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Higher Technological Institute

Mechatronics Engineering Department

Compressor Manufacturing

Prepared by:
Omar Mohamed Ezzat

ID: 20190476
Contents
2.1 Crank Case production line: ................................................................................................................... 4
2.1.1 The machining steps done on crank case: ....................................................................................... 5
2.2 Crank Shaft Production Line :( MB) ...................................................................................................... 10
2.2.1The machining steps done on Crank Shaft: ............................................................................................ 10
2.3 Piston Production Line (MC):................................................................................................................ 14
2.3.1 The machining steps done on piston: ........................................................................................... 14
2.4 Connecting rod: .................................................................................................................................... 16
2.4.1 The machining steps done on Connecting rod: ............................................................................. 16
2.5 Valve plate: ........................................................................................................................................... 17
2.5.1 The machining steps done on Valve plate:.................................................................................... 17
2.6 Upper bearing:...................................................................................................................................... 18
2.6.1 The machining steps done on Valve plate:.................................................................................... 18
Definition: ....................................................................................................................................................... 21
3.1 Stator: ................................................................................................................................................... 21
3.1.1 Definition: ...................................................................................................................................... 21
3.2 Rotor: .................................................................................................................................................... 14
3.2.1 Definition: ...................................................................................................................................... 14
3.2.2 Production Stages of a Rotor:........................................................................................................ 14
Compressor Assembly Steps: ......................................................................................................................... 20
Introduction
MCMC (Misr Compressors Manufacturing Company) or ZMC
(Zanussi

Manufacturing Compressors)
Misr Compressor Manufacturing Company for cooling
compressors is a joint stock company established in 1988 under
the law no. 203 for the year 1998 & the law no. 8 for the year
1997 with an authorized and paid in capital of around
LE210MM. Its main clients include such brands as Ideal,
Kiriazi,

Goldi & Olympic. MCMC hold 55% local market share and 40% of
its production exported
ZMC is a market leader in the Middle East in producing
hermetic compressors for Household and commercial
refrigerators. They offer a wide
range of products, so each customer can find the optimum solution to
meet.

MCMC is able to produce environment friendly compressors, using

non CFC coolants which are not harmful to the earth Ozone layer and
do not contribute
to the atmosphere “greenhouse effect”.

The Factory is equipped with the most modern production

machinery of the kind, and with high degree of automation, is
able to produce 2,000,000 compressors per year. This is the first
industry in this field not only in Egypt
but also in the Arab world and Africa.

So we’re aiming to view how this compressor is made; its

electrical and mechanical parts, then the assembly of these parts and
how to guarantee the quality. The machines used to establish these
parts and its service. We’re also providing the safety precaution
that must be taken and the production management used.
 CHAPTER ONE
MECHANICAL PARTS WORKSHOP
Introduction: is the chabter contains all the mechanical parts of the
compressor are
manufactured and it consists of 4 sections:

1- Crankcase line.(MA)

2- Crankshaft line.(MB)

3- Connecting rod (MC)

4- Piston line. (ME)

5- Valve plate (MD)

6- Upper bearing line.( MF)

2.1 Crank Case production line:

*Crank case is very important mechanical part in compressor that carries

all the other parts of the compressor.
*Crank case produced in a German production line called (MA)
*Crank Case part comes to the factory in the form of casting element as
shown in Fig. 2.1 then it will be machined.
 04

Fig 2.1(Casting Crank Case The primary form)

2.1.1 The machining steps done on crank case:

In the first machine 'MA01'

1- Milling of the five crank case and
internal

2- Turning for the crank shaft hole.

3- Outside turning for
the crank shaft hole
4- Semi finishing work.

Fig: 2-2 ( MA 01)

 05
Second machine 'MA02'
1- make drilling for the cylinder hole
2- drilling the ejection hole.

3- milling the cylinder head.

Fig: 2-3 (MA 02)

Third Machine 'MA03'

1- Makes the Upper Bearing hole.
2- Milling of the bigger Discharge chamber
3- Makes hole of the bigger Discharge chamber
4- Milling of the bigger suction chamber as shown in.

Fig: 2-4 (MA 03)

 06
Four machine 'MA04'
1- make two holes by drilling in side of crank case
2- small groove to oil flow

Fig: 2-5 (MA 04)

Five machine 'MA05'

1- make milling the cylinder head
2-the cylinder hole and

3- make the chamfer.

Fig: 2-6( MA 05)

 07
Six machine 'MA06'
1- cleaning the suction muffler

Fig: 2-7 (MA06)

Seven and eight machine 'MA07-08'

1-Make cleaning
2- Burnishing to hub by roller burnish 3-
Put category marking on crankshaft
hole.

Fig: 2-8 (MA07-MA08)

 08
Nine machine 'MA09'
1- Makes lapping for the cylinder hole

Fig: 2-9 (MA 09)

 01
2.2 Crank Shaft Production Line :( MB)
▪
Crank Shaft is the part that transports the rotating motion from
the stator to the piston that is connected with a connecting rod and
turns the rotation motion to a reciprocating motion by the cam.
▪
This part comes to the factory in the form of casted shaft as shown in Fig.
2.10.

Fig.
2.10

2.2.1The machining steps done on Crank Shaft:

One machine MB01 makes turning for the

short tail and fly wheel.

Fig: 2-11 (MB 01)

 11
Second machine MB02.
1-Makes a center for the tail and turning for the outside diameter.
2-Makes a hole to the half of the long tail and undercut turning Completes
the hole of the long tail and makes chamfer.

Fig: 2-12 (MB02)

Third machine MB021 1-makes turning work

on came and its chamfer

Fig: 2-13 (MB021)

 10
Four machine MB03
1-Makes 2 holes in the short tail, 1 hole in long tail with a helix, a hole in
the came and chamfering.

Fig: 2-14 (MB03)

Five machine (MB04)

1 - Grinding on long and short tail (semi finish).

Fig: 2-15 (MB04)

11
Six machine(MB05)
1 - Grinding just on the shoulder (finish).

Fig: 2- 16( MB05)

Seven machine (MB06)

1 - Grinding just on came (finish) .

Fig: 2- 16 (MB06)

Eight machine (MB07)

1- Grinding on long and short tail (finish).

Fig: 2-17(MB07)
2.3 Piston Production Line (MC):
▪
Piston is the part that compress the refrigerant in the piston cylinder. Piston
comes to the factory as casted element of center steell

2.3.1 The machining steps done on piston:

One Machine (MC01):
1 - Makes outside chamfer and undercut (oil run) as shown

Fig: 2- 18(MC01)

Secand machine (MC03):

1- Make hole (roll pen) and another hole (piston pen) and that is for oil
running.

Fig: 2-19(MC03)

14
Third machine(MC04/1-MC04/2)
1- Beveling.
2- Grinding by diamond in the hole of the body from inside.

Fig: 2-19(MC04/1-MC04/2)

Four machine ( MC 05)

1- Final grinding.

15
 Fig: 2-20(MC05)

2.4 Connecting rod:

Connecting rod is part that connect the crank shaft and the piston
2.4.1 The machining steps done on Connecting rod:
One machine (MD01)
1-Make primary turning in big/small eyes and drilling hole connect it each
other.

Fig: 2-21(MD01)

. \

16
 2.5 Valve plate:
2.5.1 The machining steps done on Valve plate:
1- Primary Grinding on the two surface of the plate.

2- Final grinding.
3-make all holes on the surface of the valve as shown.

Fig: 2-23(ME01/ME02/ME03)

17
 2.6 Upper bearing:
2.6.1 The machining steps done on Valve plate:
One machine (MF01)
1- Primary Grinding on the two surface of the plate.

2- Holes in the edges.

Fig: 2-24(MF01)

Second machine (MF02)

3- Final grinding on surface.

Fig: 2-25(MF02)

18
Third machine(MF03)
1 - Grinding by diamond for the big hole from inside.

19
 Fig: 2-26(MF03)

After every process the quality departments make check on the parts that
manufacturing by gages and other instruments to make sure that the
product have the required quality.
Each part goes through a service treatment to get rid of oils water and any
chips, also to avoid being corroded.
 CHAPTER TWO
ELECTRICAL PARTS WORKSHOP
Definition:
It is the workshop where all the electrical parts of the compressor are
manufactured and contains :

1- Stator.
2- 2-Rotor.

3.1 Stator:
3.1.1 Definition:
The stator is the stationary part of electric system found in an electric generator
or electric motor.

the stator may act as the field magnet, interacting with the armature to create
motion, or it may act as the armature, receiving its influence from moving field

coils on the rotor.

The stator may be either a permanent magnet or an electromagnet. Where the

stator is an electromagnet in compressor.

The coil can be either copper or aluminum. To reduce load losses in motors,
manufacturers invariably use copper as the conducting material in windings.
Aluminum, because of its lower electrical conductivity, may be an alternate
material in fractional horsepower motors, especially when the motors are
used for
very short durations.

Fig: 3-1

3.1.2 Production stages of a stator:

1- The martial of stator is made from magnetic iron sheets
2- These sheets pass through a Die forming machine to create Die and Punch to
create the stator plates.

3- Treatment of stator in the furnaces by:

i. burn (to remove water and cooling oil drops from the surface )
ii. Surface heat treatment (to reduce the percentage of carbon in the material to
increase its hardness). iii. Coating by isolated material (to prevent corrosion and
isolating layers of stator). iv. Rapid quenching by using air quenching.

4- The stator plates passes through a machine to compress it and have the need
high
5- The stator plates go through the roller machine to be packed and get its height
checked.

6- Polyester cover is placed on 24 layers between cable and stator holes for
insulation of the primary winding from the stator internal surface by using
special machines.

These 24 layers are divided into 20 of a curve shape for the primary winding
and the other 4 layers are for the secondary winding.

Fig: 3-2
7- Primary winding are inserted and winded in those 20 layers in which the
machine insert and winds the wires in the first 10 layers leaving the next two
layers 8- The secondary winding then insert and winds the next 10 layers and
leaving the last 2 layers.

8- The 4 layers which are left in the previous step are now used to insert and
wind the secondary windings.

Between the two winding there is another polyester cover placed.

* The winding takes place by winding the first pole and then the second one as
the
magnetic field direction depends on the direction of this winding
9 - For the rotor to work, we take the end of the primary winding, the end of the
secondary winding and a common end for the circuit to be closed.

10 -These ends are covered with small pipes and then heated to 60 C.

11
11 - Manual insulation is done to expand the space between the primary and
secondary winding and insulate them.

12 - Crimping test is made to ensure that there’s no cut in the primary or

secondary winding and that the resistance is not high.

13 -The semi finishing operation is that these winding are threaded in order to
be protected from the rotor (inside) and from the crankcase (outside).

14 -the finishing operation is ensuring the radius of the stator.

 3.2 Rotor:
3.2.1 Definition:
The rotor is the non-stationary part of a rotary electric motor or electric
generator which rotates because the wires and magnetic field of the motor are
arranged so that a torque is developed about the rotor's axis. In some designs,
the rotor can act to serve as the motor's armature, across which the input voltage
is supplied. As shown Figure
Rotor losses, an important form of power losses in induction motors, are largely
but not entirely proportional to the square of the slip (slip is the difference
between the rotational speed of the magnetic field and the actual rpm of the
rotor at a given load). Thus, rotor losses are reduced by decreasing the degree of
slip for a given load. This is accomplished by increasing the mass of the rotor
conductors (conductor bars and end-plates) and/or increasing their conductivity
The electrical efficiency of motors can be improved by replacing the standard
aluminum electrical conductor in the motor rotor with copper, which has a much
higher electrical conductivity.

Fig: 3-3

3.2.2 Production Stages of a Rotor:

 1- The rotor is made from magnetic iron sheets which may be imported
2- These sheets pass through a Die forming machine to create Die and Punch.
* The clearance angle between the die and punch depends on the thickness of
the rotor slice (5 mm.).

* These sheets are clamped with a pilot to avoid its movement (Increasing its
quality).

Fig: 3-4

3- Packing of rotor plates and its cold pressing using the cooling oil to
avoid the temp of the friction which may affect the rotor causing it to form
chips. * The forming of rotor as pressed plates to reduce the eddy current as
the current path is divided (eddy current is directly proportional to the square
of the current) and for the easiness of it’s forming.

4- Treatment of rotor in the furnaces:

i. Burn (to remove water and cooling oil drops from the surface).

ii. Surface heat treatment (to reduce the percentage of carbon in the material to
increase its hardness).

iii. coating by isolated material (to prevent corrosion and isolating layers of rotor
at). iv. rapid quenching by using air quenching.
 5- Injecting the rotor bars with molten (Al). through the injection machine (to

increase the electrical field).

This molten (Al). are made in two furnaces which are:

These rotor bars are inclined with an angle which is inversely proportional

with the height of the rotor but directly proportional with the efficiency of the

rotor.

Fig: 3-5

6- Rotor passes through many operation of semi finishing such (surface finish,

grinding, washing and polishing).

Date and model are pressed on the rotor(for further troubleshooting)

as following:

A. Pressing Al. overbid.

B. Checking height.
C. Pressing date and model.

7- Finally Rotor passes through a washing oil machine to get rid of these oils

before going through a furnace to avoid being burnt on the rotor, This

furnace gives an isolating layer for the rotor

8- Finishing operations on the rotor take place such as (Brushing, rolling and

testing rotor).
 CHAPTER THREE
ASSEMBLY DEPARTMENT:
▪
This is the department that assembles all the compressor parts Together
to make The Hermetic Compressor of ZMC.
Colombo housing:
This machine used to produce the body of the compressor (shell, cover).

- This table shows the steps of producing the cover of the compressor in Colombo
machine.

station Cutting tool Operation

1 Ring. Punch. Primary drawing.

2 Punch. Ri Factor for Secondary drawing.

ng. withdrawal.

3 Punch. Ring. Deep drawing (top finish).

4 Ring. Scrap trimmers. Edge trimming & cleaning.

5 Flanging Punch. Bending the edges.

plate.

6 Flanging Punch. Set the flatness of the

plate. edges(lower finish).

7 Flanging Punch. Drill holes (dia.12 three holes).

plate.
(Dia.22 one hole).
FIG (5-1): draw show the stepsof producing shell & cover of
compressor.
 11

Compressor Assembly Steps:

1. We classify the valve plate with crank case, due to the difference in models.

Figure 5.1(Micro Control Device)

1. The technical assembles the piston with the connecting rod

by the piston pin.
2. Assembling the shaft with the crank case according to the
class.
3. The technical puts the piston and connecting rod with the
shaft and crank case then fixing the shaft to the crank case
by the upper bearing as shown in Fig. 5.2

Fig. 5.2
 41
Fixing shaft by upper bearing
4. Fixing the upper bearing screws.
5. justice Machine measures the valve surface clearance of
crank case to avoid any Infusion As shown in Fig. 5.3

.
Figure 5.3
Jastic Test

6. By measuring surface clearance the technical chooses the

suitable gasket.
7. Connecting valve unit as shown in Fig. 5.4
 40

.
Fig.5.4
8. Air compressor machine tests air infusion.
9. Mechanical parts rotating test that tests the performance of
the mechanical parts.
10. Connecting the stator with the rotor as shown in Fig. 5.5.

Fig. 5.5

Fixing stator to crank case

 41
11. Fixing the stator screws.
12. Rotor hole oven that expands the rotor hole for fixing the
shaft as shown in Fig. 5.6

Fig. 5.6
Rotor Hole oven
13. Fixing the oil pipe as shown in Fig. 5.7
 Fig. 5.7

14. The technical measures the clearance between the rotor and
the stator by using the filler.
15. Connecting the power cable with the three teeth on the shell.
16. Fixing the three zips in the crank case.
17. Fixing the crank case to the shell by the zips as shown in
Fig. 5.8.

Fig. 5.8
18. Fixing the internal discharge tube by wilding as shown in
Fig. 5.10

44
 Figure 5.9

The Discharge Tube

19. Testing the compressor on 15 bar.

20. The technical measures the height of the crank case and
testing it by an electrical shell cover.
21. The shell goes to an oven for one and half hour (150 0C) to
be sure of the compressor performance as shown in Fig. 5.11

45
 Figure 5.10

Shell Drying Oven

22. Welding of the shell cover one both.

23. Full welding of the shell cover by Argon and CO2 welding.
24. Testing the compressor on 18 bar.
25. Painting the compressor in a tank full of black ink as
shown in Fig. 5.12

Figure 5.11

26. Drying the paint by an oven.

▪
After assembling the compressor parts it goes to the final test
department that applies many electrical and mechanical tests on
the compressors then it is labeled and goes to be stored before
charging as shown in Fig.5.13.

46
 Figure 5.12
Labeled and Stored Compressor

47