliminates the need for the post (162) to pass through and lock into the bearing from the base, thereby preventing the receiving orifice from being fractioned by the driven gear (152) and post.
Solution Approach 2:
The bearing support structure provides a new spatial arrangement for bearing mounting, positioning the bearing in a different location and orientation relative to the driven gear and post. This dimensional repositioning allows the bearing to be securely mounted without interfering with the rotational path of the driven gear, eliminating the risk of the receiving orifice being broken.
4Reliability
If the base covers the bearing with spacing, then the bearing is protected, but the torque cannot be decreased and bearing loading increases
Solution Approach 1:
The bearing support structure acts as an intermediary that provides both protection and mechanical advantage. It shields the bearing from direct exposure while incorporating lever arms and force distribution features that reduce the torque transmitted to the bearing. The support structure's geometry is designed to optimize the force distribution, decreasing the effective loading on the bearing while maintaining adequate protection.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An air compressor (2) contains: a torque gear (57) on which a central orifice (510) and a connection rod (53) are arranged. The central orifice (510) has screw threads defined thereon and corresponds to one of multiple positioning orifices of a base (3), the one positioning orifice is configured to accommodate a bearing (6), and a screw bolt (52) is inserted through the bearing (6) in the base (3) so as to screw with the central orifice (510) via the torque gear (57). The connection rod (53) of the torque gear (57) is rotatably connected with a piston (54) so that the piston (54) moves in a cylinder (4) to produce compressed air, the torque gear (57) matingly contacts with the bearing (6) along the screw bolt (52), and the bearing (6) is not broken in the one positioning orifice, thus moving the piston (54) in the cylinder (4) reciprocately.