Air Compressor Torque Gear Assembly for Bearing Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional air compressors experience reduced air compressing efficiency and shortened service life due to deformation of plastic bases at high temperatures and improper engagement between the piston and bearing, leading to idle rotation and reduced torque, which affects the bearing's loading and service life.
Innovation Solution
The air compressor design features a piston rotatably connected to a torque gear with a screw bolt that engages with the bearing, ensuring the bearing remains in place, and a toothed portion with a non-zero spacing from the base to prevent friction, allowing the piston to move reciprocally within the cylinder without deforming the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the base is made of plastic material to reduce weight and cost, then manufacturing cost and weight are reduced, but the base softens at high temperatures causing deformation and reduced air compressing efficiency
Solution Approach 1:
The base structure is segmented into two distinct parts: an aluminum alloy base body (11) that provides structural stability and heat resistance, and a separate cover (211) made of plastic material that reduces weight and manufacturing cost. This segmentation allows each material to perform its optimal function without compromising the other.
Solution Approach 2:
The base assembly uses composite construction by combining aluminum alloy (for the base body) with plastic material (for the cover). This composite approach leverages the high strength and heat resistance of aluminum alloy while incorporating the weight-saving and cost-effective properties of plastic, resolving the contradiction between manufacturing cost and operational reliability.
2Loss of energy
If the piston is directly connected to the bearing to reduce torque transmission path, then torque loss is reduced, but the piston pulls the bearing causing idle rotation and deformation
Solution Approach 1:
A connecting rod (164) is introduced as an intermediary component between the piston (14) and the bearing (111). The connecting rod transmits the driving force from the piston to the bearing through controlled mechanical interaction, preventing direct contact that would cause the piston to pull the bearing and cause idle rotation. This intermediary mechanism reduces torque loss while maintaining bearing stability.
Solution Approach 2:
The connecting rod applies partial action by selectively transmitting force only during the appropriate phase of the compression cycle. The rod engages with the bearing through a controlled mechanism that applies force when needed for compression while preventing excessive action that would cause the bearing to rotate idle or deform, thus balancing torque transmission with bearing protection.
3Reliability
If the base covers the bearing completely to protect it, then bearing protection is improved, but the receiving orifice deforms and the piston cannot move vertically
Solution Approach 1:
The base structure is segmented to create a dedicated receiving orifice (110) with controlled geometry. This segmentation provides a specific pathway that guides the piston's vertical movement while the surrounding base structure maintains overall bearing protection. The receiving orifice acts as a controlled passage that satisfies both protection and movement requirements.
Solution Approach 2:
The base exhibits local quality by having different structural characteristics in different regions: the receiving orifice area is designed with specific dimensional tolerances and geometric features that allow smooth piston passage, while other areas of the base maintain sufficient thickness and rigidity for bearing protection. This localized differentiation resolves the contradiction between protection and operational ease.
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 air compressing efficiency and extends the service life of the air compressor by maintaining proper engagement between the piston and bearing, reducing deformation and friction, and optimizing torque distribution.
Implementation Method 1
the screw bolt is screwed with the central orifice after being inserted through the internal ring of the bearing and the torque gear, such that when the air compressor operates, the torque gear engages with the bearing by using the screw bolt so that the bearing is not removed from the screw bolt
Implementation Method 2
the piston moves in the cylinder reciprocately when the air compressor operates
Implementation Method 3
the piston 14 is driven by the motor 13 to move reciprocately in the cylinder 12 so as to draw, compress, pressurize, and discharge air
Implementation Method 4
The gear mechanism includes a drive gear 151 mounted on a central shaft of the motor 13, and the gear mechanism includes a driven gear 152 meshing with the drive gear 151
Implementation Method 5
The crank mechanism includes a counterweight portion 161 connected on the driven gear 152, a connection rod 164 rotatably connected with the piston 14, and a post 162 extending from the counterweight portion 161
Implementation Method 6
a motor 13 and a piston 14 which are both connected on the base 11, wherein the piston 14 is driven by the motor 13 to move reciprocately in the cylinder 12
Data Source
AI summary
An air compressor contains: a torque gear on which a central orifice and a connection rod are arranged. The central orifice has screw threads defined thereon and corresponds to one of multiple positioning orifices of a base, the one positioning orifice is configured to accommodate a bearing, and a screw bolt is inserted through the bearing in the base so as to screw with the central orifice via the torque gear. The connection rod of the torque gear is rotatably connected with a piston so that the piston moves in a cylinder to produce compressed air, the torque gear matingly contacts with the bearing along the screw bolt, and the bearing is not broken in the one positioning orifice, thus moving the piston in the cylinder reciprocately.