AU2012203079B2 - Counterweights for balancing rotary machines - Google Patents

Abstract

There is disclosed a counterweight for a drive shaft designed for use in each of a plurality of rotary machines having different balancing requirements, respectively, said counterweight comprising: a main body having an overall size and shape to fit within each of said plurality of rotary machines; and a recess in said body, said recess being of a volume selected to optimize the total mass of said counterweight for the particular rotary machine for which it is intended. There is also disclosed a method of manufacturing such a counterweight, and a compressor including such a counterweight. 36'

Description

Australian Patents Act 1990- Regulation 3.2A ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Invention Title "Counterweights for balancing rotary machines" The following statement is a full description of this invention, including the best method of performing it known to us: C:\NRPornb\DCC\AZM\4351988_ DOC - 25/5/12 - 1 [0001] The present invention relates to the balancing of rotary machines. More particularly, the present invention relates to counterweights to balance rotary machines. The content of the complete specification of Australian patent application no. 2005232325 as originally filed is incorporated herein by reference. 5 [0002] A class of machines exists in the art generally known as "scroll" apparatus for the displacement of various types of fluids. Such apparatus may be configured as an expander, a displacement engine, a pump, a compressor, etc., and many features of the present invention are applicable to any one of these machines. For purposes of illustration, however, the disclosed embodiments are in the form of a hermetic refrigerant compressor. 10 [0003] Generally speaking, a scroll apparatus comprises two spiral scroll wraps of similar configuration, each mounted on a separate end plate to define a scroll member. The two scroll members are interfitted together with one of the scroll wraps being rotationally displaced 180' from the other. The apparatus operates by orbiting one scroll member (the "orbiting scroll" with respect to the other scroll member (the "fixed scroll" or "non-orbiting 15 scroll") to make moving line contacts between the flanks of the respective wraps, defining moving isolated crescent-shaped pockets of fluid. The spirals are commonly formed as involutes of a circle, and ideally there is no relative rotation between the scroll members during operation; i.e., the motion is purely curvilinear translation (i.e., no rotation of any line in the body). The fluid pockets carry the fluid to be handled from a first zone in the 20 scroll apparatus where a fluid inlet is provided, to a second zone in the apparatus where a fluid outlet is provided. The volume of a sealed pocket changes as it moves from the first zone to the second zone. At any one instant in time, there will be at least one pair of sealed pockets; and when there are several pairs of sealed pockets at one, each pair will have different volumes. in a compressor, the second zone is at a higher pressure than the first 25 zone and is physically located centrally in the apparatus, the first zone being located at the outer periphery of the apparatus. [0004] Two types of contacts define the fluid pockets formed between the scroll members: axially extending tangential line contacts between the spiral faces or flanks of the wraps caused by radial forces ("flank sealing"), and area contacts caused by axial 30 forces between the plane edge surfaces (the "tips") of each wrap and the opposite end plate ("tip sealing"). For high efficiency, good sealing must be achieved for both types of contacts. [0005] The concept of a scroll-type apparatus has, thus, been known for some time -2and has been recognized as having distinct advantages. For example, scroll machines have high isentropic and volumetric efficiency, and, hence, are relatively small and lightweight for a given capacity. They are quieter and more vibration-free than many compressors because they do not use large reciprocating parts (e.g., pistons, connecting rods, etc.), and 5 because all fluid flow is in one direction with simultaneous compression in plural opposed pockets, there are less pressure- created vibrations. Such machines also tend to have high reliability and durability because of the relatively few moving parts utilized, the relatively low velocity of movement between the scrolls, and an inherent forgiveness to fluid contamination. 10 [0006] The orbiting of the one scroll member with respect to the other scroll member creates an imbalance which is typically counteracted using one or more counterweights. When designing new compressors and/or redesigning and modifying existing compressors, it is sometimes necessary to design a new counterweight . The need for a new counterweight is typically required when the mass of the counterweight needs to 15 be optimized for a specific application. Each time a new counterweight of a new mass is required, new molds for the counterweight of the specific mass must be developed. The development of the new molds incurs development time and capital costs associated with the new mold. [0007] According to a first aspect of the present invention, there is provided a 20 method of fabricating a counterweight for a given one of plural rotary machines having different balancing requirements, wherein the counterweight is cast in a mould whereby outer dimensions of a body thereof are such that the counterweight is mountable in each of the rotary machines, a core being positioned in the mould whereby the body is configured with one or more recesses having a volume which is such that the mass of the 25 counterweight is optimised for the given rotary machine, the core having been selected from plural cores each of which is able to be positioned in the mould such that the body of a counterweight cast in the mould when that core is so positioned has said outer dimensions and is configured with one or more recesses having a volume which is such that the counterweight mass is optimised for a respective one of the rotary machines. 30 [0008] According to a second aspect of the present invention, there is provided a counterweight fabricated by the method of the first aspect. [0009] According to a third aspect of the present invention, there is provided a rotary machine comprising: -3 a first scroll member having a first end plate and a first spiral wrap projecting outwardly from said first end plate; and a second scroll member having a second end plate and a second spiral wrap projecting outwardly from said second end plate, said second scroll wrap being 5 intermeshed with said first scroll wrap, a drive shaft arranged to cause said scroll members to orbit relative to one another whereby said spiral wraps will create pockets of progressively changing volume between a suction pressure zone and a discharge pressure zone, wherein a counterweight of the second aspect is mounted to balance the drive shaft. 10 [0010] According to a fourth aspect of the present invention, there is provided a rotary machine comprising a motor and a drive shaft arranged to be driven by the motor, wherein the motor comprises a stator and a rotor, and wherein a counterweight of the second aspect is attached to said rotor to balance said drive shaft. [001 OA] According to a fifth aspect of the present invention, there is provided a 15 combination, for a counterweight fabrication method according to of the first aspect, comprising: said mould; and said plural cores. [0011] The recess size and/or depth can be varied to vary the mass of the 20 counterweight. Thus, a counterweight having common outer dimensions can be manufactured in various masses by changing the size and/or depth of the recess in the counterweight to meet the required mass for the counterweight. The fact that counterweights having different masses can still maintain common outer dimensions eliminates the need for the tooling on the assembly line which assemble the counterweights 25 to the compressor assembly to be modified and/or changed when different masses of counterweights are used. [0012] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the 30 invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. [0013] The invention will now be described by way of non-limiting example only, with reference to the accompanying drawings, in which: -4 [0014] Figure 1 is a vertical cross-sectional view through the center of a scroll-type refrigeration compressor, incorporating counterweights, in accordance with a preferred embodiment of the present invention; [0015] Figure 2 is a perspective view looking down on the counterweight 5 illustrated in Figure 1; [0016] Figure 3 is a perspective view looking up on the counterweight illustrated in Figure 2; [0017] Figure 4 is a view similar to Figure 3, but showing them counterweight having a different mass; 10 [0018] Figure 5 is a perspective view looking up on an alternative counterweight, for incorporation in a rotary machine, in accordance with another embodiment of the present invention; [0019] Figure 6 is a perspective view of a mold assembly which produces the counterweight illustrated in Figures 2 and 3; and 15 [0020] Figure 7 is a perspective view of a mold assembly which produces the counterweight illustrated in Figure 5. [0021] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 20 [0022] The invention is applicable to any type of rotary machine. For exemplary purposes only, the present invention is described in conjunction with a rotary compressor and, in particular, with a scroll-type refrigerant compressor. [0023] Referring now to the drawings in which like reference numerals designate like or corresponding parts throughout the several views, there is shown in Figure 1 a 25 scroll compressor, which incorporates a balancing system, in accordance with a preferred embodiment the present invention designated generally by reference numeral 10. Compressor 10 comprises a generally cylindrical hermetic shell 12 having welded at the upper end thereof a cap 14 and at the lower end thereof a base 16 having a plurality of mounting feet (not shown) integrally formed therewith. Cap 14 is provided with a 30 refrigerant discharge fitting 18 which may have the usual discharge valve therein (not shown). Other major elements affixed to the shell include transversely extending partition 22, which is welded about its periphery at the same point that cap 14 is welded to shell 12 a main bearing housing 24 which is suitably secured to shell 12 and a lower bearing - 4a housing 26 also having a plurality of radially outwardly extending legs, each of which is also suitably secured to shell 12. A motor stator 28, which is generally square in cross section but with the corners rounded off, is press fitted into shell 12. The flats between the rounded corners on the stator provide passageways between the stator and shell, which 5 facilitate the return flow of lubricant from the top of the shell to the bottom. [0024] A drive shaft or crankshaft 30 having an eccentric crank pin 32 at the upper end thereof is rotatably journaled in a bearing 34 in main bearing housing 24, and a second bearing 36 in lower bearing housing 26. Crankshaft 30 has at the lower end a relatively large diameter concentric bore 38 which communicates with a radially outwardly included 10 smaller diameter bore 40 extending upwardly therefrom to the top crankshaft 30. Disposed -5 within bore 38 is a stirrer 42. The lower portion of the interior shell 12 defines an oil sump 44 which is filled with lubricating oil to a level slightly above the lower end of a rotor 46; and bore 38 acts as a pump to pump lubricating fluid up the crankshaft 30 and into bore 40, and ultimately to all of the various portions of the compressor which require 5 lubrication. [0025] Crankshaft 30 is rotatively driven by an electric motor including stator 28, windings 48 passing therethrough and rotor 46 press fitted on the crankshaft 30 and having upper and lower counterweights 50 and 52, respectively. [0026] The upper surface of main bearing housing 24 is provided with a flat thrust 10 bearing surface 54 on which is disposed an orbiting scroll member 56 having the usual spiral vane or wrap 58 on the upper surface thereof. Projecting downwardly from the lower surface of orbiting scroll member 56 is a cylindrical hub having a journal bearing 60 therein, and in which is rotatively disposed a drive bushing 62 having an inner bore 64 in which crank pin 32 is drivingly disposed. Crank pin 32 has a flat on one surface which 15 drivingly engages a flat surface (not shown) formed in a portion of bore 64 to provide a radially compliant driving arrangement, such as shown in U.S. Pat. No. 4,877,382, the disclosure of which is hereby incorporated herein by reference. An Oldham coupling 66 is also provided, positioned between orbiting scroll member 56 and main bearing housing 24, and keyed to orbiting scroll member 56 and a non-orbiting scroll member 68 to prevent 20 rotational movement of orbiting scroll member 56. Oldham coupling 66 is preferably of the type disclosed in U.S. Pat. No. 5,320,506, the disclosure of which is hereby incorporated herein by reference. [0027] Non-orbiting scroll member 68 is also provided, having a wrap 70 positioned in meshing engagement with wrap 58 of orbiting scroll member 56. Non 25 orbiting scroll member 68 has a centrally disposed discharge passage 72 which communicates with an upwardly open recess 74 which, in turn, is in fluid communication with a discharge muffler chamber 76 defined by cap 14 and partition 22. An annular recess 78 is also formed in non-orbiting scroll member 68 within which is disposed a seal assembly 80. Recesses 74 and 78 and seal assembly 80 cooperate to define axial pressure 30 biasing chambers which receive pressurized fluid being compressed by wraps 58 and 70 so as to exert an axial biasing force on non-orbiting scroll member 68 to thereby urge the tips of respective wraps 58, 70 into sealing engagement with the opposed end plate surfaces. Seal assembly 80 is preferably of the type described in greater detail in U.S. Pat.

-6 No. 5,156,539, the disclosure of which is hereby incorporated herein by reference. Non orbiting scroll member 68 is designed to be mounted to main bearing housing 24 in a suitable manner such as disclosed in the aforementioned U.S. Pat. No. 4,877,382 or U.S. Pat. No. 5,102, 316, the disclosure of which is hereby incorporated herein by reference. 5 [0028] Referring now to Figures 2 and 3, upper counterweight 50 is illustrated in greater detail. While the present invention is being described in relation to upper counterweight 50, it is within the scope of the present invention to incorporate the characteristics of upper counterweight 50 into lower counterweight 52, if desired. [0029] Upper counterweight 50 is stepped and it comprises a semicircular C-shaped 10 section or main body 90 having circumferentially opposite end faces 92 and a pair of opposite" circumferentially extended flange positions 94, each including an opening 96 which is utilized to secure counterweight 50 to rotor 46. C-shaped section 90 has an arcuate body portion between end faces 92 which extends circumferentially through an arc of up to, but not exceeding, 1800 so as to be disposed entirely on one side of a plane 15 extending along the axis of rotation of rotor 46. Flange portions 94 extend circumferentially from the juncture of end faces 92 to define an angular extension exceeding 1800. [0030] C-shaped section 90 defines a cavity or recess 98 which is utilized to achieve a specified mass for counterweight 50. Recess 98 extends over a specified arc and 20 it has a specified depth. Both the length of the arc and the depth of the recess can be varied by having different interchangeable cores 100 (Figure 6), which are inserted into a mold or die 102 (Figure 6), which is utilized to manufacture counterweight 50. In addition, one or more ribs 104 can be formed to extend into recess 98 to adjust the mass of counterweight 50 to the specified mass. Counterweight 50' illustrated in Figure 4 has an 25 increased mass when compared to the mass of counterweight 50 due to the shorter arc of recess 98, the shorter depth of recess 98 and the addition of one or more ribs 104. This is accomplished by having a different core or pin 100. The exterior configuration of counterweights 50 and 50' are identical, thus allowing both counterweights 50 and 50' to be manufactured in the same mold or die 102 (Figure 6) with different cores 100 being 30 utilized to define the different sizes of recess 98. Counterweight 50' would replace counterweight 50 when the operating characteristics of compressor 10 change, with the change in operating characteristics requiring rebalancing of compressor 10. [003 1] Referring now to Figure 5, a counterweight 150 is illustrated in accordance -7 with another example. Counterweight 150 is the same as counterweight 50, except that recess 98 has been replaced with a plurality of recesses in the form of holes 198. The holes 198 are circumferentially spaced along C-shaped section 90 and ea6h of them has a specified depth. Both the number of holes 198 and the depth of each hole 198 can be 5 independently varied by having a core 200 (Figure 7) having different numbers and lengths of pins 200, which are inserted into the mold or die 102 (Figure 7), which is utilized to manufacture counterweights 150. [0032] Thus, counterweights having common outer dimensions can be manufactured in different masses. This feature reduces the costs associated with additional 10 plant capital. Prior art designs of counterweights vary by height and/or diameter thus requiring the assembly tooling for the counterweight to be modified or replaced when different masses of counterweights are used. By communizing the outer dimensions for a plurality of counterweight masses, a single set of assembly equipment can be utilized for all of the plurality of counterweight masses. 15 [0033] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the 20 above described exemplary embodiments. [0034] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or 25 steps. [0035] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in Australia.

Claims (20)

1. A method of fabricating a counterweight for a given one of plural rotary machines having different balancing requirements, wherein the counterweight is cast in a mould 5 whereby outer dimensions of a body thereof are such that the counterweight is mountable in each of the rotary machines, a core being positioned in the mould whereby the body is configured with one or more recesses having a volume which is such that the mass of the counterweight is optimised for the given rotary machine, the core having been selected from plural cores each of which is able to be positioned in the mould such that the body of 10 a counterweight cast in the mould when that core is so positioned has said outer dimensions and is configured with one or more recesses having a volume which is such that the counterweight mass is optimised for a respective one of the rotary machines.

2. A method according to claim 1, wherein the counterweight is cast such that said 15 one or more recesses comprise a plurality of holes.

3. A method according to claim 1 or 2, wherein the core has been selected such that said volume is defined by a chosen number of said recesses. 20

4. A method according to claim 1 or 2, wherein the core has been selected such that said volume is defined by a chosen depth of said recesses.

5. A method according to claim 1, wherein the counterweight is cast such that said one or more recesses comprise an elongated cavity. 25

6. A method according to claim 5, wherein the counterweight is cast such that the elongated cavity is arcuate.

7. A method according to claim 5 or 6, wherein the core has been selected such that 30 said volume is defined by a chosen length of said cavity. C;WRPobIOWCCwAZ)O 610..MOC-WOtaaI -9

8. A method according to claim 5 or 6, wherein the core has been selected such that said volume is defined by a chosen depth of said cavity.

9. A method according to claim 5 or 6, wherein the counterweight is cast such that 5 said volume is defined by a rib incorporated in said cavity.

10. A method according to any one of the preceding claims, wherein the counterweight is cast such that said main body is arcuate. 10

11. A counterweight fabricated by the method according to any one of the preceding claims,

12. A rotary machine comprising: a first scroll member having a first end plate and a first spiral wrap projecting 15 outwardly from said first end plate; and a second scroll member having a second end plate and a second spiral wrap projecting outwardly from said second end plate, said second scroll wrap being intermeshed with said first scroll wrap, a drive shaft arranged to cause said scroll members to orbit relative to one another 20 whereby said spiral wraps will create pockets of progressively changing volume between a suction pressure zone and a discharge pressure zone, wherein a counterweight according to claim 11 is mounted to balance the drive shaft. 25

13. A rotary machine comprising a motor and a drive shaft arranged to be driven by the motor, wherein the motor comprises a stator and a rotor, and wherein a counterweight according to claim I 1 is attached to said rotor to balance said drive shaft.

14. A compressor comprising: 30 a shell; a compression mechanism disposed within said shell; and C:\NRPMOnbCCw2 WG2394 ,I.DOC-2010/20 2 -10 a drive shaft for driving said compression mechanism, wherein a counterweight according to claim 11 is mounted to balance said drive shaft. 5

15. A combination, for a counterweight fabrication method according to any one of claims I to 11, comprising: said mould; and said plural cores. 10

16. A counterweight fabrication method substantially as hereinbefore described with reference to the accompanying drawings.

17. A counterweight substantially as hereinbefore described with reference to the accompanying drawings. 15

18. A rotary machine substantially as hereinbefore described with reference to the accompanying drawings.

19. A compressor substantially as hereinbefore described with reference to the 20 accompanying drawings.

20. A combination according to claim 15, substantially as hereinbefore described with reference to the drawings and/or Examples.