Abstract:
This rotary compressor with an installed circulation control unit utilizes a method to control a rotary compressor to start or stop injecting refrigerant at a predetermined velocity by means of an electromagnetic coil that is installed onto the rotary compressor. The end of the electromagnetic coil is tenon-shaped and enters into a mortise that is formed on a vane or an arm of the rotary compressor so that the operation alternates between suction and compression at a predetermined period, enabling control of the rate of refrigerant circulation. In addition, the rotary compressor does not restart during its operation, which enhances the performance of the air-conditioning system, saves costs and energy, and enables the air-conditioning system to be easily maintained and repaired.

Description:
FIELD OF INVENTION 
       [0001]    The present invention relates to a rotary compressor and more particularly to a rotary compressor with an installed circulation control unit. 
       BACKGROUND OF THE INVENTION 
       [0002]    An inverter air conditioning system is an air conditioning system the capacity of which is controlled by the volume of refrigerant circulation resulting from controlling the cycle speed of its compressor. However, such inverter compressor uses an electrical frequency method, which is technologically complicated, expensive, and difficult to repair. 
         [0003]    Therefore, this rotary compressor with an installed circulation control unit disclosed under this patent application is developed to solve the above problems with its system being less complicated, economical, and easy to repair. 
       SUMMARY OF THE INVENTION 
       [0004]    This rotary compressor with an installed circulation control unit utilizes a method to control a rotary compressor to start or stop injecting refrigerant at a designated velocity by means of an electromagnetic coil that is installed onto the rotary compressor. The tip of the electromagnetic coil is tenon-shaped and enters into a mortise that is formed on a vane that separates a compression compartment into two parts, i.e. a suction chamber and a compression chamber, so that the operation of such compression compartment alternates between suction and compression at a designated period, enabling control of the rate of refrigerant circulation. 
         [0005]    The intention for developing this rotary compressor with an installed circulation control unit disclosed under this patent application is to control the rate of refrigerant circulation in an air-conditioning system so that the rotary compressor does not restart during its operation, which enhances the performance of the air-conditioning system, saves costs and energy, and enables the air-conditioning system to be easily maintained and repaired. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  shows a conventional rotary compressor in a full-load operational mode. 
           [0007]      FIG. 2  shows a conventional rotary compressor in a no-load operational mode. 
           [0008]      FIG. 3  shows an electromagnetic coil with no supply of electric current. 
           [0009]      FIG. 4  shows the electromagnetic coil with supply of electric current. 
           [0010]      FIG. 5  shows the electromagnetic coil that is installed onto the rotary compressor in the first embodiment and with no supply of electric current. 
           [0011]      FIG. 6  shows the electromagnetic coil that is installed onto the rotary compressor in the first embodiment and with supply of electric current. 
           [0012]      FIG. 7  shows the features of a vane on which a mortise is formed and the tenon of an armature  15 . 
           [0013]      FIG. 8  shows a perspective view showing the features of a vane on which a mortise is formed and the tenon of an armature  15 . 
           [0014]      FIG. 9  shows the electromagnetic coil the armature  15  of which is altered to become shorter in length. 
           [0015]      FIG. 10  shows the electromagnetic coil according to  FIG. 9  that is installed on the rotary compressor in the second embodiment and with no supply of electric current. 
           [0016]      FIG. 11  shows the electromagnetic coil according to  FIG. 9  that is installed on the rotary compressor in the second embodiment and with no supply of electric current. 
           [0017]      FIG. 12  is a diagram showing the rotary compressor with controllable circulation&#39;s controlled operation according to periods fixed at 50% circulation rate. 
           [0018]      FIG. 13  is a diagram showing the rotary compressor with controllable circulation&#39;s controlled operation according to periods fixed at 75% circulation rate. 
           [0019]      FIG. 14  shows the rotary compressor on which the electromagnetic coil is installed in the first embodiment together with an installed limit switch in a no-load operational mode. 
           [0020]      FIG. 15  shows the rotary compressor on which the electromagnetic coil is installed in the first embodiment together with the installed limit switch in a full-load operational mode. 
           [0021]      FIG. 16  shows the rotary compressor on which the electromagnetic coil is installed in the second embodiment together with the installed limit switch in a full-load operational mode. 
           [0022]      FIG. 17  shows a circuit that is used for controlling the function of a coil  16 . 
           [0023]      FIG. 18  shows a side view of the rotary compressor in the first embodiment to show the positions where the electromagnetic coil and the limit switch are installed. 
           [0024]      FIG. 19  shows the features of the vane on which the mortise is formed and modified into a notch and the tenon of the armature  15  that is modified into a slanted tooth. 
           [0025]      FIG. 20  shows the operation of the vane on which the mortise is formed and modified into a notch and the tenon of the armature  15  that is modified into a slanted tooth. 
           [0026]      FIG. 21  shows the electromagnetic coil that is installed on the rotary compressor in the first embodiment as well as the vane on which the mortise is formed and modified into a notch and the tenon of the armature  15  that is modified into a slanted tooth. 
           [0027]      FIG. 22  shows the electromagnetic coil that is installed on the rotary compressor in the second embodiment as well as the vane on which the mortise is formed and modified into a notch and the tenon of the armature  15  that is modified into a slanted tooth. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0028]    A conventional rotary compressor&#39;s structure and parts contain a rolling piston  1  that is inserted on a crankshaft  2 , which is inside a cylinder  3  (the cylinder and the cylinder block of the rotary compressor are in one single piece), a vane  4  that moves along a slot  5  of the cylinder  3 , and a spring  6  that is contained in the slot  5  to force the vane  4  to contact with the rolling piston  1  during the rotary compressor&#39;s operation in a full-load mode. 
         [0029]    According to  FIG. 1 , which shows a conventional rotary compressoris in a full-load operational mode, the vane  4  contacts with the rolling piston  1  constantly and separates a piston chamber into 2 parts, i.e. a suction chamber  7  and compression chamber  8 , respectively. Therefore, when the crankshaft  2  rotates anticlockwise, the rolling piston  1  will also rotate anticlockwise. And, because of the blockage of the vane  4 , a suction force is pcoreuced in the suction chamber  7  and pressure is pcoreuced in the compression chamber  8 . While the rolling piston  1  is wiping to inject refrigerant, the vane  4  will move back and forth along the slot  5  by the push of the rolling piston  1 , the bounce of the spring  6  and the pressure of a refrigerant injection system. 
         [0030]    According to  FIG. 2 , which shows a conventional rotary compressor is in a no-load operational mode, the vane  4  is pressed into the slot  5  entirely and the piston chamber  7  and the piston chamber  8  combine to form a single chamber, i.e. a piston chamber  9 , which induces a condition where there is no suction force or pressure regardless of the position of the rolling piston  1 . At this stage, the rotary compressor is in a no-load operational modeoperational, which consumes the least electric current. 
         [0031]    Based on this principle, the rotary compressor with controllable circulation disclosed under this patent application is developed and it is a development of the ability to control the operation or the opening and closing of the vane  4  by means of an electromagnetic coil that is installed onto the rotary compressor. 
         [0032]    According to  FIG. 3 , which shows the structure of an electromagnetic coil  10  with no supply of electric current into a coil  16 , a spring  11 , which is installed between a bushing  12  and an armature  13 , forces the armature  13  to slide completely inside an armature shield  14  at all time. One end of an armature core  15  is joined with the armature  13  and the other end is in a wedge form. This armature core  15  can slide back and forth along the channel of the bushing  12  as a result of the pressure of the spring  11  and the suction force of the coil  16  applied on the armature  13 . 
         [0033]    According to  FIG. 4 , which shows the structure of the electromagnetic coil  10  with supply of electric current into the coil  16 , the armature  13  is induced to overcome the elastic force of the spring  11  and to move up to the same level as the coil  16 . At the same time, the armature core  15  moves up. This method of function is then used to control the operation of the rotary compressor in several ways as further described. 
         [0034]    According to  FIG. 5 , the installation of the electromagnetic coil  10  onto the rotary compressor in the first embodiment to control the opening and closing of the vane  4  is further described as follows: 
         [0035]    The rotary compressor (as shown in  FIG. 1 ) is bored horizontally to make a hole that is at the same level of and perpendicular to the vane  4 . This hole passes through a shield  17  and the cylinder block  3  of the rotary compressor until it reaches the slot  5  where the vane  4  is installed. The size of the hole is small enough for the armature core  15  to move back and forth fitly. Then, the vane  4  is pressed into the slot  5  entirely and an area where the bored hole intersects with the vane  4  is to be observed. A mortise is then formed on this particular area of the vane  4  (as shown in  FIG. 7 ). Then, the electromagnetic coil  10  (as shown in  FIG. 3 ) is installed at the bored hole and welded firmly at the joint of a flange  19  (Shape may differ according to the surface of the piece to be installed.) and the shield  17  of the compressor so as to ensure that there is no leakage. The length of the armature core  15  is determined by the distance from the armature  13  in a condition where electric current is supplied to the coil  16  until the tenon of the armature  15  is inserted entirely on a mortise  18  of the vane  4 , which is simultaneously pushed by the rolling piston  1  to slide into the slot  5  completely. 
         [0036]    Because of the installation of the electromagnetic coil  10  onto the rotary compressor in the first embodiment with no supply of electric current, the vane  4  moves freely, enabling the rotary compressor to suck and compress normally. At this stage, the rotary compressor is in a full-load operational mode. 
         [0037]    According to  FIG. 6 , when electric current is supplied into the coil  16  of the electromagnetic coil  10  that is installed onto the rotary compressor in the first embodiment, the armature  13  will be sucked to the same level of the coil  16  and it will push the armature core  15  upward at the same time as the rolling piston  1  pushes the vane  4  to move entirely into the slot  5 , making the mortise  18  on the vane  4  to be exactly in the same line of the tenon of the armature  15 . Therefore, the tenon of the armature  15  enters into the mortise  18  as a result of the push of the armature  13  and is attached to the vane  4 , i.e. by attaching a side  18 A to a side  15 A (referring to  FIG. 7  and  FIG. 8 ) so as not to return to the piston chamber  9 . At this stage, the rotary compressor is in a no-load operational mode as described in  FIG. 2 . 
         [0038]    When the supply of electric current into the coil  16  stops, the spring  11  will push the armature  13  back into its shield  14  and the vane  4  will become free (according to  FIG. 5 ). Then, the rotary compressor resumes is in a full-load operational mode and it will further alternate between no-load and full-load operational modes. 
         [0039]    According to  FIG. 9 , the electromagnetic coil, which has the same structure and function as shown in  FIG. 3  and  FIG. 4 , but the armature core  15  of which is shorter, and the shape of the flange  19  of which differs depending on the surface of the piece on which it is to be installed, is used for installation on the rotary compressor in the second embodiment to control the opening and closing of the vane  4 . 
         [0040]    According to  FIG. 10  and  FIG. 11 , a conventional rotary compressor is connected to a connection arm  20  from the vane  4 . The size of the arm  20  must be at the right size to allow insertion through the spring  21  and past the shield  17  of the rotary compressor and it should be long enough to enable installation of the electromagnetic. A tube  22  is then used to cover the arm  20  inside of which a bushing  23  supports the arm  20  to provide stability and to ensure that the arm  20  is not detached from a bushing  23  at all times even when the vane  4  slides into the piston chamber  9  entirely. Thereafter, a hole is bored on the top surface of the tube  22  between the shield  17  of the rotary compressor and the bushing  23 . The electromagnetic coil  10  of  FIG. 9  is further installed at this bored hole  24 . Then, the vane  4  is pushed into the slot  5  entirely and the mortise  18  is to be formed on the arm  20  at the area to which the tenon of the armature core  15  points. 
         [0041]    Thus, the length of the armature core  15  can be calculated at the period when electric current is supplied into the coil  16  and when the rolling piston  1  pushes the vane  4  inside the slot  5  entirely (as shown in  FIG. 11 ) by measuring from the end that connects with the armature  13  to the tenon of the armature core  15  while it is inserted inside the mortise  18  of the arm  20  entirely. From this point, all joints are to be welded firmly to ensure that there is no leakage during operation, which is similar to the operation of the electromagnetic coil  10  that is installed on to the rotary compressor in the first embodiment as described above under  FIG. 5  and  FIG. 6 . 
         [0042]    Because of such ability to control the opening and closing of the vane  4 , it is possible to control the circulation rate of refrigerant in an air-conditioning system by controlling electric current supplied into the electromagnetic coil  10  at designated periods and under the difference of room temperature as shown in the diagrams of  FIG. 12  and  FIG. 13 . 
         [0043]      FIG. 12  is a diagram showing control of periods of the rotary compressor according to the present invention, control of periods of electric current supply into the coil  16  in each period is shown by the diagram. According to this particular diagram, 1 period equals 20 seconds and the electric current supply stops for 10 seconds, during which the rotary compressor is in a full-load operational mode (100%). Likewise, during 10 seconds of electric current supply, the rotary compressor is in a no-load operational mode (0%). Both periods cover 20 seconds and thus the averaged value of circulation rate can be calculated as follows:
       20 seconds operation in 1 period (20 seconds)=100% output   Thus, 10 seconds operation in 1 period (20 seconds)=50% output   Therefore, 1 period (20 seconds) results in 50% circulation rate and averaged capacity of 50%.       
 
         [0047]      FIG. 13  is a diagram showing control of periods of the rotary compressor according to the present invention, control of periods of electric current supply into the coil  16  in each period is shown by the diagram. According to this particular diagram, 1 period equals 20 seconds. When the electric current supply is stopped for 15 seconds and is further supplied for 5 seconds, this will result in 75% circulation rate and averaged capacity of 75%. 
         [0048]    As mentioned above, it is clear that, the control system of an air-conditioning system that uses the rotary compressor according to the present invention never shuts the rotary compressor down during operation and the rotary compressor does not restart during operation, which saves energy that is caused by electrical surge or transient. During such operation, the system&#39;s capacity can be controlled and adjusted as needed by controlling the averaged capacity obtained from alternating between full-load and no-load operational modes in 1 period as described above. 
         [0049]    However, during alternation from a no-load operational mode to a full-load operational mode, the vane  4  moves freely into the piston chamber  9  while the rolling piston  1  moves at high velocity, which may cause damage from a sudden impact or after being used for a certain period of time. Therefore, a limit switch  25 , which is a normally closed limit switch, is attached onto the shield  17  of the rotary compressor to prevent damage from the impact between the vane  4  and the rolling piston  1 . 
         [0050]    According to  FIG. 14 , which shows the rotary compressor on which the electromagnetic coil  10  is installed in the first embodiment, the normally closed limit switch  25  is installed onto the shield  17  of the rotary compressor according to the present invention at a 15 to 30 degree angle from the line of the vane  4  in a direction opposite to the rotational movement of the rolling piston  1  and the center of which is situated on the center of the crankshaft  2 . The shield  17  of the rotary compressor according to the present invention is further bored at this particular area until the bored hole reaches the piston chamber  9  and a size of the bored hole is exactly the same as a size of a limit arm  26 . Thereafter, the limit arm  26  is inserted through this hole. The length of the limit arm  26  is determined by the length from the surface of the rolling piston  1  while pressing the limit arm  26  to the position where the limit arm  26  retracts into the hole entirely and pushes a contact plate  27  of the limit switch  25  apart (as shown in  FIG. 15 ). With respect to such installation of the limit switch  25 , firm welding between the shield of the limit switch  25  and the shield  17  of the rotary compressor is required to ensure that there is no leakage. 
         [0051]    According to  FIG. 16 , which shows the rotary compressor on which the electromagnetic coil  10  is installed in the second embodiment, the normally closed limit switch  25  is also installed. 
         [0052]    According to  FIG. 17 , in order to control the operation in a no-load mode, a thermostat T 1  triggers the coil  16  and a contactor K 0  to operate. Alternatively, a contact K 1  of the contactor K 0  and the contact  27  of the limit switch  25 , which are serialized together, can convey electric current to trigger the coil  16  and the contactor K 0 . 
         [0053]    When the operation is switched into a full-load mode, the thermostat T 1  will be open but electric current can still pass through the contact K 1  and the contact  27  so the coil  16  can still operate. However, when the rolling piston  1  moves to contact the limit arm  26 , which causes the contact  27  to be apart as shown in  FIG. 15 , the coil  16  then stops operating and thus releases the vane  4  at the same time as the rolling piston  1  moves to this position at high velocity. As a result, there is no impact and the rolling piston  1  can suction and compress normally. Therefore, operation can alternate without causing any damage. 
         [0054]      FIG. 18  shows a position of the installation of the electromagnetic coil  10  and the limit switch  25  from a side view of the rotary compressor that is perpendicular to the vane  4 . In fact, the position of the electromagnetic coil  10  can be either on the left or on the right of the vane  4 , and can be either higher or lower than the midpoint of the vane  4  as may be deemed appropriate. 
         [0055]    In addition, a modification of the mortise  18  and the tenon of the armature  15  to prevent damage from the impact between the vane  4  and the rolling piston  1  instead of installing the normally closed limit switch  25  are also possible as follows: 
         [0056]      FIG. 19  is a three-dimensional view of the structure of the armature core  15  and the vane  4  of which the mortise  18  and the tenon of the armature core  15  have been modified and the direction of movement of the armature core  15  before inserting into the mortise  18  of the vane  4 . 
         [0057]      FIG. 20  shows the structure of the armature core  15  and the vane  4  of which the mortise  18  and the tenon of the armature core  15  have been modified and a slanted tooth is formed. The tip of slanted tooth is formed on a side  15 A and has a width H 1  as minimal as possible to ensure that it is able to mesh without disconnecting. Then, a side  18 A of the mortise is expanded towards a side  4 A for a minimal width H 2 , which must be slightly larger than the width of the slanted tooth of the tenon of the armature core  15 , and the depth of the mortise H 3  is maintained throughout the expanded width H 2 . Then, a mortise for the slot of slanted tooth is formed on the innermost angle of a side  18 B to support the tooth of the tenon of the armature core  15  with which it is to mesh, or a tooth in another shape may be formed alternatively at the tenon of the armature core  15  to mesh to the mortise on the vane  4  without disconnecting. 
         [0058]    As a result of the mesh in this nature while the rotary compressor is in a no-load operational mode, the vane  4  is still partially inside the piston chamber  9 , which enables the vane  4  to slide freely along the slot  5  as driven by the force of the rolling piston  1 , the bounce of the spring  6 , and the pressure of refrigerant applied on the side  4 A in every cycle as long as electrical current is supplied to the coil  16 , which does not adversely affect the operation. 
         [0059]    When alternating to a full load operational mode, the electric current supplied to the coil  16  is cut off. Then, the bounce of the spring  11  forces the armature  13  back to its initial position inside the armature shield  14 . However, the armature  13  is unable to retract to its initial position since the slanted tooth of the tenon of the armature core  15  still meshes to the mortise  18 B that is formed on the mortise  18 . When the vane  4  is pushed by the rolling piston  1  to move into the slot  5  entirely, the slanted tooth of the tenon of the armature core  15  becomes free and it detaches and moves back from the vane  4  following the movement of the armature  13  and the bounce of the spring  11 . The vane  4  is then released on the top surface of the rolling piston  1  appropriately, causing no impact or damage. The operation of the rotary compressor on which the electromagnetic coil  10  is installed and the mortise  18  and the vane  4  of which are modified can alternate between full load and no-load operational modes without requiring the limit switch  25 . 
         [0060]      FIG. 21  shows the rotary compressor on which the electromagnetic coil  10  is installed in the first embodiment (as shown in  FIG. 5 ) with modifications in the mortise  18  of the tenon of armature core  15 . When no electric current is supplied into the coil  16 , the tenon of the armature core  15  does not insert into the mortise  18  of the vane  4  and it moves freely following the push of the rolling piston  1 , the bounce of the spring  6  and the pressure of refrigerant applied on the side  4 . 1 . At this stage, the rotary compressor is in a full load operational mode. 
         [0061]    However, when electric current is supplied into the coil  16 , the armature  13  will overpower the bounce of the spring  11  to be in the same line with the coil  16  and the armature core  15  will move up to push the vane  4  until the rolling piston  1  pushes the vane  4  into the slot  5  entirely. The tenon of the armature core  15  enters into the mortise and is attached thereto as long as electric current is supplied to the electromagnetic coil  16 . At this stage, the rotary compressor is in a no-load operational mode. 
         [0062]      FIG. 22  shows the rotary compressor on which the electromagnetic coil  10  is installed in the second embodiment (as shown in  FIG. 10 ) with modifications in the mortise  18  on the arm  20  and the tip of the armature core  15  that is formed to be a slanted tooth and without using the limit switch L 0 . When electric current is not supplied into the coil  16 , the armature  13  will retract to the opening of the shield  14 . However, when electric current is not supplied into the coil  16 , the armature  13  will be sucked to be in the same line with the coil  16 , the operational control of which is the same as that of the rotary compressor on which the electromagnetic coil is installed in the first embodiment as shown in  FIG. 21 . 
       THE BEST METHOD OF THIS INVENTION 
       [0063]    As described in Detailed Description of The Preferred Embodiments.