Unmachined Separator Plate in Scroll Compressor
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Solution Overview
Problem
Conventional scroll compressor manufacturing processes, particularly for separator plates, involve costly and time-consuming machining steps that increase complexity and reduce efficiency.
Innovation Solution
A method of manufacturing a scroll compressor that includes assembling scroll compressor bodies and constructing a separator plate by piercing and trimming a metal blank to form an annular member with a frusto-conical shape, eliminating the need for machined surfaces and using non-material-removal processes like stamping and welding to achieve precise alignment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining is used to create the central bore of the separator plate, then position tolerances during final assembly are improved, but manufacturing cost, complexity, and time increase
Solution Approach 1:
The central bore and outer diameter are created simultaneously during the initial stamping operation before final assembly, rather than machining them separately afterward. This preliminary action establishes precise position tolerances through the stamping process itself, eliminating the need for subsequent machining operations and reducing manufacturing complexity
Solution Approach 2:
The creation of the central bore and outer diameter operations are merged into a single stamping process step. By combining these operations that were previously performed separately (with the bore machined after stamping), the manufacturing process becomes simpler while maintaining precise position tolerances through the integrated tooling
2Manufacturing precision
If machining is used to create the central bore of the separator plate, then position tolerances during final assembly are improved, but manufacturing time increases
Solution Approach 1:
The central bore is created during the initial stamping operation rather than through subsequent machining. This preliminary action reduces manufacturing time by eliminating separate machining steps while achieving the required position tolerances through the stamping process and integrated tooling design
Solution Approach 2:
The patent skips the intermediate machining step entirely by creating the central bore directly during stamping. This rushing through of the manufacturing process achieves both time savings and precision by consolidating operations into fewer steps with tighter process control
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 approach reduces manufacturing costs and time by eliminating machining steps, achieving precise positioning and a high-quality surface finish without material removal, resulting in a more efficient and cost-effective scroll compressor production process.
Implementation Method 1
piercing an inner portion of a metal blank of substantially constant thickness and trimming a perimeter portion of the metal blank, to form an annular member. Constructing a separator plate also includes forming the annular member into a frusto-conical shape
Implementation Method 2
forming the annular member into a frusto-conical shape having an axially-extending curved outer wall, and a central opening having an axially-extending curved inner wall
Data Source
AI summary
A scroll compressor includes scroll compressor bodies, which, in turn, include a fixed scroll compressor body and a moveable scroll compressor body. The scroll compressor bodies have respective bases and respective scroll ribs that project from the respective bases, and which mutually engage about an axis for compressing fluid. The scroll compressor also includes a housing to house the scroll compressor bodies. A separator plate is configured to separate a high-pressure gas chamber from a low-pressure gas chamber within the housing. The separator plate has no machined surfaces, and has an outer perimeter portion which is attached to an unmachined inner surface of the housing. Having no machined surfaces indicates that no material is removed from the separator plate during its manufacture apart from operations to form initial inner and outer diameters of the separator plate.