Modular compressor-valve design for refrigerant system
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Solution Overview
Problem
Conventional refrigerant systems face manufacturing complexity and increased costs due to the independent production and assembly of multiple valves associated with the compressor, leading to potential errors and reduced reliability.
Innovation Solution
A compressor-valve modular subassembly is designed where valves, such as discharge, suction modulation, and vapor/liquid injection valves, are preassembled outside the compressor shell, allowing for easier manufacturing, reduced costs, and improved reliability by integrating these components into a single, transportable module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple valves are independently produced and assembled into the refrigerant system, then each valve can be manufactured separately with standard processes, but the manufacturing complexity and assembly time increase, and reliability decreases due to potential assembly errors
Solution Approach 1:
The patent combines multiple independently manufactured valves (discharge valve, suction valve, economizer valve, liquid injection valve) into a single integrated valve assembly that is pre-assembled and pre-tested as one modular unit. This merging approach reduces the number of separate assembly operations required in the refrigerant system manufacturing process, eliminates potential assembly errors between multiple components, and simplifies the overall manufacturing complexity while maintaining the functional independence of each valve.
2Adaptability or versatility
If multiple valves are independently assembled into the refrigerant system, then component flexibility is maintained, but assembly time and potential for errors increase
Solution Approach 1:
The valve assembly is pre-assembled, pre-configured, and pre-tested as a complete modular unit before being integrated into the refrigerant system. This preliminary action allows all valve connections, mounting positions, and internal configurations to be established in advance during dedicated valve manufacturing operations, rather than during final system assembly. The pre-assembled module can be easily transported and installed as a single unit, significantly reducing assembly time while maintaining the adaptability to different refrigerant system configurations.
3Ease of manufacture
If valves are independently produced and assembled, then manufacturing costs for individual valves are controlled, but overall system cost increases due to additional assembly operations and quality control
Solution Approach 1:
The patent integrates multiple valves into a single pre-assembled modular unit that is manufactured and tested as one complete assembly. This merging approach ensures that all valve connections and interactions are verified during the valve assembly manufacturing process, eliminating potential assembly errors that would occur if valves were independently installed into the refrigerant system. The pre-tested modular valve assembly guarantees system reliability while controlling overall manufacturing costs by reducing the number of quality control checkpoints and assembly operations required.
Data Source
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AI summary
A compressor-valve modular design provides manufacturing simplicity, reduces applied cost, and improves quality and reliability of a refrigerant system. In this design, a valve is preferably an electronically controlled valve having a control member that controls the flow of a fluid through the valve. A discharge valve, a stepper motor modulation valve, an economizer vapor injection valve, a liquid injection valve or any combination of thereof are the examples of the valves within the compressor-valve subassembly.