Rotary Compressor Oil Separation Plate With Lower-Cost Press Forming
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Solution Overview
Problem
Conventional rotary compressors face increased manufacturing costs due to complex oil separation plate designs requiring large material amounts, complex press-molding processes, and additional processing steps, leading to higher assembly and processing times.
Innovation Solution
A rotary compressor with a simplified oil separation plate design featuring a central cylindrical portion, a curved radial portion, and an outer peripheral disk, fixed to the rotor using rivets, allowing for cost-effective press-molding and reduced processing steps, thereby lowering manufacturing and assembly costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional oil separation plate with radial spacer portions is used, then oil separation function is achieved, but the plate becomes thick and requires large amount of material, increasing manufacturing cost
Solution Approach 1:
The oil separation plate is divided into a disk portion and a cylindrical portion, where the cylindrical portion extends from the center of the disk portion. This segmentation allows the plate to form an oil separation space without requiring extensive radial spacers, thereby reducing material usage while maintaining the oil separation function.
Solution Approach 2:
Instead of using radial spacers extending from the outer perimeter (two-dimensional approach), the invention uses a cylindrical portion extending vertically from the center (adding a third dimension). This dimensional change creates the necessary oil separation space with less material, as the cylindrical portion defines the space along the axial direction rather than requiring extensive radial extension.
2Reliability
If conventional oil separation plate design is used, then oil separation is achieved, but processing and assembly times increase
Solution Approach 1:
The simplified segmented structure of the oil separation plate (disk portion plus cylindrical portion) is easier to manufacture using standard press-molding techniques compared to complex radial spacer designs. This reduces processing time while maintaining the essential oil separation functionality through the vertically-oriented cylindrical space.
3Reliability
If complex oil separation plate design is used, then oil separation function is maintained, but manufacturing cost increases
Solution Approach 1:
The oil separation plate is segmented into a simple disk portion and a cylindrical portion, which can be manufactured using conventional press-molding processes. This simplified segmentation reduces manufacturing complexity and cost compared to designs requiring multiple radial spacers and more intricate forming operations.
Solution Approach 2:
By transitioning from a radial spacer design (extending outward from center) to a cylindrical portion design (extending vertically from disk), the invention utilizes the axial dimension more effectively. This dimensional shift simplifies the manufacturing process as it can be achieved through standard press-molding operations rather than requiring complex radial forming and assembly operations.
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 solution results in a rotary compressor with reduced processing and assembly costs, improved oil separation efficiency, and streamlined manufacturing processes without the need for additional equipment or steps.
Implementation Method 1
an oil separation unit which is formed on an end plate attached to the upper end portion of the rotor core and against which a gas refrigerant flow flowing out from an upper opening of the refrigerant path collides
Implementation Method 2
a gas refrigerant flow flowing out from an upper opening of the refrigerant path collides
Implementation Method 3
an oil separation space formed between the oil separation plate and the upper surface of the rotator
Data Source
AI summary
A rotary compressor includes a compressor casing which includes a compression unit for sucking refrigerant gas from a low pressure side of a refrigerating cycle and ejecting the gas to a high pressure side of the refrigerating cycle, and a motor for driving the compression unit through a rotating shaft. The compressor has a gas hole formed on a rotor of the motor for causing a refrigerant gas below the motor to pass upward, and an oil separation plate having a central cylindrical portion, a curved portion continuous to the central cylindrical portion and curved in a radial direction, and an outer peripheral disk portion continuous to the curved portion and is fixed on the rotor by a rivet so that a lower end portion of the central cylindrical portion comes into close contact with the upper end of the rotor or an upper end plate of the rotor.