Compressor Wheel Inclined Sensor Surface for Unbalance Detection
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Solution Overview
Problem
Conventional methods for correcting rotational unbalance in electric compressors are inefficient due to the need for expensive magnetized nuts and increased production steps, which can lead to unbalanced compressor wheels if the nuts are not frequently calibrated.
Innovation Solution
A compressor wheel design with a sensor detection surface inclined to the circumferential surface, allowing for accurate detection of reference direction and position using an optical sensor, which is not affected by balance cut portions, thereby simplifying the detection process and reducing production steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetized nut is mounted on the compressor wheel to detect rotational unbalance, then the position and amount of unbalance can be detected contactlessly, but the detection cost increases due to the expensive magnetized nut
Solution Approach 1:
The patent extracts the detection function from the expensive magnetized nut and implements it through a simple mark structure that can be detected by optical sensors. The mark is directly formed on the compressor wheel surface through machining, eliminating the need for separate magnetized components while maintaining detection accuracy.
Solution Approach 2:
The patent creates a simplified copy of the detection function by using a geometric mark (inclined surface or pattern) that replicates the reference function of the magnetized nut. This mark can be detected optically without requiring magnetic properties, thus reducing cost while preserving measurement capability.
2Ease of manufacture
If a magnetized nut is removed and reused after detection, then cost is reduced, but the number of production steps increases and calibration requirements increase
Solution Approach 1:
The patent separates the detection reference (mark) from the detection tool (optical sensor), with the mark being an integral part of the compressor wheel structure. This segmentation allows the mark to remain on the wheel throughout production without requiring removal or reattachment, streamlining the process.
Solution Approach 2:
The mark is formed on the compressor wheel during the manufacturing process itself, before the unbalance detection step. This preliminary action eliminates the need for separate attachment of detection references and reduces the number of production steps while maintaining detection accuracy.
3Measurement precision
If a mark is placed on the rear surface side of the compressor wheel to detect rotational unbalance, then the unbalance direction can be obtained, but it is difficult to apply the mark in cartridge type assemblies
Solution Approach 1:
Instead of placing the mark on the rear surface as in conventional designs, the patent inverts the approach by forming the mark on the front surface or side surface of the compressor wheel that is accessible in cartridge type assemblies. This inversion makes the mark applicable to compact designs while maintaining detection functionality.
Solution Approach 2:
The patent changes the spatial dimension where the mark is located, moving it from the rear surface (axial direction) to the front surface or side surface (radial or tangential direction). This dimensional change allows the mark to be positioned in accessible locations suitable for cartridge type assemblies while preserving unbalance detection capability.
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
The solution enables more accurate and efficient detection of rotational unbalance in compressor wheels, reducing the risk of unbalanced assemblies and minimizing the need for costly calibration of detection tools.
Implementation Method 1
a sensor detection surface formed on a circumferential surface of the tip end portion of the boss portion or on a circumferential surface of the rear plate portion, the sensor detection surface being inclined to the circumferential surface of the end portion or the circumferential surface of the rear plate portion, the sensor detection surface being detectable by an optical sensor that irradiates the sensor detection surface with light and detects light reflected therefrom
Data Source
AI summary
A compressor wheel that can more effectively and accurately detect its rotational unbalance than before is provided. The compressor wheel is disposed in a compressor assembly, the compressor wheel including a boss portion mounted on a rotation shaft, a rear plate portion disposed on an opposite side of a tip end portion disposed on one end side of the boss portion, the rear plate portion extending perpendicular to an axial direction of the rotation shaft, and a sensor detection surface formed on a circumferential surface of the tip end portion of the boss portion or on a circumferential surface of the rear plate portion, the sensor detection surface being inclined to the circumferential surface of the end portion or the circumferential surface of the rear plate portion, the sensor detection surface being detectable by an optical sensor that irradiates the sensor detection surface with light and detects light reflected therefrom.