DEVELOPMENT AND ANALYSIS A NEW INTEGRATED MOTOR...

DEVELOPMENT AND ANALYSIS A NEW INTEGRATED MOTOR ROTARY

VANE COMPRESSOR

ABDUL RAHIM BIN MAT SARIP

A thesis submitted in fulfilment of the

requirements for the award of the degree of

Doctor of Philosophy (Mechanical Engineering)

Faculty of Mechanical Engineering

Universiti Teknologi Malaysia

NOVEMBER 2016

iii

Isteriku Tersayang

Doamu Menjadi Penawarku

Dayang Suhada, Muhammad Aqil, Anise Syuhada, Annur Syuhada, Ayraa Syuhada

Hj Mat Sarip Sarmidi & Hjh Suriati Masri

Hj Md Yusop Amidin & Hjh Tominah Kastan

Dan Adik beradik

Darjat Seseoarang Terletak Pada USAHA Bukan Pangkat atau Pencapaian

iv

ACKNOWLEDGEMENT

In preparing this thesis, I was in contact with many people, researchers,

academicians, and practitioners. They have contributed towards my understanding and

thoughts. In particular, I wish to express my sincere appreciation to my main thesis

supervisor, Professor Dr. Md Nor bin Musa for encouragement, guidance, critics and

friendship. I am also very thankful to my industri partner Mr Lee Heng Soon (Thermo-

Compressor Sdn. Bhd) and Mr Abdul Rahman bin Musa (Machinist) for their

guidance, advices and motivation. Without their continued support and interest, this

thesis would not have been the same as presented here.

I am also indebted to Universiti Teknologi Malaysia (UTM) for GUP funding

and Kementerian Pengajian Tinggi for PRGS funding for my Ph.D. study. Librarians

at UTM, special thanks for their assistance in supplying the relevant literatures.

My fellow postgraduate students should also be recognised for their support.

My sincere appreciation also extends to all my colleagues and others who have

provided assistance at various occasions. Their views and tips are useful indeed.

Unfortunately, it is not possible to list all of them in this limited space. I am grateful

to all my family members. Thank you very much.

v

ABSTRACT

The aim of this thesis was to develop and analyse a new rotating sleeve vane

rotary compressor and to demonstrate the possibility of integrating the compressor

with DC hollow rotor torque motor. The integration of the compressor with DC

hollow rotor torque motor completely differs from the existing conventional driven

method which is typically driven by a sequence of electrical motor or pulley to rotate

the mechanical shaft of a compressor. The novelty of this study is to develop a more

compact refrigerant compressor for a modular transport refrigeration and air-

conditioning systems, which will make the systems to be more competitive in terms

of sizing and operating stability. The main objective of the study was to design,

develop, test, and evaluate the performance of a novel rotating sleeve of single and

multi-vane compressor prototype. The novel rotary-vane design was applied to a new

integrated concept of DC hollow rotor torque motor rotary compressor. Theoretical

and experimental studies were carried out on the prototype of a single and multi-vane

(three- and five-vane) rotating sleeve vane rotary compressor prototypes, each of

which was installed on a refrigeration system as experimental test-bed. Each test

was carried out to obtain the mechanical and volumetric efficiencies, as the

refrigeration plant operated in a complete thermodynamic cycle. During these tests,

the prototype was run by an external motor connected to the compressor via a shaft.

The results show that the single vane compressor prototype has a similar volumetric

efficiency of about 80% with that of rolling piston compressor of equivalent

capacity. A double increment in capacity to about 50 cc was observed in the multi-

vane prototype models with the same overall dimension and configuration of the

rotating components to that of the single vane. The volumetric efficiency was also

comparable of about 70% to an existing multi vane rotary compressor. The DC

hollow rotor torque motor integration concept was found to be successful and the

idea is technically feasible.

vi

ABSTRAK

Kajian utama bagi tesis ini adalah untuk membangun dan menganalisa sebuah

pemampat bilah berputar baharu iaitu sarung berputar (rotating sleeve) dan

seterusnya untuk mengesahkan bahawa pemampat ini boleh diintegrasikan dengan

DC hollow rotor torque motor. Pemampat yang diintegrasikan ini adalah berbeza

sama sekali jika dibandingkan dengan kaedah pemacuan biasa bagi sesebuah

pemampat, kebiasaannya sebuah pemampat akan dipacu oleh motor elektrik atau

takal bagi memutarkan aci mekanikal pemampat. Rekabentuk integrasi pemampat

yang baru ini dijangka akan memberikan impak dalam pembangunan aplikasi yang

lebih kompak bagi unit pendingin hawa yang seterusnya berdaya saing untuk

memberikan kelebihan dari segi saiz dan juga kestabilan operasi. Objektif utama

kajian ini adalah untuk mereka bentuk, membangun, menguji, dan menilai prestasi

pemampat yang dibahagikan kepada prototaip bilah tunggal dan berbilang bilah.

Seterusnya prototaip pemampat ini akan diintegrasikan dengan DC hollow rotor

torque motor. Kajian secara teoretikal dan eksperimental telah dijalankan ke atas

prototaip pemampat bilah tunggal dan berbilang bilah (tiga dan lima bilah) dan setiap

satunya telah diuji di pelantar ujikaji sistem penyejukan. Ujikaji yang dijalankan

adalah untuk menilai kecekapan mekanikal dan isipadu prototaip pemampat semasa

kitar lengkap termodinamik system tersebut. Prototaip pemampat yang diuji ini

dipacu dengan kaedah motor elektrik dan mekanikal aci pemampat. Berdasarkan

keputusan analisis, prototaip pemampat bilah tunggal mempunyai kecekapan isipadu

yang sama iaitu sekitar 80% jika dibandingkan dengan pemampat rolling piston yang

berkapasiti sama. Peningkatan kapasiti sebanyak dua kali ganda kepada sekitar 50 cc

telah diperhatikan bagi prototaip pemampat berbilang bilah yang mempunyai

dimensi keseluruhan dan konfigurasi rekabentuk yang sama seperti pemampat bilah

tunggal. Kecekapan isipadunya adalah setanding dengan pemampat bilah berputar

sedia ada iaitu sekitar 70%. Keputusan bagi konsep pemampat yang diintegrasikan

dengan DC hollow rotor torque motor secara teknikalnya telah berjaya dan idea ini

terbukti secara teknikal sesuai untuk dilaksanakan.

vii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF SYMBOLS xv

LIST OF APPENDICES xx

1 INTRODUCTION 1

1.1 Introductory 1

1.2 Problem Statement 4

1.3 Rotating Sleeve Vane Rotary 6

1.4 Design Specification 9

1.5 Objectives 9

1.6 Scopes of Research 10

1.7 Research Methodology 10

1.8 Significance of Research 12

1.9 Thesis Overview 12

2 LITERATURE SURVEY 13

2.1 Introduction 13

2.2 Internal Leakage 14

viii

2.3 Dynamic and Vane Friction 18

2.4 Tribology 21

2.5 Heat Transfer 24

2.6 Vibration 25

2.7 Mathematical Model and Computer Simulation 26

2.8 Experimental and Performance 29

2.9 Design 33

2.10 Optimization 35

2.11 Gaps in Current Knowledge 37

3 MATHEMATICAL MODEL 38

3.1 Introduction 38

3.2 Geometry of compressor 38

3.2.1 Vane Radius 40

3.2.2 Crescent and Swept Volume 40

3.2.3 Cell Volume 42

3.2.4 Cell Volume of RSSVR Compressor 45

3.2.5 Cell Volume of RSMVR Compressor 46

3.3 Thermodynamic of RSSVR and RSMVR Compressor 46

3.3.1 Thermodynamics Cycle 47

3.3.2 Thermodynamic Analysis 48

3.3.3 Internal Leakage 49

3.4 Kinematics and Dynamics Analysis 53

3.4.1 Kinematics Analysis 57

3.4.2 Dynamics Analysis 61

3.4.2.1 Forces at Primary Vane 62

3.4.2.2 Forces at Secondary Vane 63

3.5 Friction Power 65

3.5.1 Friction on Primary Vane 66

3.5.2 Friction on Secondary Vane 67

3.5.3 Friction on Eccentric Rotor and Sleeve 68

3.5.4 Friction on End Surface of Rotor and Sleeve 69

3.6 Compressor Power 69

3.6.1 Ideal Power 71

ix

3.6.2 Indicated Power 71

3.6.3 Shaft Power 72

3.6.4 Consumption or Motor Power 72

3.7 Compressor Performance 73

3.7.1 Volumetric Efficiency 73

3.7.2 Compression Efficiency 73

3.7.3 Mechanical Efficiency 74

3.7.4 Motor Efficiency 74

3.7.5 Total Efficiency 74

4 PROTOTYPE DEVELOPMENT AND TESTING 75

4.1 Introduction 75

4.2 Design Configuration 78

4.3 Compressor Development and Standards 79

4.4 Shaft Driven Compressor Model 81

4.4.1 Shaft-Rotor 84

4.4.2 Sleeve 84

4.4.3 Primary and Secondary Vanes 85

4.5 Integrated Compressor Model 86

4.6 Computational Work 91

4.6.1 Step of Analysis 91

4.6.2 Limitation and Assumption in Analysis 93

4.6.3 Input Parameter 94

4.6.4 Geometrical Analysis 94

4.6.5 Thermodynamics Analysis 95

4.6.6 Kinematics and Dynamics Analysis 96

4.6.7 Frictional Analysis 96

4.6.8 Internal Leakage Analysis 97

4.6.9 Power and Efficiency Analysis 97

4.7 Experimental Work 97

4.7.1 Test Rig 99

4.7.2 p-h Diagram of the System 102

4.7.3 Measuring Instrument 103

4.7.4 Operating Condition 104

x

4.7.5 Testing Model 105

4.7.6 Analysis of Experiment 106

5 RESULTS AND DISCUSSIONS 108

5.1 Introduction 108

5.2 Theoretical Results 108

5.3 Experimental and Theoretical Result of RSSV

Compressor (Single-Vane) 118

5.4 Experimental and Theoretical Result of RSMVR

Compressor (Three-Vane) 124

5.5 Experimental and Theoretical Result of RSMVR

Compressor (Single, Three and Five-vane) 127

5.6 Experimental Results of Integrated Compressor 131

6 CONCLUSIONS AND RECOMMENDATIONS 136

6.1 Introduction 136

6.2 Experimental Work 134

6.3 Theoretical Work 137

6.4 Recommendations 137

REFERENCES 139

Appendices A-E 144-201

xi

LIST OF TABLES

TABLE NO. TITLE PAGE

1.1 Main Dimension of RSSVR and RSMVR compressor 9

2.1 Short Literature notes on Rotary Sliding Vane Compressor 15

3.1 Inertia and external forces 61

4.1 Design of parameters 78

4.2 Main component dimension 78

4.3 Design parameters of integrated compressor 87

4.4 Operating condition of experimental work 93

4.5 Input parameter of simulation 95

4.6 Main equipment and measuring instrument of test rig 99

4.7 Operating condition of simulation work 105

xii

LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 Sectional view of MVR compressor 1

1.2 Typical of drive train of rotary compressor

a) Hermetic compressor, (b) Semi-hermetic compressor 2

1.3 Current technology of integrated DC motor rotary compressor 3

1.4 Conceptual design of integrated of DC motor RSVR compressor 4

1.5 Motion of vane and piston of rolling piston compressor at 600 fps 5

1.6 Comparison of two position of RSMVR on each vane tip at high

speed and low speed 6

1.7 Rubbing surfaces of secondary vane and of sleeve

at different leading vane angle 7

1.8 Sectional view of a) RSSVR compressor b) RSMVR compressor 8

1.9 Research methodology flow 11

1.10 Detail research methodology 11

3.1 Main dimensions of a) RSSVR compressor,

b) RSMVR compressor 39

3.2 Crescent volume 41

3.3 Cell volume geometry 43

3.4 Geometry of cell volume 44

3.5 RSSVR compressor cycle 47

3.6 RSMVR compressor cycle 48

3.7 Internal leakage paths 50

3.8 Internal leakage of RSSVR compressor 51

3.9 Internal leakage of RSMVR compressor 51

3.10 Mode of secondary vane 54

3.11 Acting force on secondary vane 55

xiii

3.12 Acting force on primary vane 56

3.13 Acting force on rotor-sleeve 56

3.14 Vane tip condition at low speed 57

3.15 Kinematic parameter of RSVR compressor 58

3.16 Kinematic of vane 58

3.17 Friction at vane tip of secondary vane 67

3.18 Friction at vane side of secondary vane 68

3.19 Power distribution in compressor 70

4.1 Shaft driven type of RSVR compressor 76

4.2 RSSVR compressor designed by Yusof (2005) 80

4.3 Revolving vane designed 80

4.4 Three different designs of RSVR compressor

(Single, three and five-vane) 81

4.5 Sectioned drawing of RSVR compressor prototype


4.6 Isometric drawing of RSVR compressor prototype


4.7 Isometric Sectioned drawing of RSVR compressor prototype


4.8 Actual prototype of RSVR compressor

(single, three and five-vane) 83

4.9 Mechanical shaft-rotor component assembly 84

4.10 Sleeve component 85

4.11 Primary vane (left) and secondary vane (right) 86

4.12 Sectioned drawing of integrated DC motor RSSVR compressor 87

4.13 Isometric drawing of integrated compressor 88

4.14 Isometric sectioned drawing of integrated compressor 88

4.15 Actual prototype of integrated compressor 89

4.16 Prototype assembly of integrated compressor 89

4.17 Electrical connector of integrated compressor 90

4.18 Prototype and components of integrated compressor 90

4.19 Simulation step of the compressor model 92

4.20 Schematic diagram of test rig 98

4.21 Picture of test rig (1) 100

xiv




4.25 Pressure - enthalpy (𝑝 − ℎ) diagram 102

5.1 Variation of cell volume as a function of leading vane angle 109

5.2 Variation of cell pressure as a function of leading vane angle 110

5.3 𝑝 − 𝑣 diagram of cell pressure 111

5.4 Derivative of 𝑅𝜃, 𝑑𝑅

𝑑𝜃, and

𝑑2𝑅

𝑑𝜃2 as a function of leading vane angle 112

5.5 Derivative of 𝛽(휃), 𝑑𝛽

𝑑𝜃 and

𝑑2𝛽

𝑑𝜃2 as function of leading vane angle 113

5.6 Inertia forces at 1400 rpm against leading vane angle 114

5.7 Pressure forces at 1400 rpm against leading vane angle 115

5.8 Reaction forces at primary and secondary vane at 1400 rpm

against leading vane angle 116

5.9 Total internal friction force at 1400 rpm

against leading vane angle 117

5.10 Total mass flow rate at 1400 rpm against leading vane angle 118

5.11 Validation result of RSSVR compressor against rotational speed 119

5.12 Installation method of transient transducer in rotor

RSMVR compressor 120

5.13 Friction effect on sleeve and end plate 122

5.14 Comparison of mechanical efficiency amongst

various compressors 123

5.15 Validation result of RSMVR compressor ( three-vane)

against rotational speed 125

5.16 Validation result of RSSVR and RSMVR compressor

at speed 1400 rpm against rotational speed 129

5.17 Important gap clearance location for five-vane compressor 130

5.18 Schematic diagram of integrated compressor 132

5.19 Preliminary testing of assembled of hollow rotor motor

and sleeve only 133

5.20 Sectional full assembly drawing of integrated compressor 134

5.21 Stator motor connector (above) and input power

supply wire (bottom) of integrated compressor 135

xv

LIST OF SYMBOLS

𝐴𝑣 - Area of pressure force on vane

𝑓𝐿 - Friction factor

𝑓𝑝𝑣,1 - Side primary vane friction force 1

𝑓𝑝𝑣,2 - Side primary vane friction force 2

𝑓𝑠𝑣,1 - Side secondary vane friction force 1

𝑓𝑠𝑣,2 - Side secondary vane friction force 2

𝐹𝑁,𝑟 - Normal force on rotor surface

𝐹𝑁,𝑠 - Normal force on sleeve surface

𝐹𝑏 - Back pressure force

𝐹𝑐𝑒𝑛 - Centrifugal force

𝐹𝑐𝑜 - Coriolis force

𝐹𝑚𝑎𝐿 - Linear vane inertia force

𝐹𝑚𝑎𝑟 - Radial vane inertia force

𝐹𝑝 - Side pressure force

𝑔 - Gravity = 9.81 m/s2

ℎ - Enthalpy

ℎ𝑑𝑖𝑠 - Enthalpy of refrigerant at discharge process

ℎ𝑙𝑖𝑞 - Enthalpy of refrigerant after condenser

ℎ𝑠𝑢𝑐 - Enthalpy of refrigerant at suction process

𝐻𝑣 - Height of vane

HPG - High pressure gauge

𝐼𝑟 - Mass ineartia of rotor

𝐼𝑠 - Mass ineartia of sleeve

𝐿𝐿 - Length leakage path

𝐿𝑐 - Length of cell

LPG - Low pressure gauge

xvi

�̇�𝑟𝑒𝑓 - Mass flow rate of refrigerant

�̇� - Mass flow rate

𝑚𝐿 - Cell mass leakage

𝑚𝑐 - Cell mass

𝑚𝑣 - Mass of vane

𝑀 - Hydraulic mean diameter

𝑀𝑜 - Moment

𝑁𝑣 - Number of vane

𝑝𝐿𝐶 - Cell pressure of leading cell

𝑝𝑇𝐶 - Cell pressure of trailing cell

𝑝𝑇𝑋𝑉 - Pressure of refrigerant after TXV

𝑝𝑎𝑚𝑏𝑖𝑒𝑛𝑡 - Ambient pressure

𝑝𝑐 - Cell pressure

𝑝𝑐𝑜𝑛𝑑 - Pressure of refrigerant in condenser

𝑝𝑑𝑖𝑠 - Discharge pressure

𝑝𝑑𝑖𝑠 - Suction pressure

𝑝𝑒𝑣𝑎𝑝 - Pressure of refrigerant in evaporator

𝑃 - Power

𝑃𝑓𝑒 - Friction power at end surface of rotor and sleeve

𝑃𝑓𝑒𝑐 - Friction power at eccentric rotor and sleeve

𝑃𝐼,𝑟 - Inertia power of rotor

𝑃𝐼,𝑠 - Inertia power of sleeve

𝑃𝑓 𝑎𝑣𝑒 - Average friction power

𝑃𝑓 - Friction power

𝑃𝑖𝑑𝑒𝑎𝑙 - Adiabatic power

𝑃𝑖𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 - Indicated power

𝑃𝑚𝑜𝑡𝑜𝑟 - Electrical motor power

𝑃𝑠ℎ𝑎𝑓𝑡 - Shaft power

�̇�𝑟𝑒𝑓 - Cooling capacity

𝑄𝑐 - Heat transfer occurred in cell

𝑟𝑝 - Pressure ratio

rpm - Rotational speed

xvii

�̈�𝜃, 𝑎𝑣 - Vane linear acceleration

�̇�𝜃, 𝑣𝑣 - Vane linear velocity

𝑅𝑐𝑔 - Centre gravity radius of vane

𝑅𝑒 - Reynold number

𝑅𝑔 - Gas constant

𝑅𝑝𝑣,1 - Side primary vane reaction force 1

𝑅𝑝𝑣,2 - Side primary vane reaction force 2

𝑅𝑝𝑣,𝑁 - Normal primary vane reaction force

𝑅𝑝𝑣,𝑟 - End primary vane reaction radial force

𝑅𝑝𝑣,𝑡 - End primary vane reaction tangential force

𝑅𝑟 - Rotor radius

𝑅𝑠 - Sleeve radius

𝑅𝑠𝑡 - Outer sleeve radius

𝑅𝑠𝑣,1 - Side secondary vane reaction force 1

𝑅𝑠𝑣,2 - Side secondary vane reaction force 2

𝑅𝑠𝑣,𝑁 - Tip secondary vane reaction force

𝑅𝑠𝑣,𝑟 - Tip secondary vane reaction radial force

𝑅𝑠𝑣,𝑡 - Tip secondary vane reaction tangential force

𝑅𝑣 - Vane tip radius

𝑅𝜃 - Vane radius

𝑡 - time

𝑡𝑣 - Thickness of vane

𝑇 - Temperature

𝑇𝑎𝑚𝑏𝑖𝑒𝑛𝑡 - Ambient temperature

𝑇𝑐 - Cell temperature

𝑇𝑑𝑖𝑠 - Discharge temperature

𝑇𝑙𝑖𝑞 - Temperature before enter TXV

𝑇𝑠𝑢𝑐 - Suction temperature

T𝑏,𝑟/𝑠 - Torque friction at bearing of rotor or sleeve

T𝑒,𝑟/𝑠 - Torque friction at end surface of rotor or sleeve

T𝑒𝑐 - Torque friction at eccentric of rotor-sleeve surface

T𝑟 - Torque of rotor

xviii

T𝑠 - Torque of sleeve

TXV - Thermostatic expansion valve

𝑣𝐿 - Mean leakage velocity

𝑉 - Volume

𝑉𝑐 𝑚𝑎𝑥 - Cell volume maximum

𝑉𝑐 - Cell volume

𝑉𝑐𝑟𝑒𝑠𝑐𝑒𝑛𝑡 - Crescent volume

𝑉𝑠𝑙𝑜𝑡 - Vane slot volume

𝑉𝑠𝑤𝑒𝑝𝑡 - Swept volume

𝑉𝑡𝑣 - Vane thickness volume

VAC - Voltage alternating current

VDC - Voltage direct current

𝑤𝐿 - Width leakage path

𝛽1 - Start of suction angle

𝛽2 - End of suction angle

𝛽3 - Start of discharge angle

𝛽4 - End of discharge angle

휂𝑐𝑜𝑚𝑝 - Compression efficiency

휂𝑚𝑒𝑐ℎ - Mechanical efficiency

휂𝑚𝑜𝑡𝑜𝑟 - Electrical motor efficiency

휂𝑡𝑜𝑡𝑎𝑙 - Total efficiency

휂𝑣 - Volumetric efficiency

휃𝛽2 - Leading vane angle at end of suction

𝜇𝑓 - Coeficient of friction

𝜇𝑔 - Dynamic viscocity of refrigerant

𝜇𝑜𝑖𝑙 - Dynamic viscocity of lubricant

𝜈1 - Specific volume at point 1 ( suction port)

𝜈𝑔 - Kinematic viscocity of refrigerant

𝜌𝑐 - Cell refrigerant density

𝜌𝑠𝑢𝑐 - Suction refrigerant density

𝜙 - Swivel angle

𝜎 - ratio of 2𝜋

𝑁𝑣

xix

휃 - Leading vane angle

휁 - ratio of 𝜀

𝑅𝑠

휀 - Eccentric of rotor -sleeve

𝛿,c - Clearence

𝛾 - Index Isentropic

𝛽 - Sleeve angle

Ω - ratio of 𝑅𝑟

𝑅𝑠

Γ - ratio of 𝐿𝑐

𝑅𝑠

∆ - Losses

�̇� - Swivel angular velocity of primary vane

𝜔𝑠, �̇� - Sleeve angular velocity

𝜔𝑟𝑒𝑙 - Relative angular velocity of sleeve and rotor

𝜔𝑟 , 휃̇ - Rotor angular velocity

Subscript

𝑎 - axial

𝑏 - bearing

𝑐𝑔 - centre of gravity

𝑐𝑜𝑚𝑝 - compression

𝑑𝑖𝑠 - discharge

ec - eccentric

𝑓 - friction

𝑖 - in

𝐿 - leakage, linear

𝐿𝑉 - leading vane

𝑜 - out

𝑝𝑣 - primary vane

𝑟 - radial, rotor

𝑠𝑢𝑐 - suction

𝑠𝑣 - secondary vane

𝑇𝑉 - trailing vane

𝑥, 𝑦 - Cartesian coordinate

xx

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Geometrical of RSVR compressor 144

B Component analysis (FEM) 153

C Refrigerant plant components

and instrumentation 166

D Programing code (Mathcad) 177

E Experimental data and result 196

CHAPTER 1

INTRODUCTION

1.1 Introductory

In the original model of a conventional multi-vane rotary (MVR) compressor,

the tip of each vane rubs against the cylinder wall, creating friction and wear to the

rubbing surfaces as shown in Figure 1.1.

Figure 1.1 Sectional view of MVR compressor

The compressor is typically driven by a sequence of electrical motor/pulley –

shaft – compressor, as shown in Figure 1.2. A brilliant idea came out to change the

cylinder wall to a new concept of a compressor called Rotating Sleeve Vane Rotary

(RSVR) compressor. Two types of concept have been identified based on number of

vanes. The compressor is known as Rotating Sleeve Single Vane Rotary (RSSVR)

compressor and Rotating Sleeve Multi Vane Rotary (RSMVR) compressor,

respectively. On further analysis it was found that this idea is theoretically and

technically feasible. However due to financial and time constraint the new idea is

Rr

o

o'

Rs

r

.rs

Cylinder

Rotor

Vane

2

developed only up to a preliminary prototype stage to demonstrate the potential

possibility and opportunity of succesfull integration of a hollow rotor torque motor

rotary compressor model.

(a) (b)

Figure 1.2 Typical of drive train of rotary compressor a) Hermetic compressor,

(b) Semi-hermetic compressor

To date, no other rotary compressor concepts can make this integration possible.

With no shaft, hence less number of bearings, the mechanical efficiency is expected to

improve. The hermetic tank that houses the motor-compressor assembly will now be

smaller and shorter. It is interesting to find out the mutual beneficial process of

superheating the refrigerant vapour and the cooling of the motor which is now located

very close to the suction port. The current motor compressor and motor assembly is

shown in Figure 1.3, where brushless motor is connected to the compressor via an

external shaft to drive the compressor. Motor and compressor are enclosed in a fully

hermetic tank and becomes an integrated system.

Ele

ctr

ica

l

Mo

tor

Sh

aft

C

om

pre

ss

or

Pulley Shaft Compressor

3

Figure 1.3 Current technology of integrated DC motor rotary compressor

(Mavrigian,2013)

The design of a concentrically RSMVR compressor can be a breakthrough in

rotary vane compressor technology. Furthermore, integrated DC RSMVR compressor

is totally different from current technology. It can be explained in Figure 1.4 that the

compressor does not need external connecting shaft anymore as it is located inside a

hollow rotor motor, resulting in the size of the hermetic compressor assembly to be

significantly more compact.

The aim of present study is two-fold. First is to conduct analytical and

experimental study on RSSVR and RSMVR compressor concepts. Second is to

demonstrate the possibility of integrating the new compressor model with a hollow

rotor torque motor.

4

Figure 1.4 Conceptual design of integrated of DC motor RSVR compressor

1.2 Problem Statement

The current vane rotary compressors, such as that of MVR and rolling piston

rotary types, have disadvantages at low speed and high speed of rotation, respectively.

For MVR compressor, at low speed of rotation, each vane has not developed sufficient

enough centrifugal force to pull itself out of the slot in the rotor for the vane tip to be

always in contact with and to rub against the stationary cylinder wall, hence fails to

create a compression chamber. While at high rotating speeds, high centrifugal force

produces negative effect by creating high rubbing friction between the vane tip and the

inner cylinder surface. For the rolling piston compressor on the other hand, at high

speed of piston rotation the linear motion of the vane cannot synchronize with the fast

rolling movement of the piston, creating a gap between the vane tip and surface of the

rolling piston, as shown in Figure 1.5. This causes the gas to leak from the high

pressure (compression) chamber to the low pressure (suction) chamber, thus reduces

the volumetric efficiency of the compressor.

Compressor Electrical

motor

5

Figure 1.5 Motion of vane and piston of rolling piston compressor at 6000 fps,

(Tesla500, 2009, 1:50)

The new RSVR compressor concept can simultaneously address the

weaknesses posed by the two respective existing rotary compressor models. In an

RSVR compressor, as the rotor rotates, the sleeve will pull the primary vane out of the

slot thus creating the gas suction chamber. As soon as suction mode ends a

compression mode begins. This happens when the sleeve begins to push the primary

vane back into the slot in the rotor. At certain high speed, both centrifugal force and

the force exerted by the sleeve on each secondary vane tip begin to serve the four of

secondary vanes, thus creating the multi suction/compression chambers, respectively.

The primary vane is one of the most important components in this compressor on

which the rotation of the sleeve is totally dependent on it. In this concept, the primary

vane ensures that suction, compression and discharge of the gas occur at all speeds of

rotation as shown in Figure 1.6 which also shows that at certain low speeds all

secondary vanes do not participate in the compression process. In addition, at the same

low speeds there is no leakage around the tip of the secondary vane and this will give

a higher volumetric efficiency.

piston

vane

6

Figure 1.6 Comparison of two positions of RSMVR on each secondary vane tip

at high speed and low speed

Furthermore, the eccentricity between the rotor and the rotating sleeve creates

an interesting movement of each secondary vane in relation to the sleeve. When

centers of rotor, any secondary vane and sleeve are all three in line, as shown in Figure

1.7 the rubbing action of the sliding vane with the inner surface of the sleeve is in the

direction of rotation and occurs within a certain small angle. However, when the same

three centers are in line for the second time within the same revolution, the rubbing

action is in the opposite direction. The friction on the tip of each secondary vane is

estimated to be small and the rubbing angle of the portion on the sleeve that each

secondary vane rubs is about 15º. However, in a conventional MVR compressor, the

vane tip is rubbing against the cylinder wall throughout the rotation (or 360º).

Therefore, at high speed the friction between secondary vane tip and the inner surface

of sleeve is less than that MVR compressor due to no more rubbing against the

stationary wall but now with relative velocity of the vane tip and the sleeve. In general,

the RSVR compressor is supposed to perform better compared to the existing MVR

and rolling piston compressor, in term of mechanical and volumetric efficiencies

Discharge

Port

All vane in contact

Discharge

Port

Vane in non - contact

7

Figure 1.7 Rubbing surfaces of secondary vane and of sleeve at different leading

vane angle

1.3 Rotating Sleeve Vane Rotary Compressor

In the year 2001, Musa (2007) developed a new concept of single vane

compressor namely, rotating sleeve single vane rotary (RSSVR) compressor. As

shown in Figure 1.8(a), one end of the vane is embedded into the sleeve and during

rotation the other part of the vane is pushed in and pulls out of a slot in the rotor. The

primary function of the vane is to drive the sleeve to rotate along and together with the

rotor; all components perform the compression process. A patent was filed in the same

year and granted in year 2007. There are also other similar concepts, some are

modifications to this model, being developed and studied by other researchers.

Examples of such concepts are the synchronal vane by Zong Chang et al. (2004), the

revolving vane by Teh and Ooi (2009a). Figure 1.8(a) shows the typical diagram of

RSSVR compressor. Evolved from this single primary vane of embedded end model,

a multi-vane concept which has a single primary vane and multiple secondary vane is

introduced. Unlike the primary vane the function of these secondary vanes is to

perform compression only. The invention is called a rotating sleeve multi vane rotary

(RSMVR) compressor and the concept is as shown in Figure 1.8(b). The

thermodynamic process in this RSMVR compressor concept is similar to that in a

conventional MVR compressor.

MVR compressor has an advantage over other models in terms of compact

size, simple mechanism, low level of noise of 59 dB and below (Chang, 1983) and

8

very high speed of rotation of up to 4000 rpm ( Ucer and Aksel, 1980 ). However, the

compressor is not suitable for large capacity operations if the discharge pressure is

more than 14 bar. It will cause bending of the vane due to high bending stresses and

may cause the vane to get stuck in the slot. In addition, non-lubricated compressor

operation is not suitable for this vane type. Moreover, in a frictional analysis, the 84%

of total compressor power is to overcome vane friction and about 85% of vane friction

is produced at the vane tips each of which rubs against the stationary inner cylinder

surface (Kaiser, 2004). In fact, if the coefficient of friction is more than 0.2, friction

from vane tips requires up to 50% of the theoretical compressor power.

Back to RSMVR compressor, other advantage is that the swept volume is

virtually increased to about twice that of the RSSVR. For example, if the RSSVR

compressor has radius of rotor 30 mm, inner radius of sleeve 34.5 mm and length 32.6

mm, then the swept volume is 32.46 cc. On addition of four secondary vanes becomes

an RSMVR compressor, the virtual swept volume is 66.63 cc. Thus, if a swept volume

is specified as 32.46 cc, adopting an RSMVR concept makes the compressor smaller,

compact and lighter.

(a) (b)

Figure 1.8 Sectional view of a) RSSVR compressor b) RSMVR compressor

The working principle of the RSMVR compressor is basically the same as that

of MVR compressor. Both have four thermodynamic processes namely expansion,

suction, compression and discharge and total mass delivered is a multiple of the

number of vanes with the leading cell as a rotating reference angle.

Rr

o

o'

Rs

.

RV

sr

Sleeve (s)

Primary Vane (pv )

Secondary Vane (sv )

Rotor (r )

Rr

o

o'

Rs

RV

sr

Sleeve

Primary Vane

Rotor

.

.

R R

p p

9

1.4 Design Specification

Table 1.1 shows the main dimensions for RSSVR and RSMVR compressor.

The details of the configuration and working condition can be referred in Chapter 4.

The arrangement locations of each component are based on established conceptual

design by Yusof (2005) and Teh and Ooi (2009c).

Table 1.1 : Main dimension of RSSVR and RSMVR compressor

Parameter Value Unit

Rotor radius, 𝑅𝑟 31.0 mm

Inner Sleeve radius, 𝑅𝑠 34.5 mm

Chamber length, 𝐿𝑐 35.0 mm

Vane width, 𝑇𝑣 4.0 mm

Vane heigth, 𝐻𝑣 15.0 mm

Suction open, 𝛽1 5o degree

Suction close, 𝛽2 144o degree

Discharge open, 𝛽3 318o degree

Discharge close, 𝛽4 338o degree

1.5 Objectives

The objectives of the research are as follows:

i. To show that the number of vanes has some effects on the performance of

RSVR compressors.

ii. To predict well the performance of an RSVR compressor by a new

mathematical model which is to be developed and validated.

10

1.6 Scopes of Research

Scopes of research are outlined as follows:

i. Undertake literature review for rotary vane compressor (leakage,

lubrication, design, mathematical model and experimental work)

ii. Develop a mathematical model for RSVR compressor with one, three and

five number of vanes, respectively.

iii. Design and fabricate the new RSSVR and RSMVR compressor based on

established conceptual design.

iv. Design and build (all in accordance to British Standard) a test rig for

compressor performance testing on and of a refrigeration plant

v. Undertake performance testing, also according to British Standard.

vi. Validate the theoretical and experimental results.

vii. Arrange a demonstration for the operation of a hollow rotor torque DC

motor

1.7 Research Methodology

The methodology of the research is shown by a flow chart shown in Figure 1.9

and the detail of some task is described in Figure 1.10.

11

Figure 1.9 Research methodology flow

Figure 1.10 Detail research methodology

Research Methodology

Horizontal RSVR compressor

Shaft Driven(1,3,5 vane)

Mathematical

Modeling

Integrated Dc

Hollow Rotor Torque Motor

Prototyping

Computer analysis

Prototyping

Testing and

Commissioning

Performance

ValidationDesign Validation

Testing and

Commissioning

Findings Findings

Methodology of Research

Mathematical Model &

Computer Simulation

1. Volume Displacement

2. Kinematics of Vane & Sleeve

3. Thermodynamics

•Compression process

• Internal leakage

•Suction Loss

•Discharge Loss/Valve

•Heat Transfer

4. Kinematic & Dynamics of

rotating part

•Vane, sleeve and rotor

5. Friction analysis

•Friction from vane motion

•Friction from sleeve motion

•Friction from rotor motion

•Friction from bearing motion

6. Lubrication system

•Path flow

7. Performance Analysis

•Volumetric efficiency

•Mechanical Efficiency

Prototyping Work1. Parametric study of Main

Component

• Rotor, Sleeve, Vane

2. Reverse Engineering of existing

design

• Design configurations

• Discharge port

• Suction port

3. Engineering Drawing

• Tolerance

• Assembly

• Fabrication Drawing

4. Material Selection

• Ferrous metal

• Hardness

5. Strength Analysis

• Vane thickness

• Cylinder thickness

6. Fabrication

• Inspection

7. Quality Control

• Flatness

• Circularity

8. Assembly of all Parts/ components

• Gap tolerance of rotating part

Experimental Work

1. Experimental Test Rig

• Design & fabricate test rig

• Equipment selection

• Instrumentation &

Measurement equipment

• Electrical power

2. Testing & Commissioning

• Initial Set-up

• Lab Sheet

• Re-test of failure

3. Conduct Experiment

• RPM varies

4. Verify the result

• Analytical vs Experimental

Results & Conclusion

Literature Review

11

12

1.8 Significance of Research

The main focus of the research is on the attempt to design, develop, and test

the mechanism of RSSVR and RSMVR compressor and to demonstrate the operation

of the hollow rotor torque motor. The expected output of the research will be a new

idea of knowledge to design and fabricate a new RSSVR and RSMVR compressor

model which is relatively small, lighter, more compact and efficient than that of the

existing models of equivalent capacity. Examples of immediate and future

applications of the new compressor technology are for air-conditioning of cabins of

parked trucks and motor homes, electric car, hybrid car and conventional vehicles,

refrigerated trucks, luxury boats and yachts, etc.

1.9 Thesis Overviews

The report of the research work is presented in the proceeding chapters.

Chapter 2 presents the review of research papers/report on rotary vane compressors,

that have been published since 1972 to 2014. It covers eight topics such as internal

leakage, dynamics of vane, lubrication, heat transfer, mathematical model,

experimental work, design and optimization. Chapter 3 presents the methodology on

how to predict the performance of each of the newly developed compressors by using

own respectively developed mathematical models. The development of each model

involves geometrical, thermodynamics, kinematics and dynamics, and performance

analysis. Chapter 4 presents the prototyping work, development of test rig, testing and

commissioning and collecting data to evaluate the performance of the new

compressors. In Chapter 5, result of theoretical analysis and validation of the

compressor models are presented against that obtained from experiment. Chapter 6

presents conclusion of the entire work and as well as recommendations for future

initiatives.

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