Two-Piece Scroll Compressor Counterweight for Tight-Space Balancing
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Solution Overview
Problem
The development of compact and cost-effective scroll compressors requires a counterweight that can fit into tight spaces between the electric drive unit and the upper bearing member, addressing weight imbalance and vibration issues while maintaining efficiency.
Innovation Solution
A two-piece counterweight is manufactured using powdered metal, comprising a base and an outer plate that are axially offset and attached via mechanical fasteners, brazing, or welding, allowing for complex shapes that fit within the constrained space, with configurations such as arcuate and stepped portions to optimize positioning and attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a compact scroll compressor design is used to reduce size and cost, then the overall dimensions and manufacturing cost are improved, but the space available for counterweight components is reduced
Solution Approach 1:
The counterweight is divided into two separate pieces: a base portion and an outer plate portion. This segmentation allows each component to be manufactured independently using cost-effective powdered metal molding, and then assembled together to form the complete counterweight assembly that fits within the compact compressor space
Solution Approach 2:
The two-piece counterweight assembly is positioned within the tight space between the electric drive unit and the upper bearing member, effectively nesting the counterweight components into the available volume of the compact compressor design
2Area of stationary object
If a complex-shaped counterweight is designed to fit tight spaces, then the space utilization is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
By dividing the counterweight into two simpler components (base and outer plate), each piece can be manufactured using standard powdered metal molding processes without requiring complex single-piece tooling or extensive machining operations
Solution Approach 2:
The invention changes the manufacturing approach from traditional single-piece machining to powdered metal molding, which allows for cost-effective production of components with complex geometries by adjusting molding parameters rather than requiring complex machining
3Strength
If traditional single-piece counterweight manufacturing is used, then the structural integrity is maintained, but the manufacturing cost and machining requirements increase
Solution Approach 1:
The counterweight is segmented into two pieces that are subsequently joined together using mechanical fasteners, brazing, or welding, maintaining structural integrity while enabling cost-effective powdered metal manufacturing of each component
Solution Approach 2:
The two-piece counterweight assembly functions as a composite structure, combining the base portion and outer plate portion through various joining methods to achieve the required mechanical strength and structural integrity
Data Source
AI summary
A method of manufacturing a two-piece counterweight for a scroll compressor is provided. The method includes molding an outer plate, and molding a base having a first opening configured to receive a scroll compressor drive shaft having a longitudinal axis. The method further includes configuring the base for assembly and attachment to the drive shaft. The method also includes attaching the outer plate to the base such that the outer plate is axially offset from the base. In a particular embodiment of this method, the base and outer plate are molded from powdered metal. In certain embodiments, the base and outer plate include one or more openings aligned to permit attachment by inserting a mechanical fastener through the aligned openings. In alternate embodiments, the base and outer plate are attached via brazing or welding.