Compressor including bearing and unloader assembly

Abstract

A compressor is provided that may include a drive shaft, a compression mechanism, a bearing and an unloader. The drive shaft may include a main body and a crank pin extending from the main body. The compression mechanism may include first and second members. The crank pin may drivingly engage the second member and cause motion of the second member relative to the first member. The bearing may rotatably supporting the main body of the drive shaft. The unloader may rotatably engage the bearing and slidably engage the main body.

Claims

1. A compressor comprising: a shell; a drive shaft including a main body and an eccentric portion, said main body including a recess; a compression mechanism disposed within said shell and including a first member and a second member, said eccentric portion drivingly engaging said first member and causing motion of said first member relative to said second member; a bearing housing fixed within said shell; a bearing housed within and supported by said bearing housing, said bearing axially spaced apart from said first and second members, said bearing rotatably supporting and engaging said main body of said drive shaft; and an unloader rotatably engaging said bearing and slidably received in said recess of said main body, wherein said bearing is disposed radially outward relative to said unloader and extends circumferentially around said unloader, wherein said unloader is slidable within said recess in a direction that is perpendicular to a rotational axis of said drive shaft.

2. The compressor of claim 1, wherein said recess is defined by a flat surface of said drive shaft that is substantially parallel to a rotational axis of said main body, and said unloader includes a flat surface that slidably engages said flat surface of said drive shaft.

3. The compressor of claim 1, wherein said recess is defined by first and second flat surfaces of said drive shaft that are substantially parallel to a rotational axis of said main body.

4. The compressor of claim 3, wherein said unloader includes first flat surface and a second flat surface, said first flat surface of said unloader engages said first flat surface of said drive shaft, said second flat surface of said unloader faces said second flat surface of said drive shaft.

5. The compressor of claim 4, wherein said first and second flat surfaces of said unloader are substantially perpendicular to each other.

6. The compressor of claim 4, further comprising a biasing member disposed between said first flat surface of said drive shaft and said first flat surface of said unloader, said biasing member biasing said first flat surface of said drive shaft and said first flat surface of said unloader away from each other in a direction that is substantially perpendicular to said rotational axis of said main body.

7. The compressor of claim 4, wherein said unloader includes a curved surface that extends from said first flat surface of said unloader to said second flat surface of said unloader, said curved surface rotatably engaging said bearing.

8. The compressor of claim 1, wherein said eccentric portion extends from an axial end of said main body.

9. The compressor of claim 1, further comprising another bearing rotatably supporting said main body.

10. The compressor of claim 9, further comprising a drive bearing rotatably supporting said eccentric portion and disposed within an annular hub of said first member.

11. The compressor of claim 1, wherein said first and second members are scroll members.

12. The compressor of claim 1, further comprising a variable-speed motor driving said drive shaft.

13. The compressor of claim 1, wherein said recess extends only partially around a circumference of said main body of said drive shaft.

14. The compressor of claim 13, wherein said unloader is rotationally fixed relative to said drive shaft.

15. A compressor comprising: a compression mechanism; a drive shaft having a main body and a crank pin, said crank pin having a longitudinal axis that is offset from a longitudinal axis of said main body, said crank pin drivingly engaging a first member of said compression mechanism and causing motion of said first member relative to a second member of said compression mechanism, said main body rotatably engages a bearing and is radially compliant at said bearing; and an unloader received within a recess in said main body, wherein said unloader rotatably engages said bearing during operation of the compressor, wherein said bearing is disposed radially outward relative to said unloader and extends circumferentially around said unloader, wherein said unloader is slidable within said recess in said main body during operation of the compressor, wherein said recess is axially spaced apart from said crank pin, and wherein said unloader is slidable within said recess in a direction that is perpendicular to a rotational axis of said drive shaft.

16. The compressor of claim 15, wherein said recess is defined by first and second flat surfaces of said drive shaft that are substantially parallel to a rotational axis of said main body, and wherein said unloader includes a first flat surface and a second flat surface, said first flat surface of said unloader engages said first flat surface of said drive shaft, said second flat surface of said unloader faces said second flat surface of said drive shaft.

17. The compressor of claim 16, wherein said first and second flat surfaces of said unloader are angled relative to each other.

18. The compressor of claim 16, further comprising a biasing member disposed between said first flat surface of said drive shaft and said first flat surface of said unloader, said biasing member biasing said first flat surface of said drive shaft and said first flat surface of said unloader away from each other in a direction that is substantially perpendicular to said rotational axis of said main body.

19. The compressor of claim 16, wherein said unloader includes a curved surface that extends from said first flat surface of said unloader to said second flat surface of said unloader, said curved surface rotatably engaging said bearing.

20. The compressor of claim 15, further comprising: another bearing rotatably supporting said main body; and a drive bearing rotatably supporting said crank pin and disposed within an annular a hub of said first member.

21. The compressor of claim 15, wherein said first and second members are scroll members.

22. The compressor of claim 15, wherein said crank pin extends from an axial end of said main body.

23. The compressor of claim 15, further comprising a variable-speed motor driving said drive shaft.

24. The compressor of claim 15, wherein said recess extends only partially around a circumference of said main body of said drive shaft.

25. The compressor of claim 15, wherein said unloader is rotationally fixed relative to said drive shaft.

26. A compressor comprising: a drive shaft including a main body and an eccentric portion, said main body including a recess defined by first and second flat surfaces of said drive shaft that are substantially parallel to a rotational axis of said main body; a compression mechanism including a first member and a second member, said eccentric portion drivingly engaging said first member and causing orbital motion of said first member relative to said second member; a bearing axially spaced apart from said first and second members, said bearing rotatably supporting and engaging said main body of said drive shaft; an unloader rotatably engaging said bearing and slidably received in said recess of said main body, said unloader includes first and second flat surfaces that are not parallel to each other, said first flat surface of said unloader engages said first flat surface of said drive shaft, said second flat surface of said unloader faces said second flat surface of said drive shaft, said unloader including a curved surface that extends from said first flat surface of said unloader to said second flat surface of said unloader, said curved surface rotatably engaging said bearing; and a biasing member disposed between said first flat surface of said drive shaft and said first flat surface of said unloader, said biasing member biasing said first flat surface of said drive shaft and said first flat surface of said unloader away from each other in a direction that is substantially perpendicular to said rotational axis of said main body.

27. The compressor of claim 26, wherein said recess extends only partially around a circumference of said main body of said drive shaft.

28. The compressor of claim 27, wherein said unloader is slidable within said recess in a direction that is perpendicular to a rotational axis of said drive shaft.

29. The compressor of claim 28, wherein said unloader is rotationally fixed relative to said drive shaft.

Description

DRAWINGS

(1) The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

(2) FIG. 1 is a cross-sectional view of a compressor according to the principles of the present disclosure;

(3) FIG. 2 is a top view of a drive shaft and a portion of a bearing assembly of the compressor of FIG. 1;

(4) FIG. 3 is a perspective view of the drive shaft according to the principles of the present disclosure;

(5) FIG. 4 is a perspective view of a bearing unloader according to the principles of the present disclosure; and

(6) FIG. 5 is a top view of another drive shaft and a portion of a bearing assembly according to the principles of the present disclosure.

(7) Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

(8) Example embodiments will now be described more fully with reference to the accompanying drawings.

(9) Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

(10) The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms a, an, and the may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms comprises, comprising, including, and having, are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

(11) When an element or layer is referred to as being on, engaged to, connected to, or coupled to another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being directly on, directly engaged to, directly connected to, or directly coupled to another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., between versus directly between, adjacent versus directly adjacent, etc.). As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

(12) Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as first, second, and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

(13) Spatially relative terms, such as inner, outer, beneath, below, lower, above, upper, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as below or beneath other elements or features would then be oriented above the other elements or features. Thus, the example term below can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

(14) With reference to FIG. 1, a compressor 10 is provided that may include a hermetic shell assembly 12, a motor assembly 14, a compression mechanism 16, a first bearing assembly 18, and a second bearing assembly 19.

(15) The shell assembly 12 may form a compressor housing and may include a cylindrical shell 20, an end cap 22 at an upper end thereof, a transversely extending partition 24, and a base 26 at a lower end thereof. The end cap 22 and the partition 24 may define a discharge chamber 28. The partition 24 may separate the discharge chamber 28 from a suction chamber 30. The partition 24 may define a discharge passage 32 extending therethrough to provide communication between the compression mechanism 16 and the discharge chamber 28. A discharge fitting 34 may be attached to shell assembly 12 at an opening 36 in the end cap 22. A discharge valve assembly 38 may be disposed within the discharge fitting 34 or proximate the discharge passage 32 and may generally prevent a reverse flow condition through the discharge fitting 34. A suction inlet fitting 40 may be attached to shell assembly 12 at an opening 42.

(16) The motor assembly 14 may include a motor stator 44, a rotor 46, and a drive shaft 48. The motor stator 44 may be press fit into the shell 20. The rotor 46 may be press fit on the drive shaft 48 and may transmit rotational power to the drive shaft 48. The drive shaft 48 may be rotatably supported by the first and second bearing assemblies 18, 19. In some embodiments, the motor assembly 14 may be a variable-speed motor configured to drive the drive shaft 48 at any of a plurality of non-zero speeds. While the motor assembly 14 is shown in FIG. 1 as being disposed within the shell assembly 12, in some configurations, the compressor 10 could be an open-drive compressor driven a motor assembly disposed outside of the shell assembly 12.

(17) The compression mechanism 16 may include an orbiting scroll 54 and a non-orbiting scroll 56. The orbiting scroll 54 may include an end plate 58 having a spiral wrap 60 on a first side thereof and an annular flat thrust surface 62 on a second side. The thrust surface 62 may interface with the first bearing assembly 18, as will be subsequently described. A cylindrical hub 64 may project downwardly from the thrust surface 62. A drive bearing 66 may be received within the hub 64. The crank pin 50 of the drive shaft 48 may drivingly engage the drive bearing 66. An Oldham coupling 68 may be engaged with the orbiting and non-orbiting scrolls 54, 56 to prevent relative rotation therebetween. In some embodiments, the crank pin 50 could include a flat surface formed thereon that slidably engages a corresponding flat surface in a drive bushing (not shown) that engages the drive bearing 66.

(18) The non-orbiting scroll 56 may include an end plate 70 and a spiral wrap 72 projecting downwardly from the end plate 70. The spiral wrap 72 may meshingly engage the spiral wrap 60 of the orbiting scroll 54, thereby creating a series of moving fluid pockets. The fluid pockets defined by the spiral wraps 60, 72 and end plates 58, 70 may decrease in volume as they move from a radially outer position (e.g., at a suction pressure) to a radially inner position (e.g., at a discharge pressure that is higher than the suction pressure) throughout a compression cycle of the compression mechanism 16.

(19) The end plate 70 may include a discharge passage 74 and an annular recess 76. The discharge passage 74 is in communication with at least one of the fluid pockets at the radially inner position and allows compressed working fluid (at or near the discharge pressure) to flow therethrough and into the discharge chamber 28. The annular recess 76 may at least partially receive a floating seal assembly 78 and may cooperate with the seal assembly 78 to define an axial biasing chamber 80 therebetween. The biasing chamber 80 may receive intermediate-pressure fluid from a fluid pocket formed by the compression mechanism 16. A pressure differential between the intermediate-pressure fluid in the biasing chamber 80 and fluid in the suction chamber 30 exerts a net axial biasing force on the non-orbiting scroll 56 urging the non-orbiting scroll 56 toward the orbiting scroll 54 to facilitate a sealed relationship therebetween.

(20) The first bearing assembly 18 may include a bearing housing 82, a bearing 84, and an unloader 86. The bearing housing 82 may be fixed relative to the shell assembly 12 and may include an annular hub 88 that receives the bearing 84. The bearing housing 82 and bearing 84 may cooperate to support the drive shaft 48 for rotational motion relative thereto. The bearing housing 82 may also axially support the orbiting scroll 54 for orbital motion relative thereto.

(21) Referring now to FIGS. 1-3, the drive shaft 48 may include a main body 90 having first and second end portions 92, 94 rotatably supported by the first and second bearing assemblies 18, 19, respectively. The crank pin 50 may extend from the first end portion 92. An oil passage 96 may extend through the length of the drive shaft 48 from the second end portion 94 through the first end portion 92 and through the crank pin 50. During operation of the motor assembly 14, oil from an oil sump 97 may be pumped up through the oil passage 96 to supply oil to the drive bearing 66. Oil may also flow from the oil passage 96 to the bearing 84 through a supply passage 98 that extends radially outward from the oil passage 96.

(22) As shown in FIG. 1, first and second counterweights 93, 95 may be attached to the main body 90 between the first and second bearing assemblies 18, 19 to rotationally balance the drive shaft 48. The first and second counterweights 93, 95 may be configured and positioned such that an inertial force of the first counterweight 93 may counteract or balance a sum of inertial forces of the second counterweight 95, the orbiting scroll 54 and the crank pin 50.

(23) As shown in FIGS. 2 and 3, the main body 90 of the drive shaft 48 may include a recess 100 formed therein at or proximate the first end portion 92. The recess 100 may be generally aligned with the bearing 84 in an axial direction. The recess 100 may include first and second axial ends 102, 104 and first and second flat surfaces 106, 108. The first and second axial ends 102, 104 may define respective planes that may be substantially perpendicular to and intersecting a longitudinal axis A1 of the drive shaft 48. The first and second flat surfaces 106, 108 extend from the first axial end 102 to the second axial end 104 and may be substantially perpendicular to the first and second ends 102, 104.

(24) As shown in FIG. 2, the unloader 86 may be received in the recess 100 and may provide axial compliance for the drive shaft 48 and the orbiting scroll 54. As shown in FIG. 4, the unloader 86 may be a semi-cylindrical or partially cylindrical body having first and second axial ends 110, 112, a curved surface 114 and first and second flat surfaces 116, 118. A distance between the first and second axial ends 110, 112 may be approximately equal to or slightly less than a distance between first and second axial ends 102, 104 of the recess 100. The curved surface 114 may include a radius that is approximately equal to a radius of the main body 90 of the drive shaft 48. The first and second flat surfaces 116, 118 of the unloader 86 may slidably engage the first and second flat surfaces 106, 108, respectively, of the recess 100. An angle between the first and second flat surfaces 116, 118 may be substantially equal to an angle between the first and second flat surfaces 106, 108. In some embodiments, the angle between the first flat surface 106 and the second flat surface 108 and/or the angle between the first flat surface 116 and the first flat surface 118 may be approximately ninety degrees or between approximately eighty and one-hundred degrees, for example. In some embodiments, a spring 120 (FIGS. 2 and 4) may be disposed between the first flat surface 106 of the recess 100 and the first flat surface 116 of the unloader 86. The spring 120 may bias the flat surfaces 106, 116 away from each other.

(25) As shown in FIG. 2, the second flat surface 108 may be oriented at an angle B relative to an axis A3. The axis A3 may be an axis that is perpendicular to and intersects axes A1, A2. As described above, the axis A1 is the longitudinal axis of the main body 90 of the drive shaft 48. The axis A2 is a longitudinal axis of the crank pin 50 of the drive shaft 48. While a corner C of the recess 100 is shown in FIG. 2 as being disposed along axis A3, in some embodiments, the recess 100 and the unloader 86 can be oriented so that the corner C is offset from the axis A3 (as shown in FIG. 5).

(26) During operation of the compressor 10, in which the drive shaft 48 may be rotating in a direction R (FIG. 2) about the axis A1, radial gas forces F.sub.GR (occurring along axis A3) and tangential gas forces F.sub.GT (occurring along an axis A4 perpendicular to the axis A3) from the compression of the working fluid in the compression mechanism 16 are transferred to the drive shaft 48 and bearing 84. The gas forces F.sub.GR, F.sub.GT cause a reaction force F.sub.R to be applied to the main body 90 of the drive shaft 48. The reaction force F.sub.R is transferred to the second flat surface 108. The angle B of the second flat surface 108 may be selected such that a first component F.sub.R1 of the reaction force F.sub.R balances the gas force F.sub.GR and a difference between a second component F.sub.R2 of the force F.sub.R and the gas force F.sub.GT results in a sufficient force to overcome the biasing force of the spring 120 and close or reduce a gap between the flat surfaces 106, 116 of the drive shaft 48 and unloader 86, respectively. In some embodiments, the angle B may be between approximately twenty and thirty degrees, for example. In some embodiments, the angle B may be between approximately twenty and forty-five degrees, for example.

(27) While the drive shaft 48 and unloader 86 are described above as being incorporated into a vertical, hermetic compressor, it will be appreciated that the principles of the present disclosure may be applicable to horizontal and/or open-drive compressors, for example, or any other type of high-side or low-side compressor or pump. It will be appreciated that the drive shaft 48 and unloader 86 could be incorporated into a compressor having a floating non-orbiting scroll (e.g., an axially compliant non-orbiting scroll) or a compressor having a fixed non-orbiting scroll.

(28) While the compression mechanism 16 is described above as being a scroll-type compression mechanism, it will be appreciated that the principles of the present disclosure may be applicable to rotary compressors. That is, the drive shaft 48 and first bearing assembly 18 (with the unloader 86) may be configured to drive a rotor of a rotary-type compression mechanism.

(29) The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.