Multi-Piston Compressor Gear Layout for Compression and Suction
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Solution Overview
Problem
Conventional compressors for discharging a medium, such as tire sealant, lack efficiency in force transmission and volumetric flow, particularly in adapting to the different forces required for compressing and sucking air.
Innovation Solution
The compressor employs a step-up transmission wheel with partial toothing and two interlocking toothed wheels, allowing for varying force transmission based on engagement, and connects multiple pistons to improve force distribution and volumetric flow, including a multi-piston and rotary piston principles with a plate motor design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional compressor uses a single toothed wheel for force transmission, then the structure is simple, but the force transmission efficiency is insufficient for both compression and suction operations
Solution Approach 1:
The toothed wheel is divided into multiple segments (first toothed wheel segment and second toothed wheel segment) with different diameters. Each segment is optimized for specific operational phases: the larger first segment for suction and the smaller second segment for compression. This segmentation allows the system to achieve different transmission ratios for different operations without requiring entirely separate mechanisms.
Solution Approach 2:
The transmission mechanism dynamically switches between different toothed wheel segments based on operational requirements. The step-up transmission wheel engages different segments alternately during rotation, automatically adapting the transmission ratio to the current operational phase (suction or compression) without manual intervention or complex control systems.
2Productivity
If a compressor is designed for high volumetric flow, then the delivery efficiency improves, but the force distribution to multiple compression chambers becomes complex
Solution Approach 1:
The force transmission is segmented and distributed to multiple compression chambers through the alternating engagement of different toothed wheel segments. Each engagement phase naturally directs force to appropriate chambers, achieving multi-chamber operation without complex distribution mechanisms. The step-up transmission wheel's alternating engagement with first and second toothed wheel segments creates a natural force distribution pattern.
Solution Approach 2:
Multiple compression chambers are merged into a single integrated system driven by one step-up transmission wheel. The wheel simultaneously or alternately drives multiple chambers through its different segments, combining the functions of what would otherwise require separate drive mechanisms, thereby simplifying the overall force distribution system.
3Power
If the step-up transmission wheel engages alternately with different toothed wheel segments, then force transmission is optimized for both suction and compression, but the mechanism complexity increases
Solution Approach 1:
The step-up transmission wheel serves multiple functions through its different segments: it acts as both a driver and a driven element, provides different transmission ratios for suction and compression, and alternately engages with different toothed wheel segments to achieve optimized force transmission for each operational phase. This multi-functionality is achieved within a single component rather than requiring separate mechanisms.
Solution Approach 2:
The toothed wheel segments are designed with asymmetric characteristics - the first toothed wheel segment has a larger diameter than the second toothed wheel segment. This asymmetry is deliberately created to provide different mechanical advantages for different operations: the larger first segment for suction and the smaller second segment for compression, optimizing force transmission for each phase.
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 configuration enhances force transmission and volumetric flow, enabling more efficient compression and suction operations, with improved force distribution to multiple compression chambers, increasing the delivery of compressed air.
Implementation Method 1
the step-up transmission wheel is provided only partially on its circumference with a toothing and/or consists of two toothed wheels lying on each other
Implementation Method 2
the compressor has a motor which is connected eccentrically to a piston rod via an output wheel, which piston rod moves a piston in the compression chamber
Data Source
AI summary
In a compressor for discharging a medium, in particular tire sealant that is to be discharged from a container into a tire, wherein a motor (1) of the compressor (P) drives a step-up transmission wheel (3, 3.1) for moving at least one piston (6-6.6) in a compression chamber (7), the step-up transmission wheel (3, 3.1) is intended to be provided only partially on its circumference with a toothing (20) and/or to consist of two toothed wheels (11, 12) lying on each other.