R410A Rotary Compressor Bearing Design Considerations

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1 Prde Universiy Prde e-pbs Inernaional Compressor Engineering Conference School of Mechanical Engineering 1998 R41A Roary Compressor Bearing Design Consideraions J. R. Lenz Tecmseh Prodcs Company Follow his and addiional works a: hp://docs.lib.prde.ed/icec Lenz, J. R., R41A Roary Compressor Bearing Design Consideraions (1998). Inernaional Compressor Engineering Conference. Paper 128. hp://docs.lib.prde.ed/icec/128 This docmen has been made available hrogh Prde e-pbs, a service of he Prde Universiy Libraries. Please conac epbs@prde.ed for addiional informaion. Complee proceedings may be acqired in prin and on CD-ROM direcly from he Ray W. Herrick Laboraories a hps://engineering.prde.ed/ Herrick/Evens/orderli.hml

2 R41A ROTARY COMPRESSOR BEARIG DESIG COSIDERATIOS James R. Lenz Tecmseh Prodcs Company Research Laboraory 3869 Research Park Drive Ann Arbor, MI 4818 ABSTRACT In his paper we explore wo design alernaives for a 12 BTU/hr rolling pison compressor. Saring wih an R22 compressor we will redce he displacemen of he compressor o he R41A displacemen by eiher redcing he cylinder heigh or by increasing he roller diameer. The bearing loads are compared for hese compressors. ITRODUCTIO The planned phase-o of chlorinaed refrigerans has lef he air condiioning indsry looking for an alernaive o R22. Two candidaes are R47C and R41A. The aracive feare ofr47c, a 23/25/52 blend of R32, R125 and R134a, is ha is operaing pressres and volme flow raes are similar o R22, which will allow i o be sed in he same sysems. Becase i is a ''drop in replacemen, manfacrers of air condiioning eqipmen will no need o make any major hardware changes. For his reason R47C will probably be he refrigeran of choice a firs. The aracive feare ofr41a, a 5/5 blend ofr32 and R125, is ha is flow properies allow for smaller bing, hea exchangers, and compressors. Therefore, he end prodc is poenially smaller. For his reason, R41A will probably appear firs in window room air condiioners where size is an imporan consideraion o he csomer. The disadvanage o R41A is ha operaing pre ssres are significanly higher. Since pressre indced sresses in bing is direcly proporional o diameer, he smaller bing sed in R41A sysems will heoreically compensae for he higher pressres. However he compressor design is significanly affeced in hree ways. Firs, he displacemen ms be redced for a given capaciy, second, he shell of he compressor ms be srenghened for he higher sysem pressres, and hird, he bearing loads may be higher, depending on he design and how he redcion in displacemen is achieved. In general, bearing loads are a fncion of he scion o discharge pressre difference. The larger pressre difference in sysems wih R41A implies higher bearing loads. AALYSIS In roary compressors, here are he hree jornal bearings, known as he main bearing, he eccenric bearing, and he oboard bearing. There are also bearing srfaces associaed wih he vane. The wo criical bearing srfaces on he vane are he vane slo and he vane ip. Of lesser imporance are he bearing srfaces beween he ends of he vane and he end plaes ha consrain he vane axially in he compressor. Theoreically hese vane end bearings srfaces have no load on hem and will no be discssed here. Table 1 shows a comparison beween an R22 and an R41A sysem operaing a ARI raing poin condiions. oe ha he scion gas densiy wih R41A is significanly higher hen wih R22. Ideally he capaciy is direcly relaed o he prodc of he scion gas densiy and he displacemen of he compressors. Therefore he reqired displacemen for he R41 compressor is redced. oe also ha he discharge o scion pressre difference has increased. This wold case higher bearing loads in he same machine. However, since he reqired displacemen is redced, here is an opporniy o miigae he higher bearing loads, depending on he selecion of cylinder heigh, cylinder bore, and roller diameer. Comper simlaion was sed o predic bearing loads in wo concep R41 OA roary compressors nder endrance es condiions. The resls are compared wih he same capaciy R22 compressor in Table 2. All compressors se he same cylinder bore. The Concep 1 R41A compressor has he same roller oside 7

3 diameer (OD) as he R22 compressor and ses a redced cylinder heigh o achieve he redced displacemen. The second compressor achieves he redcion in displacemen by increasing he roller OD while mainaining he same cylinder heigh as he R22 version. In all cases he cylinder block has he same op view. Vane Slo Loads The porion of he vane exending ino he cylinder has a ne force acing on i ha is he prodc of he is area and he pressre difference beween scion pressre, which acs on one side, and he compression volme pressre, which acs on he oher. Boh he exending area and he compression volme pressre (a.k.a. cylinder pressre) are a fncion of ime. Afer vane boom dead cener (VB DC), he area of he vane exending ino he cylinder is decreasing while he cylinder pressre is increasing. However he pressre is rising faser han he area is falling and he resl is ha he vane side pressre load rises nil cylinder pressre reaches discharge pressre a which poin i reaches a maximm. This pressre force acing on he vane exension is balanced by a reacion force and momen from he vane slo. For design prposes i is sefl o hink of hese reacions as an eqivalen se of forces acing a he op and boom of he vane slo bearing. These reacion forces are also a fncion of he disance beween he wo poins a which hey ac, and his also varies wih crank angle. For he prposes of his paper he vane slo force closes o he roller will be referred o as he lower vane slo force. The lower vane slo force is always larger han he pper, and i is cied here for comparison prposes. Figre 1 shows cylinder pressre and lower vane slo load as a fncion of crank angle for he R22 compressor. Figre 2 shows lower vane slo load for he wo R41A compressors. As can be seen, he peak vale is abo he same for all compressors. oe however ha he load is concepally applied over he heigh of he cylinder, so he ni load (i.e. force per ni lengh) is more imporan han he magnide of he load iself. The ni load is mch higher for he shor cylinder heigh Concep 1 compressor. Vane Tip Loading Under normal operaing condiions he vane ip is in conac wih he roller. In a high side compressor (i.e. discharge pressre in he hosing) he conac force beween he ip and roller is primarily de o discharge pressre acing on he back of he vane. This is redced somewha by he pressre disribion on he ip of he vane. Scion pressre acs over ha porion of he vane ip on he scion side of he vane-roller conac poin, and cylinder pressre acs over he porion of he vane ip on he discharge side. Again he cylinder pressre varies wih ime, as does he posiion of he vane ip in conac wih he roller. Cylinder pressre and vane ip normal load is ploed agains crank angle in Figre 3. Vane ip load is ploed for he wo concep R41A compressors in Figre 4. Peak vane ip normal load happens abo 9 degrees afer vane op dead cener (VTDC), hogh is vale is relaively consan beween and 12 degrees. This can be explained as follows. The componen of he p load in he direcion of he vane cenerline, call his he x-direcion, peaks o a VIDC becase here is only scion pressre on boh sides of he vane-roller conac poin. This conines nil abo 4 degrees afer VTDC when he scion por is sealed off by he cylinder-roller conac poin. B even hen he cylinder pressre is changing very slowly. Ths he x componen of he ip load remains fairly consan. However, becase ofhe vane ip radis, he angle of he normal vecor a he conac poin on he vane ip increases nil abo 9 degrees afer VIDC. This creaes a y-componen of he ip force vecor. This is wha cases he sligh rise in vane ip load magnide afer VTDC. Ineria forces are relaively small nder endrance es condiions. As shown in Table 2, he vane ip load is significanly higher for he Concep 2 R41A compressor. However afer dividing by he cylinder heigh, he ni load is abo he same for he wo R41A compressors. Unfornaely he ni load is significanly higher for boh R41A models. Eccenric Bearing Loads Peak eccenric bearing load is also a srong fncion of he high side o low side pressre difference. Again, ineria and vane spring forces are relaively small, and in any case will no very wih sysem pressres. The cylinder o scion pressre difference acs on he recanglar area formed by he cylinder 8

4 heigh and he line beween he wo conac poins (vane-roller and cylinder-roller). This area varies wih ime, as does he cylinder. Figre 5 shows cylinder pressre and eccenric bearing load as a fncion of crank angle for he R22 compressor. Figre 6 shows he eccenric bearing load for he wo R41A compressors. For he same mechanism charging wih R41A wold lead o significanly higher bearing loads. However, for a given capaciy, he reqired displacemen wih R41A is.71 imes ha reqired for R22. If his redcion in capaciy were aken by redcing he cylinder heigh o.71 imes he R22 compressor cylinder heigh, hen he peak eccenric bearing load wold be redced proporionaely which almos ps i back o he original R22 compressor vale. Main and Oboard Bearing Loads Excep for some minor ineria effecs, he main and oboard bearing loads follow direcly from he eccenric bearing loads. Becase he firs concep compressor has he smaller eccenric bearing load, he Concep 1 main and oboard bearings have he smaller loads of he wo R41 compressors. COCLUSIOS From he above heoreical analyses we can draw he following conclsions: 1. Redcing cylinder heigh can redce jornal bearing loads. The higher pressre difference from sing R41A does no necessarily mean higher bearing loads if he lower displacemen needed for R41A is achieved solely by redcing cylinder heigh, as in he Concep 1 compressor. Mainaining jornal bearing loads a R22 levels means ha bearing dimensions, in oher words diameers, lenghs, and clearances, do no need o change. Frhermore, crankshaf deflecion will no increase, so increasing he srcral siffness of he crankshaf and main bearing will no be reqired. 2. Conversely, increasing roller diameer can redce ni vane slo loads. Since vane slo lbricaion is less ndersood han jornal bearing lbricaion, one can arge ha mainaining R22levels by increasing roller diameer and mainaining cylinder heigh, as in he Concep 2 compressor, is he way o go. Increasing he bearing lenghs or diameers can compensae for he increased jornal bearing loads. 3. Uni vane ip loads are going o go p in eiher case. Frher research in vane ip ribology and exensive endrance esing wih alernaive maerials and lbricans will be reqired. Table 1: R41 OA vs. R22 ARI Raing Poin Properies Evaporaing emperare 45 F Condensing emperare = 13 F Rern gas emperare = 65 F Temperare of Liqid enering expansion valve= 115 F Scion Pressre Discharge Pressre Enhalpy increase across expansion valve and evaporaor Mass Flow Rae reqired for 12 BTU!hr Capaciy Scion gas densiy Volme flow rae of scion gas for 12 BTU!hr Ideal displacemen for 12 BTU!hr a 345 RPM Scion gas viscosiy Discharge gas viscosiy (2 F) R41 OA displacemen I R22 displacemen R psia psia 68.6 BTU/Ibm lbmlhr lbm/c.f 113. c.flhr.9433 c.in 8.3E-6 1.8E-6 R41A psia (dew poin) psia (dew poin) BTU/lbm lbmlhr lbm/c.f c.flhr.6716 c.in 9.E E

5 Table 2: Endrance Tes Bearing Load Com12arison Evaporaor Temperare = 2 F Condenser Temperare= 155 F Cylinder Refrigeran Heigh (inches) Roller OD Displacemen (inches) (c.in) Uni Lower Lower Vane Slo Vane Slo Load (lbf) Load (lbf/in) Vane Tip ormal Load (lbf) Uni Vane Tip Peak Ecc ormal Brg Load Load (lbf) (lbf/in) Uni Peak Ecc Brg Load (lbf/in) Prodcion Concep l Concep 2 R R41A R41A < '. o.o '-JO :: 1 ' ll. CIO <=o - >,, ,-I,,.,, ;,, -r,,_ - -- Is. +. H - f ---4 Y,:., +.:v v Y v. LG. r Y11 '+ f' + 1.! -=- '-''.. -=- +,. E :.. +,,.,,,. < I I :.!. 4-., <' - -l- E J!.,:'\_ Cl(oT PTooo., l,.,. l.,,,., o'-'! :::- co- ' : )I -c < - -co (f) >o J. +,.,, J.,,,.,.-f.,.,. ol,,jiilllollf,,, f,l l1' JOO 36 Cronk Angle (deg) 1 I J I I I ' I l I 1 I ' ' I I j i i I ;. I 1 1 I l E [ I I BO 24 JOO 36 Crank Angle (de9) Pi,re 1: Cylinder Pressre and Vane Slo LoadinJ or he R22 Model Fiare 2: Vane Slo Laadin, for Concep I and Concep 2 R41A Yodels

6 ' ::; + i }.,A, CI:Jll 2 '' J + ve + w [ ' z a.,_. -o >,. o -c- l'. :. +. j ,.. f.! + : '! l > J.,,,. + --, + +,. +.J,., '''., +.. ;-r--+-r+--+-+t-+-_,-+-+-r BO 24 JOO J6 Crank Angle (deg) Fl,re 4: Vane Tip Lo dln, for Concep 1 and Concep 2 R41A Kadel -.,a.,o o' J ' -g ' m Cono Fl _.o o c wo. ' -..; <' -+ '.,.,. I '. +.!!,j I ' ' 4 4 I ' i I I ' I. ' ' I i ' ' ' r ; i i I l I BO 24 JOO J6 Crank Angle (deg) Fi&re 6: Eccenric Bearing Load or Concep I and Concep 2 R4JOA Modele T - r - - H + +. Q.O,_,a 11 a. ' '<> O - >.! 1 - -=- - vo.:: -. i - ov 4 -.:- -!-J. +-- R v-+ I 1 -+ :. r--- --; ! + A--- V'-.:.-vi J - 1-l + ' j E :.. 'l!! :.. I..! I -=-. -=-, I ; J l +., i l ro <> '' ' z a. o.;-o- ' > I I. '. I ' ' I ' ' ' ' 4 ' ' ; ' 1 ' I I ' 1 ' 4 ' ' ' JOO Cronk Angle (deg) J6 Ficre 3: Cylinder Preoore and Vane Tip Lo&dinr for R22 Hodel :. : -r :--:- _ -.,. _,, l - j l '-}.A- -:jk i v -[._, I f ::g,.,r,_,.,., ) '., L ; i, :.-: _zh:r:i! ' oj[:=:=r-r; r±:+-r-r-j;,6r, JOO Cronk Angle (deg) o.,., o., a, J ' g. 'o m. o. gw Fiere 6: Cylinder Pre ore and Ecoenrlo Bearlnc Load for R22 Kodelo

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