Two-Stage Scroll Rotary Compressor Vibration Noise Reduction
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Solution Overview
Problem
Existing refrigerant compressors face issues with vibration noise, unstable intermediate pressure, high fabrication costs, and efficiency losses due to dead volume, particularly in two-stage scroll compressors, which affect compression efficiency and oil stirring.
Innovation Solution
A two-stage compressor design incorporating a scroll side compression unit and a rotary side compression unit, where the first-stage compression unit operates in scroll mode and the second-stage in rotary mode, with specific geometrical configurations to minimize vibration, stabilize pressure, and reduce dead volume, including the use of a bush bearing made of plastic material for reduced friction and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a two-stage scroll compressor is designed, then compression efficiency is improved, but fabrication complexity and cost increase significantly
Solution Approach 1:
The patent merges scroll compression and rotary compression mechanisms into a single integrated compressor body. The scroll compression unit and rotary compression unit share common structural elements including the compression chamber, suction port, and discharge port, allowing two-stage compression functionality while reducing overall device complexity and fabrication cost.
Solution Approach 2:
The compression chamber serves multiple functions: it acts as the compression space for both scroll and rotary compression mechanisms, contains the suction port for refrigerant intake, and provides the discharge port for high-pressure refrigerant output. This multi-functionality reduces the number of separate components needed.
2Power
If scroll compression mode is used, then stable torque and high compression ratio are achieved, but vibration noise increases
Solution Approach 1:
The compression process is segmented into two distinct stages: scroll compression for the first stage and rotary compression for the second stage. This segmentation allows each mechanism to operate in its optimal range, with the rotary stage specifically designed to reduce vibration noise in the final compression phase.
Solution Approach 2:
Different compression modes are applied to different stages of the compression process. The scroll compression unit handles the initial compression with high compression ratio, while the rotary compression unit handles the final stage with optimized geometry to minimize vibration and noise.
3Stability of the object's composition
If orbiting scroll is supported by rotation prevention member, then orbital movement is maintained, but behavior destabilization occurs
Solution Approach 1:
The patent removes the rotation prevention member that was previously used to support the orbiting scroll. Instead, the orbital movement is maintained through the engagement between the orbiting wrap and fixed wrap of the scroll mechanisms, which naturally constrain the motion without additional stabilizing components that could cause destabilization.
4Strength
If boss portion is protruded for crankshaft coupling, then mechanical connection is achieved, but oil stirring loss increases
Solution Approach 1:
The crankshaft connection geometry is optimized to minimize the protrusion of the boss portion. The dynamic interaction between the crankshaft and the orbiting scroll is designed to achieve adequate mechanical connection with reduced oil agitation, thereby minimizing oil stirring losses and improving overall efficiency.
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 design maintains low vibration noise, stabilizes intermediate pressure, reduces fabrication costs, enhances compression efficiency by minimizing dead volume, and improves oil management, leading to increased suction volume and overall compressor performance.
Implementation Method 1
the use of a bush bearing made of plastic material for reduced friction and noise
Implementation Method 2
a two-stage compressor having a scroll side compression unit and a rotary side compression unit
Data Source
AI summary
A compressor according to the present disclosure may include a container; a drive motor provided in the container; a crankshaft coupled to a rotor of the drive motor; a first scroll coupled to the crankshaft to receive a rotational force of the drive motor to perform an orbiting movement; a second scroll coupled to the first scroll to form a first compression unit and a second compression unit along with the first scroll; and a vane provided in the first scroll or second scroll to be brought into contact with the other side scroll to form the second compression unit, wherein the first compression unit is carried out in a scroll compression mode and the second compression unit is carried out in a rotary compression mode.