Direct-Coupled Compressor Assembly With Integrated Oil-Pump Drive

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Solution Overview

Problem

Existing compressor assemblies face challenges with compact design, energy efficiency, operational reliability, and cross-contamination due to the use of intermediate gear transmissions and separate oil-pump driving mechanisms, which result in space inefficiency, energy losses, and contamination risks.

Innovation Solution

A compressor assembly design featuring a direct coupling between the motor shaft and compressor rotor shaft, with the oil-pump integrated and driven by the same motor, eliminating the need for intermediate gear transmissions and allowing for modular, compact, and efficient operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If an intermediate gear transmission is used to connect the motor shaft and compressor rotor shaft, then the motor can operate at reduced speed while driving the compressor at high speed, but the device complexity and space occupation increase significantly

Engineering Contradiction:

Improvecompressor rotor speedVSAvoidtransmission system complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The patent removes the intermediate gear transmission system entirely, directly coupling the motor shaft to the compressor rotor shaft. This extraction of the disturbing element (gearbox) simplifies the device structure while maintaining the ability to achieve high-speed compression through direct motor-driven rotation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The motor and compressor rotor are merged into a single direct-drive system where the motor shaft and rotor shaft are coupled without intermediate transmission components. This merging eliminates the complexity of gear transmissions while integrating the driving and compressing functions into a unified structure.

Inventive Principle:

Principle #5Merging (Combining)

2Speed

If an intermediate gear transmission is used between motor shaft and compressor rotor shaft, then speed conversion is achieved, but energy losses due to friction increase

Engineering Contradiction:

Improverotational speed conversionVSAvoidfriction energy loss

Core Design Contradiction:

SpeedVSLoss of energy

Solution Approach 1:

By removing the gear transmission system, the patent eliminates the sources of frictional energy loss associated with meshing gears and transmission components. The direct coupling ensures that motor power is transmitted to the rotor with minimal energy dissipation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The complex mechanical gear transmission system is replaced with a direct mechanical coupling, substituting a multi-component friction-prone system with a simple direct-drive connection that minimizes energy loss while achieving the required rotational speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If separate driving mechanisms are used for the oil-pump and compressor, then independent control is possible, but the device complexity and space requirements increase

Engineering Contradiction:

Improveindependent control capabilityVSAvoiddriving mechanism complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The oil-pump and compressor are both driven by the same motor through direct coupling, merging the driving mechanisms into a single unified system. This reduces device complexity and space requirements while maintaining coordinated operation of both components through their shared connection to the motor shaft.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single motor serves multiple functions by directly driving both the compressor rotor and the oil-pump through the coupled shaft system. This universal driving approach eliminates the need for separate motors while providing integrated control of both compression and lubrication functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Speed

If intermediate gear transmission components are used, then speed control is achieved, but the compact design of the compressor assembly is compromised

Engineering Contradiction:

Improvemotor speed controlVSAvoidcompressor assembly volume

Core Design Contradiction:

SpeedVSVolume of moving object

Solution Approach 1:

The bulky intermediate gear transmission components are extracted and removed from the system. The direct coupling of motor shaft to rotor shaft eliminates the need for a large gearbox, enabling a compact compressor assembly design while maintaining effective speed control through direct motor-driven rotation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The motor and compressor rotor are merged into a compact integrated assembly through direct coupling, eliminating the space-consuming gear transmission components. This merging allows for a space-efficient design where the motor shaft and rotor shaft form a unified compact structure.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20240360830A1Compressor assembly

Publication Date: 2024.10.31 ATLAS COPCO AIRPOWER NV

AI summary

Compressor assembly including a motor having a motor shaft which drives at least one compressor rotor of a compressor element as well as an oil-pump, in which a compressor rotor includes a compressor rotor part which is mounted on a compressor rotor shaft which is connected to the motor shaft by means of a direct coupling so to form a composed driving shaft and wherein-in which the oil-pump is mounted directly on the composed driving shaft or on another compressor rotor shaft.