Compressor :
Compressor is basically used for increasing the pressure of a fluid by compressing the fluid in a closed
chamber for compressible fluids OR by imparting Kinetic energy in it and subsequently changing
Kinetic Energy into Pressure Energy for incompressible fluids.
Types of Compressors :
• Reciprocating compressors
• Rotary compressors
• Screw compressors
• Scroll compressors
Hermetic Compressor :
When the motor, the gas pump assembly and other parts are placed in side the dome OR housing and
completely sealed , is called Hermetic Compressor.
Hermetic Compressors are generally used in the Refrigerators , Air - Conditioners , Water coolers and
Chillers.
Generally Reciprocating compressors are used in Refrigerators and Rotary compressors are in Air -
conditioners.
Role of the compressor in the Refrigerator / Air conditioner / Water cooler / Chiller is vital and the entire
functioning and efficiency of the system depends on the working and efficiency of the Compressor.
Cost of the compressor is around 50 % of the Refrigerator / Air -Conditioner / Water cooler / Chiller.
• Elevating the temperature of the refrigerant gas and pressure to such values at which the vapor
refrigerant change its phase from vapor to liquid at room temperature.
• Returning the evaporated liquid from the evaporator maintaining the mass flow of the gas in the system.
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Importance of Refrigeration :
There are few phases of modern living untouched by refrigeration and air conditioning. business
operations, manufacturing processes, storage, and shipping are almost always carried out today under
controlled temperature conditions.
The refrigeration and air conditioning industry helps make possible this system of living. Air conditioning
has improved business and industrial efficiency, while adding to human comfort .
More and more factories and heavy industries are being air conditioned.
Many fruits and vegetables are refrigerated immediately upon being harvested the quality of such
products is much better for this reason.
Cooling and freezing of meat and meat products makes possible their handling in a much
sanitary way than would be possible without mechanical refrigeration.
Beverages, desserts , and even staple foods are all at least partially processed by refrigeration
equipment.
• GE
• Whirlpool
• Electrolux
• Maytag
• LG
• Samsung
• Matsusitha / Panasonic
• Haier
• Kelon
• Estimated Sale for 2003 - 2004 is 3.4 Mln - 3.65 Mln units.
• The 165 - 225 litre segment comprises 75% of the total demand.
Technology changes :
The simplest form of a vapor compression system is an open vessel containing any liquid which has a
boiling point well below surrounding space temperature. The liquid picks up heat ( latent heat ) required for
its change of phase from liquid to vapor. And lowers the temperature of the vessel wall and surrounding air.
This method of refrigeration is uneconomical since the recovery of evaporating liquid is not possible.
Therefore an economical refrigeration system must consists of a method of refrigerant recovery back into
the form of liquid for continuous evaporation. In all the refrigerant systems, the process of evaporation take
place in the evaporator and the conversion of vapor to liquid achieved by the compressor and condenser.
Function of compressor :
• Elevating the temperature of the refrigerant gas and pressure to such values at which the vapor
refrigerant change its phase from vapor to liquid at room temperature.
• Returning the evaporated liquid from the evaporator maintaining the mass flow of the gas in the system.
Function of condenser :
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The condenser aids the recovery by receiving the refrigerant at high pressure and high temperature and
lowers it temperature up to the condensing temperature for converting it to liquid dissipating the heat to the
surrounding atmosphere.
The main function of a capillary tube is to reduce the temperature of refrigerant from condensing
temperature to below evaporate temperature ( by the principle of cooling and throttling ) to enable heat
removal from evaporator. Capillary divides the system into a high side and low side. The low side is for
lowering the boiling point of the refrigerant below the conditioned space temperature and the high side for
conversion of vapor to liquid. Another function of the capillary tube in a system is to meter the flow of
refrigerant at the same rate as of its evaporation in the evaporator.
Refrigerant :
Refrigerant are heat carrying mediums which during their cycle in the refrigeration system absorb heat at
low temperature level and discard the heat so absorbed at a higher temperature. Refrigerants have boiling
points much below ordinary room temperature and so they exist as gases and are only held as liquids by
keeping them under pressure, such as in a refrigerant cylinder.
Types of Refrigeration :
Refrigerator is basically a reversible heat engine. It follows the theoretical 'Carnot' cycle. 'Carnot' cycle
comprises of two ' Isotherm ' processes and two 'Adiabatic ' processes. Different techniques are practiced to
achieve this. They are
• Vapor compression refrigeration.
• Vapor absorption refrigeration.
The most common type used in household refrigeration is Vapour Compression Refrigeration .The two
isotherms of ' Carnot ' cycle are the two heat exchange process, viz. Condensation and Evaporation and two
Adiabatic are throttling valve expansion and compression by Compressor.
In Isotherm process, the system temperature is always constant but pressure varies.
As the refrigerant circulates through a vapor compression refrigeration system , it passes through a number
of changes in state or condition in a definite sequence and returns to the initial condition to complete a
cycle. This cycle is made up of fundamental processes viz. Expansion, vaporization, compression,
condensation.
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(4) - (1) Evaporation.
So, compressor is the heart of refrigerator. It takes the refrigerant vapor at low pressure low temperature
and delivers it at high pressure high temperature. By taking up the refrigerant vapor from evaporator, it also
maintains the flow in the refrigeration circuit.
The performance of a compressor is measured by C.O.P value and it varies from 3.1 to 5.4 BTU / Watt Hr.
C.O.P is co-efficient of performance. For a refrigerator it is defined as the ratio of refrigerating effect
obtained and compressor work input to the system.
Range of Compressors :
Based on the capacities the compressors are categorised into Low back pressure, Medium and High back
pressures. The L.B.P range varies from 98 to 148 Kcal/Hr. The M.B.P ranges from 148 to 300 Kcal/Hr. The
H.B.P ranges from 340 Kcal/Hr and above.
Ton of Refrigeration :
The method for rating refrigeration equipment goes back to the days when ice was used as the source for
removing heat.
It takes 144 Btu of heat to melt 1 pound of ice. It would take 2000 times that much heat to melt a ton of ice.
Types Refrigerants :
Properties of Refrigerants :
CFC Refrigerants :
HCFC Refrigerants :
• R-22
• R-123
HFC refrigerants :
This contains one or more hydrogen atoms and no chlorine atoms. Common HFCs are
• R-134a.
• R-124.
Refrigerant blends :
• Azeotropic blend
1. Zeotropic blend.
• R600a
• R290
Ozone layer :
The ozone layer is a fairly thin layer of the earth‘s upper atmosphere .(stratosphere ) it is
approximately thirty five miles above the ground. The ozone layer functions as a filter for the sun‘ s
ultra violet rays .This protects human, plant, and sea life from the damaging effects of sun .
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Scientists have found that releasing Chlorofloro carbons ( cfc ) from refrigerants can harm the
ozone layer . the chlorene content in the cfc is the cause for depletion of ozone layer. This
concern has developed into what we refer as the EPA ( Environmental Protection Agency )
regulations. these regulations identify types of refrigerants that can be produced and used. and
define the phase out program of these cfcs. Countries through out the world have passed
legislation preventing the use of chemicals that effect this layer .
This measures the capacity of the refrigerant to destroy the ozone layer by reacting with the ozone gas.
Montreal protocol :
Montreal protocal on substances that deplete the ozone layer was agreed to on september
16, 1987. the montreal protocal obligates all parties to phase out ozone depleting substances
according to a specified time table and was so designed that the phase out schedules could be
revised on the basis of periodic scientific and technological assessments.
As per Montreal protocol provisions for article 5 countries, the Indian industries have to phase out the
production and / or use of Ozone depleting substances by the year 2010.
Earth's outer atmosphere is having a thick layer of ozone gas, which protects us from different ultra violet
and cosmic rays. It has been found that in some areas this ozone layer is being depleted because of many
reasons, use of CFCs is one of them. Chlorine of CFC reacts with ozone and thus destroys the ozone layer.
Thus for refrigerator industry, the immediate alternative for R12 is R134a which is Hydrofluoro carbon
( HFC ). As there is no chlorine atom, hence it does not react with ozone.
But this changeover requires a lot of change in system design and manufacturing of refrigerator.
• Displacement of Compressors.
Compressor :
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Compressors are basically used for increasing the pressure of a fluid by compressing the fluid in a closed
chamber for compressible fluids OR by imparting Kinetic energy in it and subsequently changing
Kinetic Energy into Pressure Energy for incompressible fluids.
Types of Compressors :
When the motor and the compressor are placed in side the dome OR
Housing and completely sealed, is called Hermetic Compressor.
• Reciprocating compressors
• Rotary compressors
• Screw compressors
• Scroll compressors
Among these types the most common type of compressor used for
Refrigeration is Reciprocating compressor.
Basically, this type of compressor belongs to the positive displacement class machines. Generally
reciprocating compressors are driven by means of a electric motor.
During downward movement of piston, the refrigerant vapour is taken in through suction line via intake
valve. During upward movement, vapour is compressed and passed through a small diameter pipe and
subsequently through expansion valve.
Gas pump assembly is a critical part of the compressor which facilitates the function of pumping the
refrigerant gas for circulating in the closed loop cycle of refrigeration. The refrigerant has to be in
continuous circulation in the system at different temperatures and pressure to complete the refrigeration
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cycle. This is achieved by continuous compression and pumping of the same with the help of gas pump
assembly.
The gas pump assembly consists of the following components:
• Compressor block
• Piston
• Connecting Rod
• Piston pin
The piston operates in a reciprocating motion in the cylinder bore, which is an integral part of the
compressor block. The connecting rod which is connected to crank shaft - upper bearing- rotor group ,
helps in transmitting the rotary motion generated by stator & rotor, into the reciprocating motion of the
piston. By the reciprocating motion of the piston, it sucks refrigerant gas into the cylinder and pumps the
same into the system after compression. The refrigerant gas is sucked into the pump assembly through
suction muffler assembly, valve plate and suction valve. After compression in the cylinder the same is
pumped into the system through valve plate, discharge valve and discharge muffler of the block and
discharge pipe connecting the compressor to the system.
The pump assembly will be seated on the springs in the compressor body and it forms the frame for all
other components.
Compressor block :
Compressor block castings are made up of grey cast iron by the sand moulding process. The cast iron must
be dense enough to prevent seepage. Some Nickel is usually added to give the casting the desired density.
Usually the crank case is part of the same casting. This practice cuts down number of joints that might leak.
It also permits close alignment between crank shaft and cylinder.
Piston :
Pistons castings are usually made up of cast iron by the sintering process. Smaller sizes do not have piston
rings. The temperature of piston seldom goes higher than 250 degree F. Thus there is not much expansion
of either piston or cylinder. Smaller pistons have oil grooves cut in them.
Piston pin :
Piston pins are made up of Special alloy steel and made through machining process and accurately ground
to size. Usually they are hollow to reduce weight. They are usually of full floating type. This means the
pin is free to turn both connecting rod bushing and piston bushing.
Connecting rod :
The connecting rod castings are made up of aluminium alloy by pressure die casting process . It holds the
piston rigidly by a piston pin and connected to the crank shaft.
Crank shaft :
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Crankshaft is made up of grey cast iron and by sand moulding process. The reciprocating motion is
achieved by the crankshaft/ connecting rod / piston assembly.
Upper bearing :
Upper bearing is usually made up of Aluminium alloy and by pressure die casting process. It is placed in
between Crank shaft collar and rotor. It acts as a bearing.
Rotor :
It is Basically an assembly of lamination stack and aluminum counter weights. Rotor is made by Die
casting process by pouring the Aluminium in the slots of the lamination. It is the part of the motor which
rotates under the action of the magnetic field created by stator.
Split pin :
Split pins are made up of hardened and tempered steel and made through machining process. This split pins
are used to lock the piston pin.
Cylinder head :
Cylinder head castings for Hermetic compressor are usually made of cast iron/ Aluminium and these
castings are made by sand moulding process for cast iron and by pressure die casting process for
Aluminium. The head serves as a pressure plate. It supports and holds valves and valve plates in position.
It also provides vapour passage into and out of compressor. The pressure of compression may amount as
much as 300 psi. These pressure depends on type of refrigerant used. The valve plate must have good
support. There must be no leakage at the gaskets on either side of the valve.
Cylinder head fixing screws are made up of tensile strength steel and through machining process.
Valve plate :
Valve plates are made up of cast iron by sintering process. It supports the suction valve and discharge
valve.
Discharge valve pins are made up of steel with copper coating and through machining process.
Discharge valve :
Discharge valves are made up of carbon steel and by blanking and piercing process.
Suction valve :
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Suction valves are made of made up of carbon steel and by blanking and piercing process.
Valve reed :
Valve reed is made up of carbon steel and by blanking and piercing process.
Valve stop :
Valve stops are made of cold rolled steel and by of blanking and piercing Process.
Oil pump:
Oil pump is made up of steel (C75) and by blanking, piercing and forming process.
Rotor :
It is Basically an assembly of lamination stack and aluminium counter weights. Rotor is made by Die
casting process by pouring the Aluminium in the slots of the lamination. It is the part of the motor which
rotates under the action of the magnetic field created by stator.
Rotor Lamination :
Rotor lamination is made up of low silicon steel semi processed through blanking and piercing process.
Stator :
It is Basically an assembly of lamination stack , copper wire wound on the lamination stack with the
mylor film for insulation. It creates the magnetic field for rotation of the Rotor.
Stator lamination :
Stator laminations are made up of low silicon steel, semi processed and by blanking and piercing process
.
Mylar film :
Mylar film is made up plastic material of polyester film, and by process of plastic extrusion process .
Copper wire :
Stack cleats :
Stack cleats are made up of cold rolled steel and by drawing process
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Heat shrink tube is made up plastic material of polyester film, and by injection moulding process .
Connector :
Stator fixing screw is made up of high tensile strength steel and by machining process.
Upper shell :
Upper Shell is made up of cold rolled steel EDD quality, and by blanking and forming process.
Crankshaft stop :
Crankshaft stop is made up of cold rolled steel EDD quality, and by blanking and forming process.
Lower shell :
Lower Shell is made up of cold rolled steel EDD quality, and by blanking and forming process .
Compressor block:
• Tolerance on cylinder bore -- 10 microns
• Surface finish of cylinder bore -- 0.33 Ra
• Flatness of cylinder head face -- 25 microns
Piston:
• Tolerance on outer diameter -- 10 microns
• Surface finish of outer diameter -- 0.25 Ra
• Tolerance on piston pin hole -- 10 microns
• Surface finish of piston pin hole -- 0.5 Ra
Connecting rod:
• Tolerance on big end hole diameter -- 5 microns
• Tolerance on small end hole diameter -- 8 microns
• Surface finish of big end diameter -- 0.4 Ra
• Surface finish of small end diameter -- 0.4 Ra
Crank shaft:
• Tolerance on main axis diameter -- 8 microns
• Tolerance on eccentric axis diameter -- 8 microns
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• Surface finish on main axis -- 0.2 Ra
• Surface finish on eccentric axis -- 0.2 Ra
Upper bearing:
• Tolerance on shaft hole diameter -- 8 microns
• Surface finish of shaft hole -- 0.4 Ra
• Flatness of block seating face -- 10 microns
Valve plate:
• Surface finish of both the faces -- 0.16 Ra
• Flatness of both the faces -- 10 microns
Gauges:
Machined compressor components will undergo in-process/ final inspection on various gauges like
• Air gauges with dial type display units with 0.5 micron accuracy - Baker / Accurate make
• Electronic gauges with digital type display units with 0.5 micron accuracy - Baker / Accurate make
• Mechanical gauges :
Plug gauges
Snap gauges
Relational gauges
Cutting Tools:
The following type of cutting tools are used in the machining of compressor components to the accuracy of
the components as per the specifications.
Oils:
The Cast Iron castings of Compressor block will undergo the following
Machining and cleaning operations.
1. SPM - I :
The following operations are performed on the stator seating side
of the compressor block .
2. SPM - II :
The components are turned and positioned to perform the operations
on suspension spring supports side of the compressor block.
6. Washing machine :
The Sintered Cast Iron piston will undergo the following process before sending into the Pre
- assembly.
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• Finish grinding of outer diameter on Center less grinding machine
• Rough boring of Big end hole and Small end hole on rough
Boring machine.
• Finish boring of Big end hole and Small end hole on final
Boring machine.
The Cast iron castings will undergo the following machining and
Cleaning operations before being sent to pre assembly.
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• Cleaning of machined crank shafts in the High pressure washing
Machine with OKAITE - 445, non - CFC grade chemical.
The Sintered Cast Iron casting valve plate will undergo the following
Process before sending it in to the pre - assembly / assembly.
1. Shell fabrication :
1
Steel strip coil for the Upper shell will undergo the following
Process before sending it to the welding line.
2. Shell welding :
After pre treatment these upper shells will be going to the assembly.
1. Shell fabrication :
2
Steel strip coil for the Upper shell will undergo the following
Process before sending it to the welding line.
2. Shell welding :
After pre treatment these Lower shells will be going to the assembly.
Silicon steel sheet is fed into high speed press through a de coiler for
auto feed and blanking of the bore , slots for rotor are made .
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• Stator slots & stator lamination blanks
Stamping treatment:
Then the stator lamination is sent for stator assembly line and rotor
lamination is sent for Rotor line.
The motor is placed inside housing. The motor must drive the compressor directly. It should have good leak
proof electrical connections and must be of an induction type. Motors using rotor windings requiring either
brushes or slip rings cannot be used.
N = 120 * f / p.
Where, N = RPM
f = Frequency
p = No. of pole.
Hermetic motors are generally single phase induction motors. They are of
four types
• Split phase Induction motor
• Capacitor Start, Induction Run (CSIR ).
• Capacitor start, Capacitor run (CSCR).
• Permanent split phase Capacitor ( PSC ).
• Resistance start Induction run ( RSIR ).
• Resistance start capacitor run (RSCR ).
Motor Capacitor:
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Capacitors changes current flow in A.C circuit. It is changed from a single phase to a two phase current
flow. Capacitors are used in both starting and running windings.
It has good starting torque, which is obtained by placing a capacitor in series with the starting winding. It
can use current relay, potential relay or thermal relay.
This generally uses two motors. Both are in the starting winding circuit but only the start capacitor is
controlled by the relay switch.
When motor is started, the capacitors turn the motor power surges into two phase power and produces a
high starting torque. After the motor reaches 60% load or 75% of its rated speed, the relay opens the circuit
to the starting capacitor. The running capacitor is left in the circuit.
This action produces a two phase motor that is very efficient. The power factor is improved. Large
Hermetic units in commercial systems use this type of motor.
The permanent split phase capacitor is popular for air conditioning systems. It does not use
relay. Current flows through both the running winding and the starting winding when
power is on . A running capacitor is connected in series with the starting winding
such motors are sensitive to line voltage. A 5% drop in line voltage will cause starting
difficulty and over heating.
Starting torque is low . Thus, if the motor tries to start when the system is not
balanced , the motor will over heat.
In motors for resistance start, the start winding is made of wire of a smaller dimension than that of the main
winding. The result is a large difference in the ohmic resistance, causing the current in the start winding to
be less inductive than the current in the main winding, and the required phase displacement is obtained.
These type of motor are having start winding as resistance start, and the run winding as capacitor run.
The electrical terminals that carry current through the dome must be electrically insulated
from the dome or housing. They also must be leak proof. Most motor terminals are fused to
glass. The glass, in turn fused to a metal disk . This assembly may be welded to the hermetic
dome or housing . The terminal must be leak proof after thousands of heating and cooling and
expansion and contraction cycles. Further more, it must have a high insulating value ( 50kv )
After machining of each and every component of compressor as per specifications, they are sent for
grouping in pre - assembly . This grouping is a selective.
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Grouping / Selective assembly :
Manufacturing the mating parts exactly with the dimensions to get this clearance is not practical in mass
production and every machining process requires some tolerance on the sizes of the component. Hence in
order to overcome this problem, the components like cylinder block, piston, connecting rod , piston pin ,
crank shaft, upper bearing are made within a specified range of dimensions. Then these components are
classified in different classes like A, B, C etc. based on the size defined for each class.
In the selective assembly mating parts of each group are selected such that the difference between OD & ID
is as per the specification.
In the pre - assembly the grouping is done mainly in three different lines. They are
The following sequence of operations are performed in the assembly of oil pump , crank shaft, upper
bearing and rotor.
• Selection and coupling of crank shaft and upper bearing such that clearance between both is as per the
specification.
• Placing the thrust washer in the rotor and positioning the rotor in the fixture of the hot fitting machine.
After the hot fitting the rotor group assembly will be sent to assembly.
The following sequence of operations are performed in the assembly of block , piston, connecting rod and
piston pin assembly.
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• Classification of connecting rod small end on Air /Electronic gauge
• Selection and insertion of piston pin in the piston and con rod small end holes
After the insertion of piston pin , this block- piston - con rod group will be sent to assembly.
The following sequence of operations are performed in the assembly of valve plate.
• Fixing of spring
After the leak testing , the valve plate assembly will be sent to assembly.
The following sequence of operations are performed in the assembly of Suction muffler.
After spring fixing , this suction muffler assembly will be sent to assembly.
• Various sheet metal parts like Spring pins , Foot brackets , Hermetic terminal , Relay guard will be
projection welded on the lower shell on special purpose projection welding machines.
• Connectors / Tubes of different sizes will be brazed manually to the welded lower shell.
• The upper shell and lower shell will be sent for pre-treatment in a pre- treatment plant and sent to
Compressor assembly.
• Various machined parts / selectively assembled parts will be assembled in the lower shell on a
continuous assembly conveyor with pneumatic nut runners. After this assembly it is passed through
Dehydration oven for a period of 4 hrs and taken out and Moisture level is checked ( < 150 mg )
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• After placing the upper shell on the lower shell, the compressor is welded on a MIG welding machine
and leak tested at 17 kg / sq. cm.
• After testing , the compressors will be sent for packing and then to finished goods stores for despatch.
The detailed description of process for Assembly of compressors / sub assemblies / manufacturing of
components , that goes into Compressor are as follows.
• On Block - Piston - Con rod assembly, Crank shaft - Upper bearing - Rotor assembly are placed.
• The following components / sub assemblies are placed on the above assembly before the next stage.
Stator.
Valve plate assembly.
Cylinder head & Suction muffler assembly.
Discharge muffler cover assembly.
• The spring bushes and spring fittings are placed on the lower shell.
• Then it is open tested in a open test bench and placed in a Dehydration oven for dehydration by hot air
injection.
• After taking lower shell assembly from dehydration oven the upper shell assembly is kept on the top.
Then it is sent for MIG welding.
Vaccumising.
Oil charge.
Run test.
Compression & Absorption test.
Noise test.
Marking.
INDEX
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Compressors and Application :
• What is Compressor
• Types of Compressors
• Hermetic Compressor
• Application of Compressors
• Function of Compressor in Refrigeration
Refrigeration :
• Importance of Refrigeration
• Global and Indian market - Refrigerator
• Global and Indian market - Compressor
• Principle of Refrigeration
• Types of Refrigeration
• Vapor compression refrigeration cycle
• Types of Refrigerants
• Ozone layer
• Montreal Protocol
Manufacturing of Compressors :
Compressor block
Piston
Connecting rod
Crank shaft
Upper bearing
Valve plate
Upper shell
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Lower shell
Lamination
Stator
Gauges :
Machined compressor components will undergo in-process/ final inspection on various gauges like
• Air gauges with dial type display units with 0.5 micron accuracy - Baker / Accurate make
• Electronic gauges with digital type display units with 0.5 micron accuracy - Baker / Accurate make
• Mechanical gauges :
Plug gauges
Snap gauges
Relational gauges
Cutting Tools :
The following type of cutting tools are used in the machining of compressor components to the accuracy of
the components as per the specifications.
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• Turning - Standard tools / Special brazed tools
• Drilling / CSK - Standard / Special - HSS drills
• Reaming - Special - Carbide reamers
• Final boring - Special - Diamond boring tools
• Milling - Standard / Special cutters
• Honing - Special honing tools
• Grinding (Rough) - Special grinding wheel - 38A46 2 L8 V11
• Grinding (Finish) - Special grinding wheel - 38A150L8V11 /
SA120L6VF8
- Special regulating wheel - A80 RR 51
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