Rotary Compressor Single Suction Port Across Components
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Solution Overview
Problem
Current rotary compressors face challenges in reducing cylinder width while maintaining efficiency, as it leads to increased suction pressure loss and assembly difficulties due to limitations in suction port and pipe diameters, and concentricity issues with divided drive shafts.
Innovation Solution
A rotary compressor design where a single suction port extends across multiple components, including upper and lower cylinders and bearings, allowing for reduced cylinder widths without increasing suction pressure loss, and a manufacturing method involving temporary assembly and drilling to ensure concentricity and large-diameter suction ports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the cylinder width is reduced to shorten the axial seal length, then the leakage loss is reduced and efficiency is improved, but the suction port diameter and suction pipe diameter are limited, leading to increased suction pressure loss
Solution Approach 1:
The suction port is configured to extend in the axial direction (another dimension) rather than only radially, allowing the flow path cross-sectional area to be increased without increasing the radial dimensions. This enables maintaining large suction port effective area while keeping cylinder width reduced, thus resolving the contradiction between reducing leakage loss and preventing suction pressure loss.
Solution Approach 2:
The suction port is divided into multiple segments (first suction port in upper cylinder, second suction port in lower cylinder, third suction port in separator plate) that are arranged in the axial direction. These segmented ports work together to provide a large total flow area while accommodating the reduced cylinder width constraint.
2Loss of energy
If the cylinder width is reduced, then the axial seal length is shortened and efficiency is improved, but additional processing work is required for elongated or oval suction ports, increasing manufacturing complexity
Solution Approach 1:
The suction port function is segmented across multiple components (upper cylinder, separator plate, lower cylinder), with each component having a simpler circular or rectangular port configuration. This segmentation avoids the need for complex elongated or oval port processing in single components, reducing manufacturing complexity while achieving the required flow area.
Solution Approach 2:
Multiple simple suction ports from different components are merged to form the complete suction system. The first suction port, second suction port, and third suction port are combined in the axial direction to provide the total required flow area, avoiding the need for complex single-port geometries.
3Ease of operation
If the drive shaft is divided into two portions between upper and lower eccentric shaft portions, then assembly limitations are relaxed and seal length is increased, but the concentricity of the divided drive shaft portions is difficult to ensure
Solution Approach 1:
The separator plate serves as an intermediary component that connects the upper and lower drive shaft portions. The third suction port is formed through the separator plate, providing a reference feature that facilitates precise alignment and ensures concentricity between the divided drive shaft portions during assembly.
Solution Approach 2:
The separator plate with the third suction port is prepared in advance as a precision component. This preliminary preparation of the separator plate with its through-hole provides a pre-established reference that guides the assembly of the divided drive shaft portions, ensuring their concentricity before final assembly.
4Object-affected harmful factors
If a single suction port extends across multiple components, then large-diameter suction ports are achieved without increasing suction pressure loss, but the manufacturing and assembly process becomes more complex
Solution Approach 1:
The single suction port function is segmented across multiple standard components (upper cylinder, separator plate, lower cylinder). Each component maintains its structural independence and standard manufacturing processes, while collectively forming the complete suction port system. This segmentation avoids creating a single complex integrated structure.
Solution Approach 2:
The separator plate serves multiple functions: it acts as a structural divider between upper and lower cylinders, provides sealing surfaces, forms the third suction port, and serves as an alignment reference for the divided drive shaft portions. This multi-functionality reduces the need for additional specialized components.
Data Source
Figure 1
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AI summary
Provided is a rotary compressor which exhibits a high efficiency without an increase in a suction pressure loss due to reduction in a cylinder width and which can be easily assembled without the difficulty in assembly and manufacturing to ensure concentricity even if a suction port extending across a plurality of components is provided. Also provided is a method for manufacturing the rotary compressor. In a rotary compressor 1, two upper and lower cylinder chambers 9, 11 are formed by an upper cylinder 10, a separator plate 13, a lower cylinder 12, an upper bearing 14, and a lower bearing 15, and a single suction port 24 communicating with the upper and lower cylinder chambers 9, 11 is provided to extend across three components including the upper cylinder 10, the separator plate 13, and the lower cylinder 12.