Integrated Motor-Compressor Assembly for Refrigeration
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Solution Overview
Problem
Traditional refrigeration systems require separate and distinct components for compressors and motors, leading to inefficiencies and increased costs due to the need for external motor couplings and gearboxes, and they lack a compact, energy-efficient design.
Innovation Solution
An integrated motor-compressor assembly where the impeller serves as both a compressor and a motor rotor, and the diffuser serves as both a compressor and a motor stator, utilizing stator windings to generate magnetic flux for rotation, eliminating the need for an external motor and gearbox, and incorporating a switched reluctance machine design with a multi-phase power inverter for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate motor and compressor components are used with external couplings and gearboxes, then the system can achieve reliable power transmission, but the device complexity and overall size increase
Solution Approach 1:
The patent merges the motor and compressor into a single integrated unit where the motor rotor is directly coupled to the compressor impeller, eliminating the need for separate motor housing, couplings, and gearboxes. This consolidation reduces device complexity while maintaining power transmission reliability through direct drive.
Solution Approach 2:
The motor-compressor assembly performs multiple functions within a single component structure: the rotor serves as both the motor rotor and the compressor impeller, while the stator serves as both the motor stator and the compressor diffuser. This multi-functionality reduces the overall number of components without compromising reliability.
2Manufacturing precision
If separate motor and compressor components are used, then each component can be optimized independently, but the overall system size and cost increase
Solution Approach 1:
The motor and compressor are merged into a single integrated assembly where the motor rotor and compressor impeller are the same component, and the motor stator and compressor diffuser are the same component. This merging reduces system volume while allowing each component to be optimized for its dual functions.
Solution Approach 2:
The compressor elements (impeller and diffuser) are nested within the motor housing structure, with the impeller forming part of the rotor assembly and the diffuser forming part of the stator assembly. This nesting arrangement minimizes overall system size while maintaining independent optimization capabilities.
3Ease of repair
If traditional separate motor-compressor design is used, then maintenance access is easier, but energy efficiency and compactness are reduced
Solution Approach 1:
The motor and compressor are combined into a single sealed housing that eliminates mechanical couplings and gearboxes, reducing energy losses from friction and misalignment. The direct-drive design improves energy efficiency while the integrated housing can be designed for modular maintenance access.
4Reliability
If external motor couplings and gearboxes are used, then power transmission is reliable, but losses from mechanical interfaces increase
Solution Approach 1:
The motor rotor and compressor impeller are merged into a single rotating component, eliminating mechanical couplings, gears, and other intermediate transmission elements. This direct-drive configuration eliminates energy losses from mechanical interfaces while maintaining reliable power transmission through the unified structure.
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 achieves a compact, energy-efficient, and cost-effective solution for refrigeration systems by integrating the compressor and motor functions within a single housing, eliminating the need for external couplings and gearboxes, and enabling high-pressure ratios and efficient fluid compression.
Implementation Method 1
stator windings being supplied with current to generate sufficient magnetic flux for rotating said impeller
Implementation Method 2
a rotating impeller to compress a fluid passing therethrough
Data Source
AI summary
Embodiments provide an integrated motor-compressor assembly including a rotating impeller to compress a fluid passing therethrough, and diffuser vanes radially spaced from the impeller, each of the diffuser vanes including a stator winding therearound, the stator windings being supplied with current to generate sufficient magnetic flux for rotating the impeller. Embodiments provide an integrated motor-compressor assembly including a volute casing housing a rotating impeller to compress a fluid passing therethrough, a stator fixedly positioned in the volute casing proximate to the impeller, the stator including stator poles axially spaced from the impeller, each of the stator poles including a stator winding, the stator windings being supplied with current to generate sufficient axial magnetic flux for rotating the impeller.