Tubular Cylinder Coupling for Compact Air Compressor Vibration Reduction
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Solution Overview
Problem
Conventional compact reciprocating piston compressors face issues with increased weight and manufacturing costs due to integrally formed cylinders, complex structures, and high vibration leading to durability and performance problems.
Innovation Solution
A compact air compressor design featuring a tubular-shaped cylinder manufactured separately from the block, with O-rings and fixing rings made of Teflon for improved sealing and reduced vibration, and integrally formed suction and discharge mufflers to enhance assembly efficiency and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cylinder is integrally formed with the block, then the structural strength is improved, but the weight and manufacturing cost increase
Solution Approach 1:
The cylinder is separated from the block into independent components. The block and cylinder are manufactured separately and then coupled together using coupling bolts, allowing each part to be optimized independently and reducing overall weight while maintaining structural integrity through the coupling mechanism.
2Weight of moving object
If the cylinder is manufactured separately from the block, then the weight and manufacturing cost are reduced, but the sealing performance deteriorates
Solution Approach 1:
A sealing ring is introduced as an intermediary element between the block and cylinder to ensure proper sealing at the joint interface. The sealing ring compensates for any gaps or irregularities in the coupled surfaces, maintaining reliable sealing performance despite the separate manufacturing of components.
3Ease of manufacture
If the cylinder is manufactured separately from the block, then the manufacturing cost is reduced, but the assembly complexity increases
Solution Approach 1:
The compressor is divided into modular segments (block, cylinder, valve assembly, mufflers) that can be manufactured independently using appropriate processes and then assembled together. This segmentation enables cost-effective manufacturing of each component while the standardized coupling interface keeps assembly complexity manageable.
4Ease of manufacture
If conventional sealing materials are used, then the manufacturing cost is reduced, but the wear resistance deteriorates
Solution Approach 1:
The sealing ring is made of Teflon (PTFE), a composite material known for its excellent wear resistance, low friction, and chemical inertness. This material choice extends the service life of the sealing component while maintaining compatibility with compressed air applications, reducing the need for frequent replacement.
Data Source
AI summary
A cylinder coupling structure of a compact air compressor includes a block, a tubular-shaped cylinder assembled to the block, a valve cover which covers the valve assembly, and at least one pressurized bolt which assembles the valve cover and the block. A piston is reciprocated inside the cylinder. A stator is assembled to the block, a rotator is located to relatively rotate as to the stator, and a crank axis is assembled to the rotator to integrally rotate with the rotator to be axially supported in the block and to be rotatable. A connecting rod, each of both ends thereof is connected to the crank axis and the piston, respectively.