Compressed-air compressor neutral chamber pressure balancing

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Solution Overview

Problem

Compressed-air compressors experience high peak torque requirements during operation, leading to increased drive motor size and weight, as well as stress on components like crankshaft and connecting rod bearings, which can reduce durability and efficiency.

Innovation Solution

Charging the neutral chamber of the compressor with an auxiliary pressure, derived from the compressed-air system, to maintain an average pressure higher than atmospheric pressure, thereby reducing the maximum torque required for driving the compressor to approximately half, and using a compressed-air stabilization device to provide a stabilized auxiliary pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the neutral chamber is charged with auxiliary pressure, then the maximum torque required for driving the compressor is reduced, but the device complexity increases due to additional components

Engineering Contradiction:

Improvemaximum torqueVSAvoiddevice complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The compressed air system serves multiple functions: it not only provides compressed air for pneumatic components but also supplies auxiliary pressure to the neutral chamber to reduce torque requirements. This multi-functionality reduces the need for separate torque reduction mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The compressed air system serves itself by using its own output (compressed air) to charge the neutral chamber with auxiliary pressure, thereby reducing the torque required to drive the compressor. This self-service approach eliminates the need for external torque reduction devices.

Inventive Principle:

Principle #25Self-service

2Weight of moving object

If the neutral chamber is charged with auxiliary pressure, then the drive motor size and weight are reduced, but the manufacturing complexity increases

Engineering Contradiction:

Improvedrive motor weightVSAvoidease of manufacture

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The compressed air system is designed to perform multiple functions including supplying auxiliary pressure to the neutral chamber. This allows the use of a smaller drive motor while maintaining system functionality, avoiding the need for separate torque reduction mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

By changing the pressure parameter in the neutral chamber (charging it with auxiliary pressure), the torque requirements are reduced, allowing for a smaller and lighter drive motor. This parameter change approach simplifies the overall system design.

Inventive Principle:

Principle #35Parameter changes

3Strength

If the neutral chamber is charged with auxiliary pressure, then the stress on compressor components is reduced, but the system reliability requirements increase

Engineering Contradiction:

Improvecomponent strengthVSAvoidsystem reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The auxiliary pressure in the neutral chamber acts as a counterbalancing force that reduces the stress on compressor components during operation. This counterweight effect allows for the use of components with lower strength ratings while maintaining durability.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Solution Approach 2:

By pre-charging the neutral chamber with auxiliary pressure before compression cycles begin, the system prepares a cushioning pressure that reduces peak stresses on components during operation, thereby protecting them from excessive loads.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 approach significantly reduces peak torque values, allowing for smaller, lighter drive motors and reducing stress on compressor components, enhancing robustness and durability, while maintaining efficient compressed air production.

Implementation Method 1

the pressure in the neutral chamber increases to a value above the temporally average value of the pressure, and in the compression phase, the pressure in the neutral chamber falls to a value below the temporally average value of the pressure

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS9074594B2Compressed-air compressor and method of operation

Publication Date: 2015.07.07 ZF CV SYST EURO BV

AI summary

A compressed-air compressor for producing compressed air for a compressed-air system of a vehicle includes a cylinder and a piston. The piston is arranged in the cylinder and divides the interior space of the cylinder into a compression chamber, which can be connected to the compressed-air system of the vehicle for the purpose of conveying compressed air, and a neutral chamber. The neutral chamber is charged with an auxiliary pressure such that the pressure in the neutral chamber is temporally on average higher than atmospheric pressure. The compressed air production using the piston/cylinder-type compressed-air compressor is improved such that the maximum value of the torque to be imparted for driving the compressor is reduced.