Compressor
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Solution Overview
Problem
Vacuum cleaner compressors face challenges in size, weight, manufacturing cost, efficiency, reliability, and noise, limiting their performance and power.
Innovation Solution
A compressor design featuring a diffuser assembly with separate first and second diffuser stages connected by a fastener, allowing for complex geometries and improved pressure recovery, acoustic characteristics, and modular configuration, enabling enhanced performance and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the diffuser stages are formed as a single component, then the manufacturing process is simpler, but the geometry complexity is limited and performance is reduced
Solution Approach 1:
The diffuser assembly is divided into multiple separate diffuser stages (first diffuser stage, second diffuser stage, etc.), each with optimized blade geometries. These stages are connected by fasteners to form a complete diffuser assembly. This segmentation allows each stage to be manufactured with high precision using separate moulding processes while enabling complex overall geometry that would be impossible in a single component.
2Productivity
If the diffuser stages are formed as separate components, then complex geometries and improved performance are achieved, but the manufacturing cost increases
Solution Approach 1:
The diffuser is segmented into multiple stages that can be manufactured separately using injection moulding or other suitable processes, then assembled using fasteners. This allows each stage to be optimized for its specific function while enabling parallel manufacturing, reducing overall production time and cost despite the increased number of components.
Solution Approach 2:
The fastener design serves multiple functions: it mechanically connects the diffuser stages together, provides anti-rotation engagement through protrusions and recesses, and ensures proper alignment of the stages. This multi-functionality reduces the need for additional separate components, thereby controlling manufacturing cost.
3Weight of moving object
If the diffuser stages are formed as separate components, then weight is reduced and performance is enhanced, but the assembly complexity increases
Solution Approach 1:
The diffuser assembly is segmented into multiple lightweight stages connected by fasteners, reducing overall weight compared to a solid single-piece construction. The segmentation allows for optimized material usage in each stage while maintaining structural integrity through the fastener connections.
Solution Approach 2:
The fastener acts as an intermediary component that simplifies the assembly process by providing a standardized connection mechanism between diffuser stages. The fastener includes integrated anti-rotation features and alignment protrusions that guide the assembly process, reducing the complexity that would otherwise arise from aligning multiple precision components.
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
The design achieves improved pressure recovery, increased suction power, and better acoustics by allowing for complex blade geometries and modular configurations, addressing the limitations of existing compressors.
Implementation Method 1
a diffuser assembly for acting on the airflow generated by the impeller, wherein the diffuser assembly comprises a first diffuser stage and a second diffuser stage
Implementation Method 2
a diffuser assembly for acting on the airflow generated by the impeller
Data Source
AI summary
A compressor has a rotor assembly having an impeller for generating an airflow through the compressor, a stator core assembly for causing rotation of the impeller, and a diffuser assembly for acting on the airflow generated by the impeller. The diffuser assembly has a first diffuser stage and a second diffuser stage. The first and second diffuser stages are separate components connected to one another by a fastener.