Small Air Compressor Cylinder Coupling Structure
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Solution Overview
Problem
Conventional small reciprocating piston type compressors face issues with large size, high weight, and manufacturing costs due to integral cylinder and block design, leading to deformation, noise, and reduced durability, along with vibration and friction problems.
Innovation Solution
A small air compressor design where the cylinder is manufactured separately from the block, with a supporting end on the cylinder to reduce deformation and precise coupling, and bushings and journal bearings are used to support the crankshaft for reduced vibration and oil-free operation, while sealing rings at both ends of the piston improve wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the cylinder is manufactured separately from the block, then the size and weight of the compressor are reduced, but the coupling precision and structural stability may deteriorate
Solution Approach 1:
The compressor is divided into separate modular components: the block, the cylinder, and the crankcase are manufactured independently and then assembled together. This segmentation allows each component to be optimized separately for weight reduction while maintaining manufacturing precision through standardized coupling interfaces and precision bearing supports.
2Ease of manufacture
If the cylinder is manufactured separately from the block, then manufacturing costs and material usage are reduced, but cylinder deformation may increase
Solution Approach 1:
Precision bearings are introduced as intermediary components between the crankshaft and the cylinder-block assembly. These bearings provide stable support points that prevent cylinder deformation while allowing the cylinder to be manufactured separately. The bearings act as mediators that maintain structural stability without requiring the cylinder to be integrally formed with the block.
3Stability of the object's composition
If conventional integral design is used, then structural stability is maintained, but vibration and friction increase
Solution Approach 1:
The harmful friction and vibration generated by direct contact between moving parts are addressed by extracting and replacing them with bearing-supported rotation. The crankshaft is separated from direct contact with the cylinder walls and instead rotates on precision bearings, which extract the harmful friction and vibration while maintaining structural stability.
4Reliability
If oil lubrication is used for the crankshaft, then bearing durability is improved, but the complexity of the lubrication system increases
Solution Approach 1:
The bearing support system is designed to be self-lubricating or maintenance-free, where the bearings are pre-lubricated or use solid lubricant materials that provide lasting lubrication without requiring external oil delivery systems. This allows the system to maintain bearing durability through self-service lubrication, eliminating the need for complex oil pumps, filters, and delivery channels.
Data Source
AI summary
A cylinder coupling structure of a small air compressor according to the present invention, in which a cylinder is integrally coupled to a block by which a crankshaft is shaft-supported, wherein the block is provided with a supporting end by which the cylinder is pressed to be supported; a latching end is formed on the outer surface of the cylinder; and a press bolt is fastened to the block and a valve cover so that the valve cover presses the front end of the cylinder while the latching end of the cylinder is latched and supported on the supporting end.