Case Studies

Compressor Pump Bearing Flange

Client: Air Conditioner Manufacturer

Background:
The development of the technology used in room air conditioner compressors (hermetically sealed rotary compressors) dates back to the 1950's. Design modifications have been incorporated since that time but the basic concept has remained unchanged. The heart of the compressor is the pump assembly which contains two bearing flanges. The efficiency of the end product, the air conditioner, is largely dependant on the accuracy of the pump components. To achieve the desired efficiency, the tolerances of the pump components are very critical.

 Manufacturing Challenge:
Not only did the design of the compressor date back to the 1950's but the manufacturing technology relating to its components were of a similar vintage. The tolerances required though, are very demanding. The tolerance on the flange bore is .0002 inches (5 microns), the perpendicularity requirement between the bore and the flange face is also .0002 inches (5 microns), and the flatness requirement of the flange face is .000040 inches (40 millionths of an inch or 1 micron). While these requirements are severe, the problem is amplified when the required quantities are brought into the picture; 7,000 - 10,000 parts per day!

Solution:
To cost effectively achieve the desired result, Everite redesigned and modernized the manufacturing process. The labor required to produce the product was reduced from 45 people per shift to only six, making the domestic production of these components competitive with anyone in the world. This was accomplished by replacing manpower with technology while at the same time reducing cost and improving component quality.
 

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