A meshing points capture-based approach for geometric modeling and parametric analysis of variable base-circle scroll compressors

Scroll compressors serve as critical components of heat pump systems, yet calculating working chamber volumes in designs with variable base-circle radius remains computationally challenging. This study presents a novel volume calculation method based on meshing points calculation, and the effects of three key geometric parameters radius correction increment, initial wall thickness, and modified spreading angle on the internal volume ratio of the scroll compressor were investigated. Additionally, the envelope principle of the scroll profile was applied to analyze how initial wall thickness, base-circle radius, and modified spreading angle influence the feasible domain of theoretical maximum discharge port. The results reveal that the proposed approach was validated through programmatic implementation and comparison with three-dimensional models, achieving accuracy within 0.05 %. Comparative analysis shows that this method has higher accuracy compared with traditional volume calculation methods. Reducing the radius correction increment decreases from 0 to -0.05, increases suction chamber volume by 11.4 %. While maintaining constant scroll disk diameter, increasing the modified spreading angle from 100° to 180° results in a 20.9 % increase in compression chamber volume. However, increasing the wall thickness from 4.0 mm to 6.1 mm by 0.3 mm will result in a decrease in compressor volume. In addition, the theoretical extended arc–straight added line maximum discharge port has a better display area than other discharge port, and the maximum exhaust hole area increases with increasing wall thickness and base-circle radius. The findings provide a theoretical foundation for the integrated design of scroll profiles and discharge ports in high-performance scroll compressors.