Abstract:
A wave cam type compressor is provided. The compressor has a wave cam body mounted on a rotary shaft for integral rotation and pistons operably contacting said cam body by way of shoes. The shoes are moveable relative to the cam body according to the rotation of the cam body. The shoes move on predetermined paths on cam surfaces of the cam body. The rotation therewith of the rotary shaft is converted into a reciprocation movement of the pistons between top dead center and a lower dead center in cylinder bores to compress fluid supplied into the cylinder bores. Each cam surface has a contour matching the locus of a predetermined smooth two-dimensional imaginary curve when the curve is translated from its plane in the direction perpendicular to the plane. A first portion is provided on the cam surface to drive the piston to the bottom dead center and a second portion is provided on the cam surface to drive the piston to the top dead center. The second portion has a greater radius of curvature than the first portion.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation in part application of the U.S. patent application Ser. No. 08/254,970 filed Jun. 7, 1994, which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Background of the Invention 
     The present invention relates to a compressor. More particularly, it pertains to a wave cam type compressor having a wave cam body integrally rotatable with a rotary shaft about an axis thereof. The rotation and cam action of the plate are converted to the reciprocating movements of pistons, thus causing the compression of gas. 
     2. Description of the Related Art 
     In a swash plate type compressor, the double-headed piston performs one reciprocating movement in accordance with one complete rotation of the swash plate. More specifically, a movement diagram indicative of one rotation of the swash plate is represented by one cycle of a sine wave curve. Accordingly, one rotation of the shaft causes a piston head to compress the refrigerated gas only once. There has been a need for a swash plate-like compressor having an improved compression capacity for a single shaft rotation. 
     During recent years, a compressor replacing a swash plate with a cam body has been proposed. In this type of compressor, the rotation of the cam body is converted to the reciprocation of pistons. The plate has either cam surfaces or cam grooves on both sides thereof. A movement diagram indicating one rotation of the plate is represented by a sine wave curve having a plurality of cycles. Accordingly, one rotation of the shaft causes a piston head to compress the refrigerated gas several times. Therefore, compression capacity is improved at least twice as much as compared to the swash plate design. 
     The Japanese Unexamined. Patent Publication 57-110783 discloses a compressor having rollers interposed between both front and rear cam surfaces of a cam plate and both heads of a piston. Each of the rollers are rotatably and permanently fitted within the piston head. The rollers move relatively with respect to the cam surfaces when the plate rotates. The displacement of the cam surface is transmitted to the associated piston head via the rollers. This causes the piston to reciprocate in a cylinder bore based on the curve of the cam surface. 
     The Japanese Unexamined Utility Model Publication 63-147571 discloses a compressor having a cam body on which cam grooves are formed on its front and rear surfaces. Piston heads are coupled to the plate by way of balls interposed between the cam grooves and the piston heads. 
     In the above publications, both the rollers and the balls interposed between the cam plate and the piston move relatively with respect to the plate. In these constructions, the roller or ball is kept in a line of contact with the plate. However, in a microscopic view, the deformation of the contacting portions causes a planar contact area between the balls or rollers and the plate. This decreases the pressure per unit of area acting on the balls or rollers and the plate. This decrease in pressure is an important facter when considering the durability of the compressor. 
     A decrease in Hertz&#39;s contact pressure can be achieved by enlarging the planar contact portion. This can be achieved by increasing the length of the contact portion and/or decreasing the curvature of the contact portion (increasing the radius of curvature). In order to decrease the pressure acting on the roller and the plate, the length and/or the diameter of the roller is increased. In order to decrease the pressure acting on the ball and the plate, the diameter of the ball is increased. However, since the rollers or balls are fitted in the pistons, the length of the roller or the diameter of the ball is affected by the dimension of the piston. Therefore, it is necessary to enlarge the diameter of the piston in order to increase either the length of the roller or the diameter of the ball. This makes it necessary to provide a large size compressor. However, vehicle-mounted compressors are preferably compact and lightweight. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide a wave cam type compressor which is kept compact and has a improved durability. 
     To achieve the above object, a wave cam type compressor is provided. The compressor has a wave cam body mounted on a rotary shaft for an integral rotation therewith and a piston operably contacting said cam body by way of a shoe. The shoe is relatively moveable relative to the cam body responsive to the rotation thereof. The shoe moves along a predetermined orbit on a cam surface provided on the cam body whereby the rotation of the rotary shaft is converted into a reciprocation movement of the piston between a top dead center and a bottom dead center in a cylinder bore to compress fluid supplied into the cylinder bore. The cam surface has a contour matching the locus of a predetermined smooth two-dimensional imaginary curve of finite length when translated from its plane in the direction perpendicular to said plane. A first portion of the cam surface is provided to drive the piston to the bottom dead center, and a second portion of the cam surface is provided to drive the piston to the top dead center, with the second portion having a larger radius of curvature than the first portion. 
     According to another aspect of the present invention, a compressor has a wave cam body having a first cam surface and a second cam surface respectively provided on opposite surfaces of the cam body and mounted on a rotary shaft for integral rotation therewith, a plurality of pairs of cylinder bores arranged around an imaginary circle centered about an axis of the rotary shaft, each of said pairs of bores consisting of two axially opposed cylinder bores, a plurality of pistons each having a pair of piston heads respectively accommodated in an associated pair of cylinder bores, and a plurality of pairs of shoes respectively coupled to the piston heads and relatively slidably moveable relative to the cam body according to the rotation thereof, wherein the shoes slide along predetermined orbits on each cam surface whereby the rotation of the rotary shaft is converted into a reciprocating movement of each piston between a top dead center and a bottom dead center in the associated cylinder bores to compress fluid supplied into the cylinder bores. Each cam surface has a contour matching the locus of a predetermined smooth two-dimensional imaginary curve of finite length when translated from its plane in the direction perpendicular to said plane, wherein the predetermined smooth curve is non-finite and has two straight lines at its ends each inclining with a predetermined angle, and an arc connecting the straight end lines. The cam surface further includes an outer peripheral edge defined by a first circle greater than and concentric with the imaginary circle and an inner peripheral edge defined by a second circle smaller than and concentric with the imaginary circle. The cylinder bores respectively include axes extending on the surface of an imaginary cylinder. Each predetermined orbit is axially and alternatingly convex and concave along a surface of said imaginary cylinder connecting the axes of the cylinder bores. The cam surface has a pair of advancing portions provided on each cam surface to advance the heads of each piston to the top dead center and a pair of retrieving portions provided on each cam surface to retrieve the heads of each piston to the bottom dead center, wherein said advancing portions have a larger radius of curvature than said retrieving portions. The predetermined orbits being axially aligned and equidistantly spaced throughout the entire area of the cam body. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a cross sectional view illustrating a compressor according to the present invention; 
     FIG. 2 is a cross sectional view illustrating the compressor along line 2--2 of FIG. 1; 
     FIG. 3 is an enlarged side view illustrating a cam body used in the compressor; 
     FIG. 4 is an enlarged plan view illustrating the cam body; 
     FIG. 5(a) is a perspective view illustrating the cam body; 
     FIG. 5(b) is a schematic perspective view depicting a method for manufacturing the cam body; 
     FIG. 6 is a graph depicting a movement curve on a flat surface of the cam body; 
     FIG. 7 is a graph depicting a movement curve on a curved surface of the cam body; 
     FIG. 8 is a schematic side view illustrating an imaginary cylindrical surface connecting axes of cylinder bores, the cylindrical surface crossing another cylindrical surface for defining a profile of the cam body; 
     FIG. 9 is a graph depicting a requirement (J) for keeping two shoes equidistant on both sides of the cam body; 
     FIG. 10 is a partial cross section illustrating a modification of the cam body; 
     FIG. 11(a) is a partial cross section illustrating further modification of the cam body; and 
     FIG. 11(b) is a schematic side view illustrating an imaginary cylindrical surface connecting axes of cylinder bores, which crosses another cylindrical surface for defining a profile of the cam body. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     A preferred embodiment of the present invention will now be explained with reference to FIGS. 1-9. 
     Referring to FIG. 1, a pair of cylinder blocks 1, 2 are securely fastened to each other by bolts (not numbered). A rotary shaft 3 is rotatably supported within the blocks 1, 2 by radial bearings 4, 5. Cylinder blocks 1, 2 have longitudinally aligned pairs of cylinder bores 1a, 2a (5 pairs in this embodiment), the axes of which are positioned on the same circle at equal circular spacing. A center axis L 1  of each cylinder bore 1a, 2a is positioned on a phantom cylindrical surface C 0  (FIG. 2), the center of which coincides with an axis L 0  of the rotary shaft 3. All the pistons are identical, therefore only one is described. A piston 6 has a pair of opposed heads 60a, 60b slidably disposed within the cylinder bores 1a, 2a, respectively. 
     A cam body 7 is integrally mounted on the rotary shaft 3. The cam body 7 has cam surfaces 7A, 7B on its rear (to the right in FIG. 1) and front surfaces, respectively. Shoes 8, 9 are interposed between the cam Surfaces 7A, 7B and the heads 60a, 60b, respectively. Each head 60a, 60b has a recess portion 6a, 6b, respectively, on its internal surface. Each of the shoes 8, 9 has spherical surfaces 8a, 9a and flat surfaces 8b, 9b (FIG. 3). The spherical surfaces 8a, 9a are received in the associated recess portion 6a, 6b. The flat surfaces 8b, 9b slide on the associated cam surfaces 7A, 7B. The shoes 8, 9 are fitted in recess portions 6a, 6b and thus coupled to the piston 6. Each radius center Q 1 , Q 2  of the shoes 8, 9 is at the center of the flat surfaces 8b, 9b. 
     The first and second cam surfaces 7A, 7B have movement curve lines F 1 , F 2  for determining the reciprocation cycle of the piston 6. Each of the lines F 1 , F 2  alternately curves axially forward and rearward on the cylindrical surface C 0 . The radius centers Q 1 , Q 2  of the shoes 8, 9 move along the movement curve lines F 1 , F 2  for the radius centers Q 1 , Q 2  are at the center of the flat surfaces 8b, 9b. 
     Referring to FIGS. 2 and 5, the first cam surface 7A includes a pair of curved surfaces 7b 1  and a pair of flat surfaces 7a 1 . Each of the curved surfaces 7b 1  is a part of a phantom cylinder, the axis of which is perpendicular to and intersects with the axis of the rotary shaft 3. The flat surfaces 7a 1  are formed to be continuous with the curved surfaces 7b 1 . The phantom straight lines K 1  represent the lines of intersection between the surfaces 7a 1 , 7b 1 . The two lines K 1  perpendicularly cross with the cylindrical surface C 0  at four points P 1 , P 2 , P 3 , P 4 . Accordingly, the movement curve line F 1  of 7A is divided into four portions at equal intervals of 90° along the cam surface 7A. The flat surface 7a1 is inclined at an angle of 45° to the axis L 0  of the rotary shaft 3. A normal vector m 1  to the flat surface 7a 1  is steered away from the axis L 0  rearward in the compressor (to the right side in FIG. 1). A normal vector n 1  to the curved surface 7b 1  is parallel to the axis L 0  and steered forward (to the left side in FIG. 1). 
     The second cam surface 7B includes a pair of curved surfaces 7b 2  and a pair of flat surfaces 7a 2 . Each of the curved surfaces 7b 3  is a part of an imaginary cylinder, the axis of which is perpendicular to and intersects with the axis of the rotary shaft 3. The flat surfaces 7a 2  are formed to be continuous with the curved surfaces 7b 2 . The phantom straight lines K 1  represent the lines of intersection between the surfaces 7a 2 , 7b 2 . The two lines K2 perpendicularly cross with the cylindrical surface C 0  at four points P 5 , P 6 , P 7 , P 8 . Accordingly, the movement curve line F 2  of 7B is divided four portions at equal intervals of 90° along the cam surface 7B. The flat surface 7a 2  is inclined at an angle of 45° to the axis L 0  of the rotary shaft 3. A normal vector m 2  to the flat surface 7a 2  is steered away from the axis L 0  forward in the compressor. A normal vector n 2  to the curved surface 7b 2  is parallel to the axis L 0  and steered rearward. 
     The points P 1 , P 2 , P 3 , P 4  on the first cam surface 7A are axially aligned with the points P 5 , P 6 , P 7 , P 8  respectively, on the second cam surface 7B. Each flat surface 7a 1  axially corresponds with one of the curved surface 7b 2  on the opposite side of the cam body 7. Similarly, each curved surface 7b 1  axially corresponds with one of the flat surfaces 7a 2  on the opposite side of the cam body 7. On the flat surface 7a 1  of the first cam surface 7A, two low points 7a 11  are separated from each other by 180°. On the curved surfaces 7b 1 , two high points 7b 11  are provided between the two low points 7a 11 . On the flat surfaces 7a 2  of the second cam surface 7B, two low points 7a 22  are axially aligned with the high points 7b 11 . On the curved surface 7b 2 , two high points 7b 22  are axially aligned with the low points 7a 11 . 
     A rotation of the cam body 7 causes the low points 7a 11 , 7a 22  to drive the piston heads 60a, 60b to bottom dead centers within the cylinder bores 1a, 2a, respectively. The high points 7b 11 , 7b 22  move the piston heads 60a, 60b to top dead centers within the cylinder bores 1a, 2a, respectively. 
     One complete rotation of the cam body 7 having the cam surfaces 7A, 7B will result in two reciprocation cycles of the piston 6 based on the movement curves F 1 , F 2 , respectively. The movement of the piston 6 causes a refrigerant gas within a suction chamber 10 to be drawn into the cylinder bores 1a, 2a via a suction valve 11 and a suction port 12. The further movement of the piston 6 discharges the refrigerant gas within the cylinder bores 1a, 2a into a discharge chamber 15 from a discharge port 14 and a discharge valve 13. 
     A constant distance between centers Q 1 , Q 2  of the two spherical surfaces 8a, 9a needs to be maintained for the piston 6 to reciprocate smoothly, i.e. a constant axial distance between the movement curves F 1 , F 2  must be maintained. The cam body 7 fulfills this requirement, denoted herein as requirement (J). Factors necessary to satisfy requirement (J) will now be explained. Referring to FIG. 5(a), a y axis corresponds to the axis L 0 , a z axis is parallel to the axis of the curved surface 7b 1 , and an x axis is parallel to the axis of the curved surface 7b 2 . As shown in FIG. 5(b), an open cylindrical surface P of the cam surface 7A is determined by the locus of a curved line L when translated in a direction along the z axis. Surface P extends between a large circle 7C 1  and small circle 7C 2 , both concentric to the cylinder C 0 , to define the cam surface 7A in a projected sight (FIG. 2). In the present embodiment, the curve line L has two straight end lines both inclining with an angle |α|° to the x axis and connected to one another by an arc. The straight lines S define the planar surfaces 7a 1  and the arc between them, which is part of an imaginary circle I, defines the curved surfaces 7b 1 . Similarly, a locus of an identical curved line as it is displaced along the x axis defines the shape of the opposite cam surface 7B. 
     FIG. 5(a) shows the cam body 7 in the xyz coordinate system for better understanding. FIG. 6 shows a diagram which represents the displacement of the shoe 8 using the xy coordinate system. The displacement of the shoe 8 will be described referring to FIGS. 5(a) and 6. 
     A displacement amount y of the shoe 8 during the movement of the center Q 1  along the movement curve F 1 , is represented by formula (1). 
     
         y=y.sub.1 +Rbp-tan α-cos θ                     (1) 
    
     Referring to FIG. 6, y 1  is an intersection point of the plane 7a 1  and y axis. Alpha (α) is the angle of plane 7a 1  with respect to the x axis. Theta (θ) is an angle of rotation of the cam body 7 about the y axis. The rotation angle θ is 0° when the piston head 60a is at the top dead center. Rbp is the radius of the cylinder C 0 . 
     Formula (1) is indicative of a cosine curve representing the movement curve F 1  along the plane of the surface 7a 1  (or the movement curve F 2  along the plane 7a 2 ). Therefore, to fulfill requirement (J), the movement curve F 2  along the curved surface 7b 2  corresponding to plane 7a 1 , or F 1  along 7b 1  must be indicative of a cosine curve represented by the next formula (2) where y (θ) represents the displacement of the shoe 9 (or 8). 
     
         y (θ)=C.sub.1 +C.sub.2 -cos θ                  (2) 
    
     C 1 , C 2  are constant. 
     Formula (3) is indicative of a displacement amount y (θ) of the shoe 9 along the curve F2 (or the shoe 8 along the curve F 1 ), wherein R co1  denotes the radius of curvature of the curved surface 7b 2  (or 7b 1 ) as shown in FIG. 7. Each variable or constant y (θ), y 2  (θ), y 2 , x (θ) is defined as shown in FIG. 7. 
     
         y (θ)=y.sub.2 (θ)-y.sub.2                      (3) 
    
     Formula (4) is indicative of y 2  (θ) ##EQU1## 
     Formula (2) can be changed to the next formula (5). 
     
         y (θ)=C.sub.1 +C.sub.2 -(1-sin.sup.2 θ).sup.1/2(5) 
    
     To fulfill requirement (J), the constants concerning formula (4) and formula (5) can be established from the next formula (6). 
     
         R.sub.co1 =Rbp=C.sub.2                                     (6) 
    
     Therefore, formula (7) derives from formulas (1), (5), (6). 
     
         Rbp=Rbp.tan α                                        (7) 
    
     
         tan α=1, α=45° 
    
     The inclination angle of plane 7a 1  to the axis L 0  is 45°, as understood in formula (7) to fulfill the above-mentioned requirement (J). Furthermore, the elements of the curved surface 7b 2  needs to be perpendicular to axis L 0  and the radius R co1  equal to the radius Rbp of the cylindrical surface C 0 . When the same conditions are fulfilled for the flat surface 7a 2  and the curved surface 7b 1 , the above-mentioned requirement (J) becomes effective. 
     FIG. 9 shows a diagram which shows the movement curves F 1 , F 2  when the requirement (J) is fulfilled. A curve line D 1  is indicative of the movement curve F 1  on the flat surface 7a 1 . A curved line E 1  is indicative of the movement curve F 1  on the curved surface 7b 1 . A curved line D 2  is indicative of the movement curve F 2  on the flat surface 7a 2 . A curved line E 2  is indicative of the movement curve F 2  on the curved surface 7b2. The phases of both movement curve lines F 1 , F 2  are separated by π/2. Referring to FIG. 9, the axial distance between the movement curves F 1 , F 2  is kept constant along the entire circumference of the cam body 7. 
     As shown in FIGS. 3 and 4, the cam body 7 which fulfills the requirement (J), allows the flat surfaces 8b, 9b of the shoes 8, 9 and the flat surfaces 7a 1 , 7a 2  to be in planar contact. The cam body 7 permits the surfaces 8b, 9b and the surfaces 7b 1 , 7b 2 , to be in linear contact. FIG. 4 is a plan view of the cam body 7 rotated 90° with respect to the plate shown in FIG. 3. The above planar contact minimizes the Hertz&#39;s contact pressure between the shoes 8, 9 and the cam body 7. In this embodiment, the shoes 8, 9 slide on the flat surfaces 7a 1 , 7a 2 , respectively, for about one half of the rotation of the cam body 7. Therefore, the Hertz&#39;s contact pressure is minimized for half of the time the compressor is in operation. This provides the shoes 8, 9 and the cam body 7 with resistance to wear. Accordingly, the durability of the compressor is improved. 
     FIG. 8 shows the imaginary cylindrical surface C 0  intersecting with the curved surface 7b 1 . If the cylindrical surface C 0  perpendicularly intersects with the curved surface 7b 1 , an intersecting curve F between the cylindrical surface C 0  and the curved surface 7b 1  will be on a plane inclined with the angle α of 45° with respect to the axis L0. The curve F is indicative of an oval represented by the next formula (8). 
     
         x.sup.2 /cos.sup.2 α+y.sup.2 =Rbp.sup.2              (8) 
    
     A line of intersection between the cylindrical surface C 0  and the curved surface 7b 2  is also defined by the same formula. The movement curve lines F 1 , F 2  and parts of the intersecting curve F are congruent. 
     In the compressor according to the above embodiment, the cam surfaces 7A, 7B have convex surfaces which are 90 degrees out of phase one from another, resulting in an improved strength in comparison with the conventional plate actuating the piston. 
     The present invention is, of course, not limited to the above embodiment. For example, with reference to FIG. 10, another design of a cam body 16 can be utilized. This plate 16 has cam surfaces 16A, 16B respectively including flat surfaces 16a 1 , 16a 2  and curved surfaces 16b 1 , 16b 2 . Normal vectors m 3 , m 4  representing the force of the shoes 8A, 9A on the flat surfaces 16a 1 , 16a 2  are directed toward the axis L 0  of the cam surfaces 16A, 16B. Normal vectors n 3 , n 4  representing the force of the shoes 8A, 9A on the curved surfaces 16b1, 16b2 are directed parallel to the axis L0. Surface 16B of cam body 16 can be defined with reference to FIG. 5(b). An open cylindrical surface P, which corresponds to the surface 16B is defined by the locus of a curved line L when translated in a direction along the z axis in FIG. 5(b), or, in a direction perpendicular to the plane of the paper in FIG. 10. A pair of straight lines S shown in FIG. 5(b) define the flat surfaces 16a 2 , and the arc between them, which is part of the circle I, defines the surface 16A when the line L is translated in a direction parallel to the plane of the paper in FIG. 10. Thus, plate 16 differs from the cam body 7 in that the curved surfaces are located at the low points of each surface and the flat surfaces are located at the high points of each surface. In this case, the requirement (J) mentioned in the above embodiment is fulfilled. The shoes 8A, 9A include spherical surfaces 8a, 9a and curved surfaces 8c, 9c. The curved surfaces 8c, 9c and the flat surfaces 16b 1 , 16b 2  are, respectively, kept in planar contact. The curved surfaces 8c, 9c and the flat surfaces 16a 1 , 16a 2  are kept in linear contact. 
     In this embodiment, the curved surfaces 16b 1 , 16b 2  and the curved surface. 8c, 9c are, respectively, kept in planar contact for about one half of the rotation of the Plate 16. Accordingly, the Hertz&#39;s contact pressure is minimized for half of the time the compressor is in operation. This results in improved durability. 
     The present invention can also be constituted by a cam body 17 as shown in FIG. 11(a), in which cam surfaces 17A, 17B include flat surfaces 17a 1 , 17a 2  and elliptic curved surfaces 17b 1 , 17b 2 . FIG. 11(b) shows the cylindrical surface C 0  intersecting with the oval curved surfaces. When the cylindrical surface C 0  perpendicularly intersects with the oval curved surfaces 17b 1 , 17b 2 , an intersecting curve G between surface C 0  and surfaces 17b 1 , 17b 2  will be on a plane inclined at the angle α&lt;45° or 45°&lt;α. This intersecting line is an oval. The movement curves F 1 , F 2  on the cam surfaces 17A, 17B and parts of the intersecting curve G are congruent. The surface of the shoe which slides on the cam body 17 is flat. 
     Furthermore, in the present invention, it is possible to use a cam body in which the flat surfaces 17a 1 , 17a 2  have normal vectors directed toward the axis L 0 . The sliding surfaces of shoes for this plate are curved. 
     According to the present invention, each cam surface 7A, 7B has a curved surface matching the locus of a predetermined smooth curve of finite length lying in a given plane when translated in a direction perpendicular to the plane. In other words, each cam surface 7A, 7B is in the form of an open cylindrical surface defined by a non-finite directrix. This enables the manufacturing process of the cam body to be simple compared with the conventional process for manufacturing the three dimensional-cam surfaces.