Electric Drive Compressor Sealed Circuit and Sensor Integration
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Solution Overview
Problem
Existing electric drive compressor systems lack a compact and lightweight design, with refrigerant circuits not sealed from the electric motor for ease of maintenance, and they do not have integrated pressure and temperature sensors for efficient operation.
Innovation Solution
The electric drive compressor system incorporates dual temperature and pressure sensors for monitoring gas conditions before and after compression, a sealed refrigerant circuit, and a compact design with a brushless DC motor, allowing for independent motor and compressor maintenance and efficient cooling using airflow passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a fan is coupled to a drive shaft of the motor for motor cooling, then the motor cooling function is achieved, but the device complexity increases and the design is not compact
Solution Approach 1:
The cooling fan is integrated with the compressor piston assembly, combining the motor cooling function with the existing compressor components. This eliminates the need for a separate fan mounted on the drive shaft, reducing device complexity while achieving effective motor cooling through the same mechanical motion
Solution Approach 2:
The piston assembly serves dual functions: compression of refrigerant and driving the cooling fan through its reciprocating motion. This multi-functionality approach allows one component to perform multiple tasks, reducing overall device complexity while maintaining effective motor cooling
2Ease of manufacture
If the refrigerant circuit is not sealed from the electric motor, then the system is easier to manufacture, but the ease of maintenance and service deteriorates
Solution Approach 1:
The system is divided into separate sealed modules: the refrigerant circuit is hermetically sealed from the motor compartment. This segmentation allows independent access to the motor for maintenance while keeping the refrigerant system intact, improving ease of repair without significantly complicating manufacturing
Solution Approach 2:
A sealed separator or barrier is introduced between the refrigerant circuit and motor compartment, allowing the two systems to coexist while maintaining distinct access paths. This intermediary structure enables independent maintenance of the motor without compromising the refrigerant system integrity
3Measurement precision
If dual temperature and pressure sensors are integrated into the valve plate, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
Temperature and pressure sensing functions are integrated into the existing valve plate structure, combining multiple measurement capabilities within a single component. This reduces device complexity by eliminating separate sensor housings and mounting structures while maintaining high measurement precision through dedicated sensing regions
Solution Approach 2:
The valve plate serves multiple functions: flow control and integrated temperature/pressure sensing. This multi-functionality approach allows the same component to perform both mechanical control and measurement tasks, reducing overall device complexity while achieving precise monitoring of compression conditions
Data Source
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AI summary
An electric drive compressor system (1) comprising: a reciprocating compressor (2) having temperature and pressure sensors (83, 84) for sensing a pressure and temperature of gas prior to compression by the compressor (1) and for sensing a pressure and temperature of gas after compression by the compressor (1); a motor (3) connected to the compressor (1) for driving the compressor (1); a cooling system (4) for cooling the motor (3); and a controller (5) for controlling the motor (3) in real time based on the temperature and pressure sensor readings of the gas prior to and after compression by the compressor (1). Features and advantages of the systems (1) as exemplified are as follows: lightweight and compact design; refrigerant circuit sealed from electric motor for ease of maintenance and service; air cooled from unique fin and airflow passage design, with fan width pulse width modulation; intelligent control system with pressure and temperature sensors/transducers and software; separate compressor working assembly to ensure piston alignment and compression is not affected by heat distortion; separate outer housing and compressor crankcase to ensure leak free operation.