Integrated Air Compressor with Parallel Cylinders and Central Motor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air compressors for vehicle air suspension systems are not compact enough due to separate, non-space-saving pneumatic and electrical connections, leading to inefficiencies in compressed air output and cumbersome component connections.
Innovation Solution
A two-cylinder piston compressor design with parallel and spaced cylinder axes, a brushless motor positioned between the cylinders, and a distribution valve unit integrated between the cylinder housings, eliminating the need for lengthy connections and enhancing compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate pneumatic and electrical pipelines are used to connect components, then component connections are established, but the system becomes non-space-saving and cumbersome
Solution Approach 1:
The patent integrates the distribution valve unit directly into the compressor housing, merging previously separate pneumatic and electrical components into a single integrated assembly. This eliminates the need for separate pipelines and reduces overall system volume while maintaining all necessary connection functions.
2Productivity
If a single-stage compressor with one pump head is used, then the structure is simple, but the inflation efficiency is low
Solution Approach 1:
The patent employs a two-stage compression process with sequentially arranged first and second compression stages. Each stage has its own cylinder and piston, allowing progressive compression of air. This segmentation into stages increases inflation efficiency while keeping each individual stage relatively simple in structure.
3Productivity
If a two-stage compressor with two piston heads on both sides of the motor drive shaft is used, then pumping efficiency increases, but the occupied space increases and compactness is reduced
Solution Approach 1:
The patent arranges the two compression stages in a sequential linear configuration along the motor drive shaft axis rather than positioning them on opposite sides radially. This dimensional reconfiguration maintains the two-stage pumping efficiency while significantly reducing the overall footprint and improving compactness.
4Ease of manufacture
If lengthy pneumatic lines are used to connect the compressor to the distributing valve unit and air springs, then connections are established, but the system becomes laborious to assemble and non-space-saving
Solution Approach 1:
The distribution valve unit is integrated directly into the compressor housing structure, eliminating the need for separate pneumatic lines. This merging of components drastically reduces the length of pneumatic connections required and simplifies assembly operations while maintaining all necessary air distribution functions.
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 improves the compactness and efficiency of compressed air generation, reduces noise and load torque fluctuations, and simplifies component connections, resulting in a more effective and space-saving air compressor system.
Implementation Method 1
a brushless motor positioned between the cylinders
Implementation Method 2
Each piston is reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder
Data Source
AI summary
The patent application discloses an air compressor. The air compressor comprises at least two separate cylinder housings, a pair of pistons, a motor, a pair of head members, and a distribution valve unit. Each cylinder housing may define a cylinder with an axis. The axes are parallel and spaced apart. The pair of pistons has each piston being reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder. The motor may be positioned between the cylinder housings and drives the pistons so as to reciprocate the pistons. The pair of head members has each head member being fastened to a different one of the cylinder housings. The distribution valve unit may be positioned in between and next to the cylinder housings.