Abstract: Addresses the technical bottlenecks in the traditional hot sleeve assembly process for air conditioner compressor rotors, such as uneven heating temperatures, excessive energy consumption, and the risk of workpiece thermal deformation. It innovatively proposes a cold sleeve assembly process. Through a combination of theoretical analysis and experimental verification, the research found that under existing dimensional tolerances, a press-fit force of 17.1 kN would cause the radial deformation of the crankshaft secondary shaft to exceed the design allowable limit (radial deformation≤2 μm). After optimizing process parameters and employing a lubricant surface treatment technology, the mean press-fit force was successfully reduced by 3.41 kN while maintaining the force stability to meet the requirement of ≥3 MPa. Comparative test data demonstrated that implementing the cold sleeve process increased the compressor COP value by 0.4% and significantly improved the process capability index (Cpk) for assembly height dimensions from 1.09 to 2.92. The results confirm that the cold sleeve assembly process offers significant technical advantages in assembly accuracy control, energy savings, and product reliability enhancement, providing an innovative solution for the efficient and precision manufacturing of compressors.

Key words: Cold assembly process, Air conditioning compressor, Pressing force optimization, Energy efficiency improvement