Reliability design of a reciprocating compressor suction reed valve in a common refrigerator subjected to repetitive pressure loads

The compressor in a commercial refrigerator was redesigned to improve its reliability. The compressor used in the refrigerator had been failing due to fracturing of the suction reed valve. Failure analysis, accelerated life tests and corrective action plans were used to identify the key control parameters and levels for the mechanical compressor system. The failure modes and mechanisms found experimentally were similar to those of the failed sample in the field. The missing controllable design parameters of the compressor system in the design phase were an overlap with the valve plate, a weak material [SANDVIK 20C 178t], and the sharp edge of the valve plate. After a tailored series of accelerated life tests with corrective action plans, the reliability of the new compressor system is now guaranteed to be 12.6 years with a yearly failure rate of 0.06%.