Integrated Cylinder Head Compressor Unit Design
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Solution Overview
Problem
Compressor units for portable/transportable devices, such as those used for inflating car tires, require a simplified design with fewer components and reduced machining key components to minimize production and assembly costs while maintaining reliable functionality, as existing designs are complex and costly due to numerous tightly toleranced parts.
Innovation Solution
The cylinder and cylinder head are integrated into a single component, incorporating outlet devices, connections, valves, and a manometer connection, with cooling surfaces and a pressure relief valve receptacle, allowing for a compact, cost-effective design with reduced processing steps and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cylinder and cylinder head are designed as separate components with multiple tightly toleranced parts, then the compressor unit achieves reliable functionality, but the production cost and assembly complexity increase significantly
Solution Approach 1:
The patent merges the cylinder and cylinder head into a single integrated component, eliminating the need for separate parts and their associated connections. This integration reduces the total number of components while maintaining the functional reliability of the compressor unit, directly resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The integrated cylinder-cylinder head component performs multiple functions simultaneously: it serves as both the compression chamber housing and the head structure, incorporates cooling surfaces, and provides mounting points for valves and connections. This multi-functionality reduces component count while ensuring reliable operation, addressing the contradiction between simplicity and reliability.
2Reliability
If multiple separate components with narrow tolerances are used, then the compressor unit functions reliably, but the machining effort and production cost increase
Solution Approach 1:
By combining the cylinder and cylinder head into one component, the patent eliminates the need for precise mating surfaces and connections between separate parts. This reduces the cumulative tolerance requirements and machining precision needed, while maintaining functional reliability through the integrated design.
3Adaptability or versatility
If the compressor unit includes all necessary outlet devices and connections as separate components, then the device is functionally complete, but the weight and number of parts increase
Solution Approach 1:
The patent integrates outlet devices, connections, and valve mounting structures directly into the cylinder-cylinder head component. This merging eliminates the need for separate mounting brackets, connection pieces, and fastening hardware, reducing the overall weight while maintaining functional completeness and versatility.
4Ease of manufacture
If numerous separate components are assembled together, then the compressor unit can be produced with standardized parts, but the assembly time and production effort increase
Solution Approach 1:
The integrated cylinder-cylinder head component eliminates multiple assembly steps involving fastening, sealing, and alignment of separate parts. By combining multiple functions into one component, the patent reduces assembly time and increases productivity while maintaining ease of manufacture through standardized production processes for the integrated component.
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 integrated design reduces the number of parts and processing steps, enabling a more affordable and reliable compressor unit with simplified assembly, improved cooling, and easy integration of additional features like a pressure relief valve and sealant bottle connection, suitable for cost-effective mass production.
Implementation Method 1
the component comprising the cylinder and the cylinder head has cooling surfaces, in particular cooling ribs
Implementation Method 2
the high dissipation due to the complicated flow geometry
Data Source
Figure 1
AI summary
The invention relates to a compressor unit which comprises a motor and a reciprocating piston compressor, driven by a slider crank mechanism that is arranged inside a crankcase. Said reciprocating piston compressor comprises a piston which can be displaced inside a cylinder that is connected to a cylinder head. The cylinder, cylinder head, outlet devices and connections are configured as a one-piece unit.