Rotary Compressor Lower End Plate Cover Bulge Design
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Solution Overview
Problem
Rotary compressors face efficiency losses due to refrigerant backflow and increased vibration caused by inadequate design of the lower end plate cover, which struggles to balance noise reduction and efficiency improvement.
Innovation Solution
A rotary compressor design featuring a lower end plate cover with a bulging portion divided into two sections, where the first bulging portion is larger than the second, optimized to connect the lower discharge valve housing concave portion and discharge chamber concave portion, reducing the spatial volume of the lower end plate cover chamber to between 20% and 40% of the total excluded volume, thereby minimizing refrigerant backflow and pressure pulsation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the lower end plate cover chamber volume is increased to reduce noise, then the noise reduction effect is improved, but the refrigerant backflow space increases and compressor efficiency decreases
Solution Approach 1:
The lower end plate cover is designed with a bulging portion that creates a non-uniform chamber volume distribution. The bulging portion is positioned specifically to reduce volume in the refrigerant backflow path area while maintaining or increasing volume in the noise attenuation area. This local differentiation allows the chamber to simultaneously achieve noise reduction and minimize refrigerant backflow space.
2Productivity
If the lower end plate cover chamber volume is decreased to improve compressor efficiency, then the refrigerant backflow is reduced, but the noise reduction effect becomes insufficient
Solution Approach 1:
The lower end plate cover chamber is segmented into functionally distinct regions by the bulging portion. One region is optimized for noise attenuation (larger volume), while another region is optimized for minimizing refrigerant backflow (smaller volume). This segmentation allows each region to fulfill its specific function without compromising the other, resolving the contradiction between noise reduction and efficiency.
3Ease of manufacture
If the lower end plate cover is made flat to reduce manufacturing complexity, then the manufacturing process is simplified, but the ability to control refrigerant flow and reduce backflow is limited
Solution Approach 1:
The lower end plate cover incorporates a bulging portion with a curved surface instead of being completely flat. This curvature is strategically designed to redirect refrigerant flow and reduce backflow through the refrigerant path hole. The curved surface guides the refrigerant flow more effectively than a flat surface, reducing energy loss while remaining manufacturable using standard forming processes.
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 design enhances the efficiency of the rotary compressor by reducing pressure pulsation and noise levels, while maintaining mechanical strength and workability, achieving a balance between efficiency and noise reduction.
Implementation Method 1
the effect of sound attenuation by the lower muffler chamber is not obtained appropriately
Implementation Method 2
the pressure in the upper muffler chamber is higher than the pressure in the compressor housing outside the upper muffler chamber and the lower muffler chamber. Therefore, in the next moment, a flow of the refrigerant from the upper muffler chamber to the inside of the compressor housing outside the upper muffler chamber and a flow of the refrigerant back through a refrigerant path hole
Data Source
AI summary
A lower end plate cover is provided with a bulging portion. In a circumferential direction of a rotary shaft, a plurality of bolt holes includes a first bolt hole arranged between a distal end portion and a proximal end portion of the lower discharge valve, a second bolt hole arranged in a position adjacent to the first bolt hole on a side close to a lower vane groove with respect to the first bolt hole, and a third bolt hole arranged in a position adjacent to the first bolt hole on a side away from the lower vane groove with respect to the first bolt hole. When the bulging portion is divided into a first bulging portion and a second bulging portion using a first straight line, the first bulging portion is larger than the second bulging portion.