Integrated connector for multi-stage compressor

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Solution Overview

Problem

Refrigerant compressors with multiple stages face inefficiencies in fluid flow transition between stages, leading to aerodynamic losses and reduced performance in HVAC chiller systems.

Innovation Solution

An inter-stage connector with multiple sections arranged about the axis, featuring radial and axial portions, and a pocket to stabilize fluid flow, providing a smooth transition between the outlet of the first radial compression stage and the inlet of the second radial compression stage, enhancing aerodynamic performance and reducing head loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a conventional connector is used to connect the outlet of the first radial compression stage to the inlet of the second radial compression stage, then the structure is simple, but aerodynamic losses increase and fluid flow continuity deteriorates

Engineering Contradiction:

Improveaerodynamic lossesVSAvoidconnector structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The connector is divided into multiple sections (first section, second section, third section) with different orientations. The first section extends radially outward from the outlet, the second section extends axially, and the third section extends radially inward to the inlet. This segmentation allows each section to be optimized for its specific flow direction, improving overall aerodynamic performance while maintaining manageable structural complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector sections are designed with curved transitions rather than sharp angles. The first section includes a curved transition from radial to axial flow, the second section provides a curved axial passage, and the third section includes a curved transition from axial to radial flow. These curved pathways reduce flow separation and turbulence, minimizing aerodynamic losses.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Productivity

If a simple connector design is used, then manufacturing is easier, but fluid flow transition efficiency decreases

Engineering Contradiction:

Improvefluid flow transition efficiencyVSAvoidconnector manufacturing

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The connector is segmented into three distinct sections that can be manufactured separately and then assembled. This segmentation allows each section to be optimized for its specific function while simplifying the manufacturing process for each individual section, making the overall complex structure more manufacturable through modular production.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector utilizes three-dimensional spatial arrangement with sections extending in different dimensions (radial and axial directions). This 3D configuration optimizes fluid flow paths in multiple directions simultaneously, improving transition efficiency while allowing each section to be manufactured as a separate component that can be assembled into the final complex structure.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Loss of energy

If the connector sections are extended outside the housing, then aerodynamic performance improves, but the compressor footprint increases

Engineering Contradiction:

Improvehead lossVSAvoidcompressor footprint

Core Design Contradiction:

Loss of energyVSArea of stationary object

Solution Approach 1:

The connector sections are arranged in a three-dimensional configuration that utilizes the axial dimension of the compressor. By extending sections axially rather than only radially outward, the design achieves improved aerodynamic performance while containing the overall footprint within the compressor housing boundaries, effectively using vertical space to reduce horizontal expansion.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 connector improves fluid flow continuity and reduces aerodynamic losses, enhancing the overall efficiency and performance of the refrigerant compressor in HVAC chiller systems by ensuring a stable and efficient transition between compression stages.

Implementation Method 1

a connector fluidly connecting an outlet of the first radial compression stage to an inlet of the second radial compression stage

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

improves fluid flow continuity and reduces aerodynamic losses

Methodology Applied

Scientific EffectAerodynamic losses:

Data Source

PatentUS11486618B2Integrated connector for multi-stage compressor

Publication Date: 2022.11.01 DANFOSS AS

AI summary

This disclosure relates to a compressor having at least two compression stages. In particular, an exemplary compressor includes a first radial compression stage arranged along an axis, a second radial compression stage arranged along the axis, and a connector fluidly connecting an outlet of the first radial compression stage to an inlet of the second radial compression stage. The connector has a plurality of sections arranged about the axis. The compressor may be a refrigerant compressor used in a heating, ventilation, and air conditioning (HVAC) chiller system.