Scroll Compressor Weld Layout for Barrel Casing Deformation Control

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Solution Overview

Problem

Existing scroll compressors face challenges in minimizing deformation of the barrel casing during manufacturing, which can lead to issues like noise generation and reduced sealing performance due to improper clearance between the fixed scroll and the casing.

Innovation Solution

The implementation of a welding technique involving repeatedly welded portions and first welds aligned along the axial direction of the barrel casing, with second welds formed over a predetermined length in the circumferential direction, helps reduce deformation by providing increased rigidity and uniform contraction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional welding methods are used to join the barrel casing and end casing, then the manufacturing process is simple, but the barrel casing deforms during welding leading to noise generation and reduced sealing performance

Engineering Contradiction:
Improvebarrel casing deformation controlVSAvoidwelding process complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The welding process is segmented into multiple sequential welds (first weld, second weld, third weld) rather than attempting to complete all welding in one operation. Each weld is performed at a different location and orientation, allowing the barrel casing to cool and stabilize between welding operations, thereby reducing cumulative thermal deformation while maintaining manufacturing feasibility

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The first weld is performed on the barrel casing before the end casing is fully assembled, and subsequent welds are performed in a predetermined sequence. This preliminary action approach allows for controlled thermal input and enables deformation management by completing welds in an optimal order rather than simultaneously or in reverse sequence

Inventive Principle:
Principle #10Preliminary action

2Reliability

If multiple welds are performed to reduce deformation, then the sealing performance improves, but the manufacturing time increases

Engineering Contradiction:
Improvesealing performanceVSAvoidmanufacturing cycle time
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The welding process employs periodic action by performing welds at distinct intervals rather than continuously. The first weld, second weld, and third weld are executed with cooling periods in between, allowing thermal management that prevents excessive deformation while maintaining a structured, repeatable process rhythm that can be optimized for production timing

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

Each weld is performed at a specific location with particular quality requirements (first weld at initial position, second weld at different position, third weld at another position). This local quality approach ensures that critical sealing areas receive appropriate welding attention while allowing less critical areas to be welded later or with different parameters, balancing overall manufacturing efficiency with localized sealing performance

Inventive Principle:
Principle #3Local quality

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 approach effectively reduces deformation of the barrel casing, maintains the intended clearance, and enhances the sealing performance and operational stability of the scroll compressor.

Implementation Method 1

The first weld is formed by welding the tubular barrel casing and the housing together

Methodology Applied
Scientific EffectWelding: Welding

Implementation Method 2

The second weld is formed by welding the tubular barrel casing and the end casing together over a predetermined length along a circumferential direction of the tubular barrel casing

Methodology Applied
Scientific EffectWelding: Welding

Data Source

PatentUS11953004B2Compressor and method for manufacturing compressor
Publication Date: 2024.04.09 DAIKIN INDUSTRIES LTD
  • US11953004B2 patent drawing
  • US11953004B2 patent drawing
  • US11953004B2 patent drawing

AI summary

A compressor includes a casing, a housing inside the casing, and first and second welds. The casing includes a tubular barrel casing and an end casing. The first weld welds the barrel casing and the housing together. The second weld welds the barrel casing and the end casing together along a circumferential direction. The second weld includes a repeatedly welded portion formed by one end portion and an other end portion of the second weld overlapping each other, or the second weld includes a plurality of second welds each including a repeatedly welded portion formed by an end portion of the second weld and an end portion of an other one of the second welds overlapping each other. The repeatedly welded portion are formed to reduce deformation of the barrel casing. The repeatedly welded portion and the first weld are aligned along an axial direction of the barrel casing.