Variable Compressor Hinge Assembly Copper Alloy Swash Plate
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Solution Overview
Problem
Variable displacement compressors with swash plates face issues due to poor bearing properties of ferrous materials, increased manufacturing complexity and cost from coatings, and insufficient support from hinge mechanisms, leading to friction and inefficiencies.
Innovation Solution
A hinge assembly with a minimal number of parts, featuring a hub integrally formed with the swash plate, press-fit arms, and a hinge pin that maintains a constant top dead center position and reduces hysteresis, using a copper alloy swash plate and support members with slots for low friction and optimal balance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ferrous material is used for the swash plate, then structural strength is improved, but bearing properties deteriorate
Solution Approach 1:
The patent uses a copper alloy material for the swash plate that inherently provides both the required structural strength and excellent bearing properties. This eliminates the need for additional coatings while achieving both strength and reliability requirements simultaneously through material selection.
2Reliability
If coatings are applied to the swash plate, then bearing properties are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the bearing property requirement from the coating application process and incorporates it directly into the base copper alloy material of the swash plate. This eliminates the separate coating step while maintaining the desired bearing properties, thereby reducing manufacturing complexity.
3Reliability
If coatings are applied to the swash plate, then bearing properties are improved, but reliability deteriorates due to warping, blistering, and peeling
Solution Approach 1:
The patent converts the potential harm of using copper alloy (which can warp under certain conditions) into a benefit by carefully selecting the alloy composition and heat treatment process. The controlled copper alloy formulation provides inherent warpage resistance while maintaining excellent bearing properties, eliminating the need for protective coatings that could blister or peel.
4Ease of manufacture
If fastening means are used to couple the swash plate to the hub, then assembly is improved, but the swash plate can warp or damage
Solution Approach 1:
The patent merges the swash plate and hub into a single integrally formed copper alloy component. This eliminates the interface between separate parts that would require fastening, thereby preventing warping or damage at the connection point while maintaining ease of manufacture through integral forming processes.
5Strength
If support arms are added to the hinge mechanism, then structural support is improved, but friction and tipping moments increase
Solution Approach 1:
The patent extracts the support function from the traditional hinge mechanism with separate support arms and integrates it directly into the copper alloy swash plate-hub assembly. The integral structure provides necessary support while eliminating the additional friction interfaces that would be created by separate support arms and hinge pins.
6Strength
If support arms are added to the hinge mechanism, then structural support is improved, but device complexity increases
Solution Approach 1:
The patent combines the support function with the swash plate and hub into a single integrally formed copper alloy structure. This eliminates the need for separate support arms, hinge pins, and associated components, thereby reducing device complexity while maintaining the necessary structural support.
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 solution provides improved balance and bearing properties, maintaining a constant piston position and reducing friction, thus enhancing the efficiency and durability of the compressor.
Implementation Method 1
A hinge pin is slideably received in the slot of the at least one support member and received in the aperture of each of the arms to hingedly couple the arms to the at least one support member
Implementation Method 2
the ferrous material does not provide the swash plate with a suitable mass to facilitate an optimal moment of inertia, which consequently affects the variation of the angle of the swash plate
Data Source
AI summary
A hinge assembly for coupling a rotor assembly to a swash plate assembly in a variable displacement compressor includes a hub integrally formed with the swash plate assembly and a pair of spaced part arms coupled to the hub and extending outwardly therefrom. Each of the arms having an aperture formed in a distal end thereof. At least one support member extending from the rotor assembly and having a slot formed therein. A hinge pin is slideably received in the slot of the at least one support member and received in the aperture of each of the arms to hingedly couple the arms to the at least one support member.