Variable Capacity Compressor Control Valve With Segmented Orifice Holes
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Solution Overview
Problem
Variable capacity swash plate compressors experience inefficiency due to unnecessary loss of control gas caused by excessive refrigerant leakage through fixed orifice holes, which are large in size due to machining limitations.
Innovation Solution
A control valve system that adjusts the angle of the swash plate by selectively opening and closing multiple orifice holes to minimize or maximize piston movement distance, eliminating the need for a fixed orifice hole in the valve assembly and instead forming it in the control valve or passage connecting the control valve and crank chamber, allowing for variable sizing based on compressor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed orifice hole is formed in the valve plate to enable variable operation, then the compressor can be variably operated by discharging refrigerant gas from the crank chamber to the suction chamber, but the orifice hole becomes large in size due to limited machinability, causing excessive refrigerant leakage into the suction chamber
Solution Approach 1:
The single fixed orifice hole is segmented into multiple orifice holes (first orifice hole, second orifice hole, third orifice hole) with different sizes. This allows selective opening and closing of specific orifices based on operational requirements, enabling variable operation while controlling refrigerant leakage through appropriate orifice selection rather than relying on a single large fixed orifice
Solution Approach 2:
The system transitions from a static fixed orifice hole to a dynamic configuration where multiple orifice holes can be selectively opened or closed using switching means (first switching means and second switching means). This dynamic adjustment allows the compressor to vary its operation by controlling which orifices are active, achieving adaptability without excessive leakage
2Adaptability or versatility
If a large fixed orifice hole is used in the valve plate, then variable operation is enabled, but continuous introduction of high-pressure refrigerant into the crank chamber occurs to supplement leakage, resulting in inefficient stroke
Solution Approach 1:
By segmenting the orifice system into multiple selectively controllable holes, the invention prevents the continuous unnecessary introduction of high-pressure refrigerant that occurs with a single large fixed orifice. The switching means can close specific orifices to stop unwanted refrigerant flow, eliminating inefficient strokes while maintaining variable operation capability
Solution Approach 2:
The system incorporates control mechanisms that monitor and respond to refrigerant flow conditions. The switching means adjusts which orifices are open based on operational requirements, providing feedback control that prevents continuous inefficient stroke by stopping the introduction of high-pressure refrigerant when not needed
3Loss of substance
If the orifice hole size is reduced to minimize refrigerant leakage, then compressor efficiency improves, but the machinability limitations of the valve plate make it difficult to form small precision orifice holes
Solution Approach 1:
Instead of attempting to machine a single small precision orifice hole in the valve plate, the invention segments the orifice function across multiple holes of different sizes. This allows each orifice to be sized appropriately for its specific function while remaining manufacturable, avoiding the difficulty of machining very small precision holes in the valve plate
Solution Approach 2:
The invention changes the parameter of orifice size from a single fixed value to multiple discrete values (different orifice holes with different sizes). This allows optimization of each orifice size for its specific purpose while maintaining ease of manufacture, as each orifice can be sized within manufacturable limits rather than requiring a single small precision hole
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 solution reduces control gas loss by enabling the control valve to machined to a smaller size than traditional orifice holes, improving compressor efficiency by minimizing unnecessary gas discharge and optimizing refrigerant flow.
Implementation Method 1
a first passage allowing the first hole (712) to communicate with the second hole (714) and a second passage allowing the second hole (714) to communicate with the third hole (716) in the valve housing (710), a first switching means for opening and closing the first passage, and a second switching means for opening and closing the second passage
Data Source
AI summary
A control valve and a variable capacity compressor having a control valve or a passage connecting the control valve and a crank chamber. A fixed orifice hole is variable which is possible by selectively opening and closing a plurality of holes depending on the operation of the compressor.