Vane compressor provided with endless camming surface minimizing torque fluctuations
BACKGROUND OF THE INVENTION 
     This invention relates to vane compressors adapted for use in air conditioning systems or the like, and more particularly to vane compressors provided with improved camming surfaces which minimize torque fluctuations. 
     As known e.g. from U.S. Pat. No. 3,834,846, a vane compressor in general comprises a drive shaft arranged to be rotated by a prime mover, a rotor arranged for rotation in unison with the drive shaft and having an outer peripheral surface formed therein with a plurality of slits, a plurality of vanes radially movably fitted in the slits of the rotor, and a pump housing having an inner peripheral surface formed as an endless camming surface and in which the rotor and the vanes are received. The rotor, the vanes and the pump housing cooperatively define therebetween at least one pumping chamber. As the rotor rotates, gaseous fluid such as refrigerant gas is sucked into the pumping chamber, compressed therein and discharged therefrom. 
     In the above vane compressor, the endless camming surface of the pump housing, along which the vanes slidingly move in unison with the rotating rotor, has an elliptical cam profile in the type where the pump housing has two pumping chambers defined therein, and a circular cam profile in the type where the pump housing has a single pumping chamber defined therein. 
     However, conventionally no particular consideration was given to minimizing fluctuations in the torque acting upon the rotor in designing the cam profile of the endless camming surface. Therefore, the conventional vane compressor has large torque fluctuations during each cycle of suction, compression and discharge of fluid, which causes occurrence of operating noise and vibrations of the compressor during operation of the compressor. 
     OBJECT AND SUMMARY OF THE INVENTION 
     It is the object of the invention to provide a vane compressor in which the pump housing has an endless camming surface having a novel cam profile minimizing the torque fluctuations, thus reducing operating noise and vibrations of the compressor. 
     According to the present invention, the endless camming surface of the pump housing has at least one portion for performing one cycle of suction, compression and discharge of fluid in cooperation with the vanes and the rotor, which portion comprises: an increasing radius portion along which the amount of protrusion of each vane from the rotor gradually increases with movement of the vane; a first decreasing radius portion along which the amount of protrusion of each vane from the rotor gradually decreases with movement of the vane; and a second decreasing radius portion along which the amount of protrusion of each vane from the rotor gradually decreases with movement of the vane. The increasing radius portion and the first and second decreasing radius portions are successively arranged in the order mentioned in the moving direction of the vanes. Each of the three portions has such a cam profile that the velocity of radial movement of each vane varies at a rate gradually decreasing as the vane approaches the terminating end of the portion. 
     Preferably, the above one-cycle performing portion of the endless camming surface further includes at least one of: a first constant radius portion located between the increasing radius portion and the first decreasing radius portion, along which the amount of protrusion of each vane from the rotor is kept substantially constant with movement of the vane; a second constant radius portion located between the first decreasing radius portion and the second decreasing radius portion, along which the amount of protrusion of each vane from the rotor is kept substantially constant with movement of the vane; and at least one third constant radius portion arranged either at a location immediately preceding the increasing radius portion or a location immediately following the second decreasing radius portion. 
     The above and other objects, features and advantages of the invention will be more apparent from the ensuing detailed description taken in connection with the accompanying drawings in which: 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side view of a typical conventional vane compressor of the double pumping chamber type, with its essential part shown in longitudinal section; 
     FIG. 2 is a sectional view taken along line II--II in FIG. 1; 
     FIG. 3 is a schematic view showing a whole cam profile for the camming peripheral surface according to one embodiment of the present invention; 
     FIG. 4 is a graph showing the relationship between a curve of radial movement of vane obtained by the increasing radius portion of the camming peripheral surface of the invention and a sine curve used for designing the cam profile of the same portion; 
     FIG. 5 is a graph showing the relationship between a curve of radial movement of vane obtained by the first decreasing radius portion of the invention and a sine curve used for designing the cam profile of the same portion; 
     FIG. 6 is a graph showing the relationship between a curve of radial movement of vane obtained by the second decreasing radius portion of the camming peripheral surface of the invention and a sine curve used for designing the cam profile of the same portion; 
     FIG. 7 is a graph showing a torque curve plotted as if obtained by individual one of the vanes of a conventional double pumping chamber-type vane compressor; 
     FIG. 8 is a graph similar to FIG. 7, showing a torque curve obtained by a double pumping chamber-type vane compressor according to the present invention; 
     FIG. 9 is a graph showing a torque curve plotted as if obtained by all the four vanes of a conventional double pumping chamber-type vane compressor; 
     FIG. 10 is a graph similar to FIG. 9, showing a torque curve obtained by a double pumping chamber-type vane compressor according to the present invention; and 
     FIG. 11 is a schematic view showing a cam profile of the camming peripheral surface according to another embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION 
     Referring to FIGS. 1 and 2, there is illustrated a typical conventional vane compressor having two pumping chambers. A pump housing 2 is enclosed by an outer shell 2, which housing is formed by a cam ring 2a, a front side block 2b and a rear side block 2c. The cam ring 2a has its inner peripheral surface 2d acting as a camming surface. Rotatably fitted in the pump housing 2 is a cylindrical rotor 3 which has its peripheral surface formed therein with a plurality of axial slits 3a and carries a plurality of plate-like vanes 3b radially movably fitted in the respective slits 3a. The rotor 3 is securedly fitted on an inner end of a drive shaft 5 rotatably supportedly extending through a bearing portion 4 formed integrally on the front side block 2b. The drive shaft 5 has a radial flange 5a  formed integrally at its inner end and axially bearing against the inner end face of the bearing portion 4 by means of a thrust bearing 6, whereas the rotor 3 axially bears against the inner surface of the rear side block 2c by means of a thrust bearing 7. With this arrangement, as the drive shaft 5 rotates, the rotor 3 is rotated in unison with the drive shaft 5. Centrifugal force produced by the rotation of the rotor 3 and back pressure of lubricant oil acting upon the vanes 3b at the bottoms of the slits 3a cooperate to radially outwardly force the vanes 3b into sliding contact at their tips with the camming peripheral surface 2d. Thus, the vanes 3b are slidingly moved along the camming peripheral surface 2d in a clockwise circumferential direction as viewed in FIG. 2, in unison with the rotating rotor 3. Each time one of the vanes 3b passes by a pump inlet 8 formed in the inner peripheral surface of the cam ring 2a, compressing fluid is sucked into a pumping chamber 10 defined by adjacent vanes 3b, the camming peripheral surface 2d and the inner surfaces of the side blocks 2b, 2c, through a suction connector 9 provided on a front head 1a. Each pumping chamber 10 has its spatial volume varying from a minimum value to a maximum value during the suction stroke, and varying from a maximum value to a minimum value during the compression stroke. The fluid thus sucked into the chamber 10 and compressed therein is discharged through a pump outlet 11 and a discharge valve 12 forcedly opened by the compressed fluid. The above operating cycle is repeatedly carried out. The compressed fluid is discharged into a delivery pressure chamber 14 defined between the pump housing 12 and the outer shell 1, after having lubricant oil mixed therein separated therefrom by a lubricant oil separator 13, and then is delivered through a discharge connector 15 into an external circuit, not shown, after temporarily staying in the chamber 14. 
     In the vane compressor having the above-described arrangement and operation, the camming peripheral surface 2d of the cam ring 2a has an elliptical cam profile in the double pumping chamber type, and a circular cam profile in the single pumping chamber type. Since these cam profiles are not specially adapted for reducing the torque fluctuations, the compressor undergoes large torque fluctuations during each cycle of suction, compression and discharge of fluid, resulting in the occurrence of operating noise and vibrations of the compressor. 
     I have made many studies and tests in an attempt to obtain a cam profile for the camming peripheral surface, which can minimize the torque fluctuations in a vane compressor, and as a result I reached the finding that a cam profile satisfying the below-mentioned requirements can minimize the torque fluctuations: 
     (1) The compression stroke length should be as large as possible; 
     (2) The timing of an increase in the compressing pressure in an initial low torque region of each operating cycle should be advanced so as to obtain increased overlapped portions of the torque curves obtained by the individual vanes. Consequently, the torque fluctuations obtained by the individual vanes are averaged to provide a generally flattened torque curve; and 
     (3) The amount of protrusion of each vane from the rotor should be small enough to reduce the value of peak torque during the high pressure compression stroke. 
     Referring next to FIG. 3 through FIG. 10, there is illustrated one embodiment of the present invention applied to a double pumping chamber-type vane compressor. The vane compressor according to the present invention has an identical construction with that of the conventional vane compressor previously described and shown in FIGS. 1 and 2, except the cam profile of the camming peripheral surface. Therefore, description of the construction of the vane compressor of the invention is omitted here. According to the present invention, the camming peripheral surface has a whole cam profile as shown in FIG. 3. In FIG. 3, reference numeral 2d designates a camming peripheral surface formed along the inner peripheral surface of the cam ring 2a, 3 a half portion of the outer peripheral surface of the rotor having a radius Ro and circumferentially extending through an angle of 180 degrees. One operating cycle of suction, compression and discharge of fluid is effected as the vanes move along this half portion. The camming peripheral surface 2d circumferentially extending through 180 degrees comprises the below-mentioned curved surface elements. Two camming peripheral surfaces each shown in FIG. 3 are symmetrically arranged to form the whole camming peripheral surface along which two operating cycles are successively carried out with movement of the vanes. In the following description, symbol θ represents the angle assumed by the tip of each vane relative to an intersecting point of the line A with the camming peripheral surface with respect to the center O of the rotor, and R the distance between the center O of the rotor and the camming peripheral surface: 
     a. A first regularly circular portion AB along which sealing is effected between the rotor 3 and the cam ring 2a, and which satisfies the relationships of: 0°≦θ≦Φ6 and R=Ro; 
     b. An increasing radius portion BC along which the amount of protrusion of each vane from the rotor gradually increases with movement of the vane, and which satisfies the relationships of Φ6&lt;θ≦Φ1 and R increasing from Ro to Ro+h where h represents the amount of protrusion of the vane from the rotor at the terminating end of the portion BC; 
     c. A first constant radius portion CD along which the vane protruding amount is kept substantially constant with movement of the vane, and which satisfies the relationships of Φ1&lt;θ≦Φ2 and R=Ro+h; 
     d. A first decreasing radius portion DE along which the vane protruding amount gradually decreases with movement of the vane, and satisfies the relationships of Φ2&lt;θ≦Φ3 and R decreasing from Ro+h to Ro+m, where m represents the amount of protrusion of the vane from the rotor at the terminating end of the portion DE and is smaller than h; 
     e. A second constant radius portion EF along which the vane protruding amount is kept substantially constant with movement of the vane, and which satisfies the relationships of Φ3&lt;θ≦Φ4 and R=Ro+m; 
     f. A second decreasing radius portion along which the vane protruding amount gradually decreases with movement of the vane, and which satisifes the relationship of Φ4&lt;θ≦Φ5 and R decreasing from Ro+m to Ro; and 
     g. A second regularly circular portion GH along which sealing is effected between the rotor 3 and the cam ring 2a, and which satisfies the relationships of Φ5&lt;θ≦180° and R=Ro. 
     The above curved surface elements AB, BC, CD, DE, EF, FG and GH circumferentially extend, respectively, through the following angles θ 1 , θ 2 , θ 3 , θ 4 , θ 5 , θ 6  and θ 7  with respect to the center O of the rotor: 
     (i) First Regularly Circular Portion AB: 0°≦θ 1  ≦10° (=Φ6); 
     (ii) Increasing Radius Portion BC: 45°≦θ 2  &lt;90° (=Φ1-Φ6); 
     (iii) First Constant Radius Portion CD: 0°≦θ 3  ≦45° (=Φ2-Φ1); 
     (iv) First Decreasing Radius Portion DE: 30°&lt;θ 4  ≦90° (=Φ3-Φ2); 
     (v) Second Constant Radius Portion EF: 0°≦θ 5  ≦30° (=Φ4-Φ3); 
     (vi) Second Decreasing Radius Portion FG: 5°≦θ 6  ≦45° (=Φ5-Φ4); 
     (vii) Second Regularly Circular Portion GH: 0°≦θ 7  ≦10° (=180°-Φ5). 
     Of the above seven curved surface elements, the increasing radius portion BC and the first and second decreasing radius portions DE and FG are essential for achieving the object of the invention and are therefore indispensable. The increasing radius portion BC has its circumferential angle set at a value smaller than 90° as noted above, so as to achieve an advanced timing of the increase of the compression pressure (fluid pressure in the pumping chamber) in the initial low torque region of one operating cycle. On the other hand, the first and second decreasing radius portions DE and FG should have their combined proportion of the camming peripheral surface for one operating cycle (i.e. the sum of their circumferential lengths) set at a value as large as possible. According to the invention, the sum of the circumferential lengths of these portions DE and FG is set at a value larger than 50 percent but smaller than or equal to 75  percent (i.e. 90°&lt;θ 4  +θ 6  ≦135°) of the whole circumferential lengths of the one cycle performing portion. Further, the first and second decreasing radius portions DE and FG each have such a cam profile that the amount of protrusion of each vane from the rotor varies very gently as the vane moves from the starting end of the portion DE or FG to the terminating end, and that the rate at which the vane protruding amount varies gradually decreases toward the terminating end E or G of the portion DE or FG. Advantageously, the cam profiles of the portions DE and FG should be such that the distance between the camming peripheral surface and the center O of the rotor varies along a sine curve or a like curve from the starting end to the terminating end. Preferably, the increasing radius portion BC should also have a cam profile such that the above distance varies along a sine curve or a like curve. By providing the portions BC, DE and FG with such cam profiles, the vanes can slidingly move from one curved surface element to the next curved surface element with their amounts of protrusion varying in a streamline manner and by a slight value. Since the first and second decreasing radius portions DE and FG have the above-stated proportion and cam profile, the vanes have very low receding velocity or velocity of radially inward movement and also have their amounts of protrusion kept low enough to provide very low peak torque or sliding movement along these portions DE and FG during the compression stroke. Further, since the first and second decreasing radius portions DE and FG have a large combined proportion of the camming peripheral surface for one operating cycle as mentioned above, the torque curves obtained by the individual vanes have large overlapped portions to provide an even or flat synthetic torque curve, substantially reducing the total torque fluctuations. 
     The first and second constant radius portions CD and EF serve to keep the torque constant, contributing to further flattening of the total torque curve as compared with a total torque curve obtained by the first and second decreasing radius portions DE and FG alone. Even if the camming peripheral surface is provided with one or both of the first and second constant radius portions CD and EF, the combined proportion of the first and second decreasing radius portions DE and FG and one or both of the first and second constant radius portions CD and EF should preferably be set at a value falling in a range similar to the aforementioned one applied to the camming peripheral surface devoid of such constant radius portions, that is, a value larger than 50 percent but smaller than or equal to 75 percent. 
     The ratio of the vane protruding amount h at the terminating end of the increasing radius portion BC to the radius Ro of the rotor is preferably 0.1-0.5 to 1. The ratio of the vane protruding amount m at the terminating end of the first decreasing radius portion DE to the value h is preferably 0.3-0.7 to 1. By setting the proportions of the values h and m as above, the camming peripheral surface can have a generally gentle and streamline cam profile, effectively reducing the operating noise and vibration of the compressor. 
     I have theoretically reached the finding that if the cam profiles of the increasing radius portion BC, the first decreasing radius portion DE and the second decreasing radius portion FG are each designed by means of trigonometric function, the overall cam profile of the camming peripheral surface can be such that the rate of change of the velocity of radial movement of the vanes is small. 
     Next, description will be made of the manner of calculating the cam profiles of the increasing radius portion BC, the first decreasing radius portion DE and the second decreasing radius portion FG, which vary along sine curves: 
     (a) Increasing Radius Portion BC: Let is be assumed that as shown in FIG. 4, the vane protruding amount increases from 0 to h as θ varies from Φ6 to Φ1 in FIG. 3, and during this increasing stroke, the vane protruding velocity varies at a rate corresponding to a sine curve sin α whose α varies from 0° to 180°. Provided that the vane protruding amount is defined as y, ##EQU1## (b) First Decreasing Radius Portion DE: Assuming that as shown in FIG. 5, the vane protruding amount decreases from h to h-m as θ varies from Φ2 to Φ3 in FIG. 3, and the sine curve sin α has its α value varying from 0° to 180°: ##EQU2## (c) Second Decreasing Radius Portion FG: Assuming that as shown in FIG. 6, the vane protruding amount decreases from m to 0 as θ varies from Φ4 to Φ5 in FIG. 3, and the sine curve sin α has its α value varying from 0° to 180°: ##EQU3## 
     Calculations were carried out to determine actual size values of the curved surface elements for a double pumping chamber-type vane compressor, by applying the following preferred parameter values to the equations determined above: 
     
         Φ1=60° Φ2=75° Φ3=120° Φ4=135° 
    
     
         Φ5=Φ6=0 Ro=36 mm h=8 mm m=2.5 mm 
    
     The size values of the curved surface elements determined are as follows: 
     Increasing Radius Portion BC: θ=0°-60°, R=40-4 cos 3θ (mm); 
     First Constant Radius Portion CD: θ=60°-75°, R=44 (mm); 
     First Decreasing Radius Portion DE: θ=75°-120°, R=41.25+2.75 cos (4θ-300) (mm); 
     Second Constant Radius Portion EF: θ=120°-135°, R=38.5 (mm); and 
     Second Decreasing Radius Portion FG: θ=135°-180°, R=37.25+1.25 cos (4θ-540) (mm) 
     In the camming peripheral surface according to the above example, the first and second regularly circular portions AB and GH are omitted. 
     FIGS. 7 through 10 show in a comparative manner torque curves obtained by a conventional double pumping chamber-type vane compressor and by a double pumping chamber-type vane compressor according to the present invention, to which the aforementioned calculated size values are applied. According to the present invention, as shown in FIGS. 8 and 10, the peak torque value is lower by about 40 percent than that obtained by the conventional compressor shown in FIGS. 7 and 9. Further, the torque curve according to the present invention is generally flat as compared with the conventional one, leading to effective reduction in the operating noise and vibration of the compressor. 
     Although the foregoing description is directed to the camming peripheral surface of a double pumping chamber-type vane compressor, the present invention can of course be applied to a single pumping chamber-type vane compressor as well. In the case of a single pumping chamber-type compressor, one operating cycle of suction, compression and discharge of fluid is carried out through 360 degrees, i.e. over the whole circumference. Although in the single pumping chamber-type compressor the aforementioned curved surface elements are formed continuously along the whole periphery extending through 360 degrees, the first regularly circular portion is located at a location immediately following the second decreasing radius portion with the second regularly circular portion omitted, as distinct from the double pumping chamber-type vane compressor. 
     FIG. 11 shows an exemplary cam profile of a single pumping chamber-type vane compressor according to the present invention. In the figure, the reference numerals and the symbols identical with those in FIG. 3 designate corresponding elements and values. The camming peripheral surface shown in FIG. 11 comprises the following curved surface elements: 
     a. A regularly circular portion AB satisfying the relationships of 0°≦θ≦Φ6 and R=Ro; 
     b. An increasing radius portion BC satisfying the relationships of Φ6&lt;θ≦Φ1 and R increasing from Ro to Ro+h; 
     c. A first constant radius portion CD satisfying the relationships of Φ1&lt;θ≦Φ2 and R=Ro+h; 
     d. A first decreasing radius portion DE satisfying the relationships of Φ2&lt;θ≦Φ3 and R decreasing from Ro+h to Ro+m; 
     e. A second constant radius portion EF satisfying the relationships of Φ3&lt;θ≦Φ4 and R=R+m; and 
     f. A second decreasing radius portion FA satisfying the relationships of Φ4&lt;θ≦Φ5 and R decreasing from Ro+m to Ro. 
     The above curved surface elements AB, BC, CD, DE, EF and FA circumferentially extend, respectively, through the following angles θ 1 , θ 2 , θ 3 , θ 4 , θ 5  and θ 6  with respect to the center O of the rotor: 
     (i) First Regularly Circular Portion AB: 0°≦θ 1  ≦20° (=Φ6); 
     (ii) Increasing Radius Portion BC: 90°≦θ 2  &lt;180° (=Φ1-Φ6); 
     (iii) First Constant Radius Portion CD: 0°≦θ 3  ≦90° (=Φ2-Φ1); 
     (iv) First Decreasing Radius Portion DE: 60°≦θ 4  ≦180° (=Φ3-Φ2); 
     (v) Second Constant Radius Portion EF: 0°≦θ 5  ≦60° (=Φ4-Φ3); 
     (vi) Second Decreasing Radius Portion FA: 10°≦θ 6  ≦90° (=Φ5-Φ4) 
     Of the above six curved surface elements, the increasing radius portion BC, the first decreasing radius portion DE and the second decreasing radius portion FA are essential for achieving the object of the present invention and are therefore indispensable for the same reasons as previously described with reference to the double pumping chamber-type vane compressor. The cam profiles, proportions and functions of these essential portions BC, DE and FA as well as the manner of calculating the cam profiles are substantially identical with those previously described with reference to the double pumping chamber-type vane compressor, description of which is therefore omitted. Also, the functions of the regularly circulation portion AB and the first and second constant radius portions CD and EF are substantially identical with those of the double pumping chamber-type vane compressor, and therefore their description is also omitted.