Compressor One-Piece Valve Element Reduces Energy Loss
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Solution Overview
Problem
Existing compressor designs for commercial vehicles face challenges in energy efficiency and assembly complexity, particularly due to the need for a two-part valve element and additional assembly openings that can lead to energy losses and leakage risks.
Innovation Solution
A compressor design featuring a one-piece valve element with an integrated actuating section and shut-off body that can be moved axially to separate the piston and dead spaces, eliminating the need for assembly openings in the cylinder head and reducing thermodynamic work by allowing air to flow into the dead space during relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-part valve element with support plate is used, then the valve element can be assembled, but assembly complexity increases and air flow is disturbed causing energy losses
Solution Approach 1:
The support plate and valve element are merged into a single integrated component. The valve element includes an integrated support plate structure that provides both structural support and proper air flow guidance, eliminating the need for separate assembly of multiple parts while maintaining optimal air flow characteristics.
Solution Approach 2:
The valve element is designed with distinct functional sections integrated into one piece: the shut-off body for sealing, the actuating section for operation, and the support plate structure for mechanical support. This segmentation of functions within a unified structure achieves both ease of manufacture and proper air flow.
2Ease of manufacture
If assembly openings are made in the cylinder head, then the valve element can be installed, but leakage risk increases and assembly becomes complex
Solution Approach 1:
The valve element is pre-assembled as a complete unit including the support plate and shut-off body before installation into the cylinder head. This preliminary assembly eliminates the need for open access to the cylinder head interior during installation, as the entire valve assembly can be installed through a single access point and then sealed.
Solution Approach 2:
Multiple components (valve element, support plate, sealing elements) are merged into a single pre-assembled valve assembly unit. This integrated unit is installed as one piece, eliminating the need for multiple separate installation steps that would require open access to the cylinder head and subsequent sealing operations.
3Use of energy by moving object
If the compressor is relieved by opening the compression chamber to dead chamber, then energy consumption is reduced, but thermodynamic work is increased
Solution Approach 1:
The valve element is designed to dynamically control the connection between the compression chamber and dead chamber based on operational requirements. During normal compression, the valve remains closed maintaining separate chambers. During relief operation, the valve opens to allow controlled communication, enabling the system to adapt between compression and relief modes efficiently.
Solution Approach 2:
The system changes the operational parameter of chamber communication from closed to open state. By controlling the valve element position, the system transitions between two distinct operational parameters: normal compression mode with separated chambers and relief mode with connected chambers, optimizing energy consumption for each operational state.
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 reduces energy consumption by minimizing thermodynamic work and eliminates the risk of leakage and assembly complexity, enhancing the reliability and efficiency of the compressor.
Implementation Method 1
Activated by a pneumatic pressure signal from a downstream air handling unit
Implementation Method 2
a spring (27) supported on the retaining plate (13) in such a way that the spring acts on the valve element (21) in the closed state of the valve device
Implementation Method 3
reduce the thermodynamic work that is performed during one crank revolution
Data Source
Figure 1~2b
Figure 3a~3b
Figure 3c~3d
AI summary
Compressor for generating compressed air for a commercial vehicle, having a housing with a piston chamber in a crankcase and a dead space which is configured at least in the cylinder head. The compressor has a valve device with a valve element which has an actuating section and a shut-off body for separating the dead space from the piston chamber, wherein the shut-off body can be lifted up from a valve seat in the direction of the piston chamber in order to open the valve device. The valve element is configured in one piece with the actuating section.