Compressor Oil Separator with Integrated Separation Chamber
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional compressors with integrated oil separators face challenges such as high production costs, limited design freedom, and complex assembly processes due to the need for multiple machining steps and a large number of parts, which restricts productivity and increases the risk of defects.
Innovation Solution
A compressor design featuring a separation chamber adjacent to the discharge chamber with communication holes arranged from the gas release side to the oil drop side, allowing efficient centrifugal separation of oil and gas without a separation pipe or seal bolt, formed by joining two compressor members to simplify assembly and reduce parts, enabling a more compact and flexible design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional oil separator with separation pipe and seal bolt is used, then oil separation function is achieved, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent integrates the separation pipe and seal bolt functions into the casing structure itself. The casing includes a separation chamber with a separated gas discharge port and an oil discharge port, eliminating the need for separate separation pipes and seal bolts. This merging of components reduces the total number of parts while maintaining the oil separation function through the centrifugal separation mechanism formed by the casing geometry.
Solution Approach 2:
The casing serves multiple functions: it provides structural containment, forms the separation chamber geometry, creates the centrifugal separation mechanism, and includes integrated discharge ports for both separated gas and oil. This multi-functionality eliminates the need for separate dedicated components for each function, reducing part count while achieving reliable oil separation.
2Reliability
If multiple machining portions are required for oil separation chamber, then oil separation function is achieved, but productivity decreases and cost increases
Solution Approach 1:
The separation chamber is formed as an integrated part of the casing structure rather than as a separate machined component. The casing includes the separation chamber with discharge ports formed during the molding process, eliminating multiple separate machining operations. This integration significantly reduces manufacturing steps and improves productivity while maintaining effective oil separation function.
3Reliability
If separation pipe and snap ring are used, then gas sealing is achieved, but assembly time increases and defect risk increases
Solution Approach 1:
The gas sealing function is integrated into the casing structure through the formed discharge ports and chamber geometry rather than requiring separate separation pipes and snap rings. This eliminates the assembly steps for installing these components, reducing assembly time and the risk of assembly defects while maintaining reliable gas sealing through the molded-in structural features.
4Reliability
If cylindrical oil separation chamber is used, then oil separation function is achieved, but space utilization is restricted and design freedom decreases
Solution Approach 1:
The separation chamber is segmented into functional zones within the casing: an oil separation section with centrifugal separation mechanism, a lower oil-storing chamber, and a separated gas discharge path. This segmentation allows flexible arrangement of functions within the available space, improving design freedom and space utilization while maintaining effective oil separation performance.
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 productivity and reduces costs by eliminating machining requirements, simplifying assembly, and increasing design freedom for the compressor's layout, while maintaining or exceeding the separation performance of conventional systems.
Implementation Method 1
separates oil-containing gas being introduced into gas and oil by centrifugal separation
Implementation Method 2
allows the separated oil to drop downward
Data Source
AI summary
A compressor incorporated with an oil separator having a separation chamber and communication holes. The separation chamber is placed adjacent to a discharge chamber, has a space formed in the entire inside of the separation chamber, separates oil-containing gas, which is introduced into the separation chamber, into gas and oil by centrifugal separation, allows the separated oil to drop downward, and upwardly extracts the separated gas. The communication holes interconnect the discharge chamber and the separation chamber and introduce the oil-containing gas, coming from the discharge chamber, into the separation chamber. The communication holes are arranged in the separation chamber, in a direction extending from a gas release side to an oil drop side. The structure of an oil separation section is simplified to improve productivity and reduce cost, and a high degree of design freedom of the position of a discharge port is obtained.