Spherical Compressor Hinge Seal Gap Compensation
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Solution Overview
Problem
The existing hinge structure in spherical compressors, as described in Chinese patent ZL03114505.1, faces challenges in mass production due to design defects that affect seal efficiency and overall performance, including difficulty in processing concave semi-cylindrical grooves and poor load-carrying capacity leading to sealing failures and increased mechanical friction.
Innovation Solution
A cylindrical hinge seal structure is designed with a fan-shaped insert that forms a dynamic seal fit between the piston and rotating disk pin seats, utilizing a central pin to connect convex and concave pin seats, and an automatic compensation mechanism that reduces the radial gap under high pressure, ensuring reliable sealing and facilitating mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complete semi-cylindrical contact surface is formed between the facing semi-cylindrical groove and the semi-cylinder to ensure sealability, then sealing performance is improved, but manufacturing complexity and difficulty increase significantly
Solution Approach 1:
The pin seat contact surface is segmented into two parts: a semi-cylindrical groove at one end and a flat surface at the other end. This segmentation allows each part to be processed independently using simpler methods, avoiding the need to machine a complete semi-cylindrical surface, thereby reducing manufacturing complexity while maintaining sealing capability.
Solution Approach 2:
A pin is introduced as an intermediary element that connects the two pin seats. The pin features a cylindrical surface that contacts the flat surface of one pin seat and a semi-cylindrical surface that contacts the semi-cylindrical groove of the other pin seat. This intermediary structure simplifies the manufacturing of the pin seats while ensuring reliable sealing through the pin's contact surfaces.
2Ease of operation
If a cylindrical hinge structure is used to connect the piston and rotating disk, then hinge joint function is achieved, but load-carrying capacity is insufficient under high pressure conditions
Solution Approach 1:
The hinge structure is designed to dynamically adapt to pressure conditions. The pin can tilt or shift position under high pressure, allowing the contact surfaces to maintain optimal engagement. The flat surface and semi-cylindrical groove configuration enables the hinge to accommodate pressure-induced deformations while maintaining structural integrity and load-carrying capacity.
3Productivity
If mass production is prioritized for the compressor, then productivity increases, but manufacturing precision and seal accuracy may be compromised
Solution Approach 1:
By segmenting the pin seat structure into a flat surface and a semi-cylindrical groove, each component can be manufactured using standard, easily controllable processes. The flat surface can be machined with high precision using conventional methods, and the semi-cylindrical groove can be formed using standard molding or machining techniques, ensuring consistent seal accuracy across mass production.
Solution Approach 2:
The design changes the geometric parameters of the pin seat contact surfaces to values that are easier to control during manufacturing. The flat surface allows for precise positioning and alignment, while the semi-cylindrical groove provides a well-defined contact geometry that can be consistently reproduced, thereby maintaining seal accuracy in mass production.
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 enhances seal reliability, reduces manufacturing complexity and costs, minimizes surface friction, and prevents damage from high pressure, ensuring efficient operation with reduced noise and mechanical stress.
Implementation Method 1
under the action of high pressure gas, the insert compensates for the gap between the convex semi-cylinder and the bottom of the concave pin seat, thereby forming a dynamic seal fit
Data Source
Figure 1~3
Figure 4~10
Figure 11~14
AI summary
Disclosed is an automatic compensation mechanism for a hinge seal gap in a spherical compressor. A cylindrical hinge is formed around a central pin (10), a rotating disk pin seat (81), and a piston pin seat (16) of the spherical compressor. A fan-shaped insert (14) thicker at both sides and thinner in the center thereof is disposed at the bottom of of a sump (161) on the pin seat of the cylindrical hinge. The shape of the insert (14) matches the shapes of the sump (161) and of the external cylindrical surface of a semi-cylinder (811) on the pin seat of the cylindrical hinge respectively, forming a dynamic seal fit, thus improving the reliability of the seal, adapting to mass production, and enhancing overall performance.