Reciprocating Compressor Segmented Support Member
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Solution Overview
Problem
The existing reciprocating compressors suffer from magnetic flux leakage, which increases motor loss and destabilizes the piston movement, and the use of non-magnetic materials to prevent leakage results in high production costs and reduced reliability due to low abrasion resistance, while misalignment between the motor and compressor components leads to refrigerant leakage and performance deterioration.
Innovation Solution
The compressor design separates the motor and compressor device, using non-magnetic support members to maintain a distance between the stators and prevent magnetic flux leakage, allowing the cylinder and piston to be made of magnetic materials with high abrasion resistance, and assembles the components into distinct blocks to ensure concentricity and reduce assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the cylinder and piston are made of non-magnetic material to prevent magnetic flux leakage, then motor loss is reduced, but production cost increases and reliability decreases due to low abrasion resistance
Solution Approach 1:
The support structure is divided into two distinct parts: a magnetic support portion that contacts the cylinder/piston and a non-magnetic support portion that contacts the stator. This segmentation allows each part to be made of material optimized for its specific function - magnetic material for abrasion resistance and non-magnetic material for preventing flux leakage.
Solution Approach 2:
A dual-material support member acts as an intermediary between the magnetic field source (stator) and the mechanical components (cylinder/piston). The non-magnetic portion blocks magnetic flux propagation, while the magnetic portion provides the necessary mechanical support and abrasion resistance, effectively mediating between conflicting requirements.
2Loss of energy
If the cylinder and piston are made of non-magnetic material to prevent magnetic flux leakage, then motor loss is reduced, but production cost increases
Solution Approach 1:
The support member is segmented into magnetic and non-magnetic portions, allowing selective material application only where necessary. This reduces the overall amount of expensive non-magnetic material required compared to making entire components from non-magnetic materials, thereby lowering production costs while still preventing motor loss.
3Device complexity
If the motor and compressor device are assembled in an overlapping manner, then device complexity is reduced, but magnetic flux leaks along the frame increasing motor loss and destabilizing piston movement
Solution Approach 1:
The non-magnetic support portion acts as a magnetic flux barrier between the stator and the frame, preventing flux leakage along the frame while maintaining the compact overlapping assembly. This intermediary element blocks the harmful magnetic path without requiring separation of the motor and compressor devices.
Solution Approach 2:
The magnetic properties of the support member are changed by using materials with different magnetic permeability in different portions. The non-magnetic portion has low permeability to block flux, while the magnetic portion has high permeability to contain flux, thereby controlling magnetic field distribution in the overlapping assembly.
4Device complexity
If the motor and compressor device are assembled in an overlapping manner, then device complexity is reduced, but piston movement becomes destabilized due to magnetic flux leakage
Solution Approach 1:
The non-magnetic support portion serves as a mediator that blocks magnetic flux from reaching the piston, thereby stabilizing piston movement. This allows the compact overlapping design to be maintained while eliminating the destabilizing effect of magnetic flux on the piston.
5Device complexity
If misalignment occurs between motor and compressor components, then assembly complexity is reduced, but refrigerant leakage increases and performance deteriorates
Solution Approach 1:
The magnetic properties of the support member are utilized to maintain proper alignment and sealing. The magnetic portion attracts and holds the piston in correct position, ensuring proper sealing between components even in the overlapping assembly, thereby preventing refrigerant leakage while maintaining simple assembly.
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 reduces magnetic flux leakage, enhances motor efficiency, lowers production costs, improves reliability, and maintains proper concentricity between the motor and compressor components, reducing refrigerant leakage and improving overall compressor performance.
Implementation Method 1
a magnetic flux generated by the motor (M) may be leaked to the compressor device (C) along the frame 20, increasing motor loss
Implementation Method 2
when power is applied to the coil 35 of the reciprocating motor 30, the mover 33 of the reciprocating motor 30 may perform a reciprocating movement
Data Source
AI summary
A reciprocating compressor is provided that may include an outer stator; an inner stator provided at an inner side of the outer stator with a predetermined gap therebetween; a mover configured to perform a reciprocating movement in the gap between the outer stator and the inner stator; a piston coupled to the mover to perform a reciprocating movement therewith; a cylinder, into which the piston may be inserted to form a compression space while performing a reciprocating movement; a frame coupled to the cylinder; a first support member coupled to the outer stator and the frame; and a second support member separated from the first support member, but coupled to the inner stator and the frame, thereby facilitating concentricity of the motor and compressor device, as well as simplifying an assembly process as the motor and compressor device are divided into several blocks for assembly.