Rotor assembly, compressor and air conditioner

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Solution Overview

Problem

Four-rotor compressors face issues with random axial forces due to manufacturing and assembly deviations, leading to incomplete counteraction of axial forces, resulting in the unnecessary use of two sets of thrust bearings, increased costs, and higher failure rates.

Innovation Solution

A rotor assembly design with coaxially arranged working portions and air pressure grooves that form a fixed gas axial force, allowing only one set of thrust bearings to be used, and a gas film to prevent friction and malfunctions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If two sets of thrust bearings are arranged to counteract random axial forces, then the compressor can handle axial forces in any direction, but the device complexity and cost increase

Engineering Contradiction:
Improveaxial force counteraction capabilityVSAvoidthrust bearing arrangement
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical thrust bearing system with a gas film bearing system. The gas film is generated by the rotation of the rotor itself, which creates a hydrodynamic pressure field that supports the axial load. This substitution eliminates the need for complex thrust bearing arrangements while maintaining the capability to handle axial forces in any direction, thereby reducing device complexity and cost while preserving reliability

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes pneumatic principles by employing gas (air) as the bearing medium. The rotating rotor draws gas into the bearing clearance, and the gas pressure generated by the rotation supports the axial load. This pneumatic bearing system replaces the mechanical thrust bearings, simplifying the device structure while maintaining the ability to counteract axial forces in any direction

Inventive Principle:
Principle #29Pneumatics and hydraulics

2Manufacturing precision

If two sets of thrust bearings are used to ensure axial force bearing in both directions, then the compressor can accommodate manufacturing deviations, but mechanical losses and lubricating oil demands increase

Engineering Contradiction:
Improvetolerance to manufacturing deviationsVSAvoidmechanical losses
Core Design Contradiction:
Manufacturing precisionVSLoss of energy

Solution Approach 1:

The patent replaces the mechanical friction-based thrust bearing system with a gas film bearing system. The gas film eliminates direct metal-to-metal contact, thereby eliminating mechanical friction losses and the associated energy waste. The system can still accommodate manufacturing deviations because the gas film adapts to the actual geometry of the rotor and housing, providing load support without requiring precise mechanical tolerances

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the previously harmful effect of manufacturing deviations into a beneficial feature. Instead of requiring tight tolerances to minimize deviations, the gas film bearing system utilizes the actual geometry (including deviations) to generate the appropriate gas pressure distribution. The manufacturing deviations become part of the bearing clearance that the gas film adapts to, eliminating the need for corrective measures while reducing energy losses

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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

Reduces the need for thrust bearings, simplifies moving parts, lowers costs, and enhances the reliability and performance of the compressor by ensuring axial forces are consistently directed, thus reducing mechanical losses and failure rates.

Implementation Method 1

the first air pressure groove is configured to form a force in a predetermined direction along the first axis when rotating

Methodology Applied
Scientific EffectGas pressurization: Pressure Increase

Implementation Method 2

a gas film to prevent friction and malfunctions

Methodology Applied
Scientific EffectGas film formation: Air Lubrication

Data Source

PatentUS12188472B2Rotor assembly, compressor and air conditioner
Publication Date: 2025.01.07 GREE ELECTRIC APPLIANCE INC OF ZHUHAI
  • US12188472B2 patent drawing
  • US12188472B2 patent drawing
  • US12188472B2 patent drawing

AI summary

A rotor assembly, a compressor and an air conditioner. The rotor assembly includes a first rotor, including a first working portion and a second working portion coaxially arranged, the first working portion and the second working portion are rotatable about a first axis; the first working portion includes a plurality of first helical blades, with a first blade groove being formed between adjacent two of the plurality of first helical blades; at least one first air pressure groove is provided on a first end face of the first working portion away from the second working portion.