R290 electric compressor for vehicle

Abstract

The utility model discloses a vehicle R290 electric compressor which comprises a cylinder body and a driving motor located in the cylinder body, the driving motor comprises a stator and a rotatable rotor which are fixedly connected to the inner wall of the cylinder body, the stator is arranged in an air inlet cavity, and a winding and an iron core gap of the stator are integrally wrapped by solidified potting glue; one end of the rotor is fixedly connected with the static disc, and the static disc and the movable disc are meshed with each other to form a compression cavity; the static disc is connected with the rear cover through bolts, a sealing structure is arranged between the static disc and the cylinder body, and the rear cover is detachably connected with the cylinder body. A front cover is arranged on the side, facing the driving motor, of the movable disc, the front cover is fixedly connected with the cylinder body, and the problems of potential safety hazards, sealing failure and structural fatigue caused by R290 flammability and high pressure are systematically solved through the three core designs of electrical all-insulation potting, two-stage composite sealing and an equal-wall-thickness vortex line structure. And the strict requirements of the new energy automobile on safety, reliability and high efficiency are met.

Description

Technical Field

[0001] This utility model relates to the field of thermal management technology for new energy vehicles, specifically to an R290 electric compressor for vehicles. Background Technology

[0002] The electric compressor in a vehicle is a core component of the thermal management system of a new energy vehicle. Its performance directly affects the energy efficiency and safety of the entire vehicle. With increasingly stringent environmental regulations (such as the EU F-Gas regulation which restricts high GWP refrigerants), the natural working fluid R290 (propane) has become an ideal alternative refrigerant due to its zero ODP, extremely low GWP (GWP=3) and excellent thermodynamic properties.

[0003] Currently, the flammability of R290 (propane) (a Class A3 refrigerant) and its high operating pressure pose a dual challenge to the safety and reliability of automotive compressors; electrical safety hazards: the stator windings of traditional electric compressors are exposed to refrigerant, and R290 may ignite and explode due to leakage sparks from the motor (experiments show that a leakage of 1mA can ignite the R290-air mixture).

[0004] Risk of seal failure: R290 has a small molecular weight and high permeability, and existing single-stage seals have excessive leakage rates under high-pressure conditions;

[0005] Insufficient structural strength: The R290 system has a high compression ratio of 8:1, and traditional non-uniform wall thickness spiral lines are prone to stress concentration, leading to fatigue cracks;

[0006] Therefore, the R290 electric compressor for vehicles was proposed to address the problems mentioned above. Utility Model Content

[0007] The purpose of this invention is to provide an R290 electric compressor for vehicles, in order to solve the three technical challenges posed by R290 (propane) as an A3-class flammable refrigerant, as mentioned in the background art. These challenges include high flammability, strong permeability of small molecules, and high working pressure, which pose a triple technical challenge to vehicle compressors: electrical safety (risk of ignition by leakage sparks), sealing reliability (excessive leakage rate of single-stage seals), and structural strength (stress concentration in the vortex line due to high compression ratio).

[0008] To achieve the above objectives, this utility model provides the following technical solution: an automotive R-type electric compressor, comprising a cylinder and a drive motor located within the cylinder.

[0009] The drive motor includes a stator fixedly connected to the inner wall of the cylinder and a rotatable rotor. The stator is disposed in the air intake chamber, and its windings and core gaps are entirely covered by a cured potting compound.

[0010] One end of the rotor is fixedly connected to the stationary disk, and the stationary disk and the moving disk mesh with each other to form a compression chamber;

[0011] The stationary disc is connected to the rear cover by bolts, and a sealing structure is provided between the stationary disc and the cylinder body. The rear cover and the cylinder body are detachably connected.

[0012] The moving disc has a front cover on the side facing the drive motor. The front cover is fixedly connected to the cylinder body. The drive shaft connected to the stator passes through the front cover and is connected to the moving disc for transmission.

[0013] Preferably, the sealing structure is a multi-stage sealing structure, which consists of at least two sealing grooves. The sealing grooves are located on the inner wall of the cylinder or the outer wall of the stationary disc, and each sealing groove is provided with an O-ring.

[0014] Preferably, the vortex lines of the stationary disk and the moving disk are spiral structures with equal pitch and equal wall thickness.

[0015] Preferably, the end of the cylinder block away from the rear cover is fixedly connected to the controller by bolts, and the controller is electrically connected to the drive motor.

[0016] Preferably, the drive motor shaft extends axially and passes through the bearing support between the cylinder block and the front cover.

[0017] Compared with existing technologies, the beneficial effects of this utility model are as follows: This automotive R290 electric compressor, through three core designs—electrically fully insulated potting, dual-stage composite sealing, and equal-wall-thickness scroll structure—systematically solves the safety hazards, sealing failures, and structural fatigue problems caused by the flammability and high pressure of R290, thus meeting the stringent requirements of new energy vehicles for safety, reliability, and high efficiency. The specific details are as follows:

[0018] 1. Comprehensive improvement in motor safety

[0019] The curing potting compound completely covers the gap between the stator winding and the iron core, forming a physical isolation layer that blocks the contact between R290 and the winding, prevents the enameled wire from being damaged by the impact of the refrigerant, avoids leakage and sparks, and thus prevents the R290 refrigerant from being ignited in extreme cases, reducing the risk of compressor use.

[0020] 2. Breakthrough in sealing reliability

[0021] The combination of two sealing grooves and O-rings forms a multi-level sealing barrier, which significantly improves sealing reliability and effectively prevents media leakage. The synergistic effect of multiple O-rings can compensate for the wear of a single seal, reduce the risk of overall sealing performance degradation due to local failure, and extend service life.

[0022] 3. Optimization of vortex-shaped pressure resistance and energy efficiency

[0023] The scroll lines of the stationary and moving discs adopt a design with equal pitch and wall thickness, which effectively improves the pressure resistance of the stationary and moving discs. The meshing process of the stationary and moving discs is more stable, reducing airflow pulsation and vibration noise. The cylinder block is fixed with bolt groups and positioning pins to ensure that the components are subjected to uniform force under high pressure conditions, avoiding deformation or cracking caused by stress concentration. Attached Figure Description

[0024] Figure 1 This is a schematic cross-sectional view of the overall structure of this utility model;

[0025] Figure 2 This is a partially enlarged structural diagram of the static disc sealing groove of this utility model;

[0026] Figure 3 This is a schematic cross-sectional view of the stator structure of this utility model;

[0027] In the diagram: 1. Cylinder block; 2. Front cover; 3. Stationary disc; 4. Compression chamber; 5. Stator; 6. Rotor; 7. Filler; 8. Intake chamber; 9. Rear cover; 10. Sealing structure; 11. Sealing groove; 12. Controller. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0029] Please see Figure 1-3 The present invention provides a technical solution: an R290 electric compressor for vehicles, including a cylinder 1 and a drive motor located inside the cylinder 1. The drive motor includes a stator 5 fixedly connected to the inner wall of the cylinder 1 and a rotatable rotor 6. The stator 5 is disposed in the air intake chamber 8, and its windings and core gaps are entirely covered by a cured potting compound 7.

[0030] By placing the stator 5 in the air intake cavity 8 and using a curing potting compound 7 to completely cover the winding and core gap, three technical advantages are achieved:

[0031] Enhanced electrical safety: The potting compound 7 completely isolates the stator winding from the R290 refrigerant, effectively blocking the discharge path even in the event of a 1mA leakage, thus fundamentally eliminating the risk of the R290-air mixture being ignited by an electric spark.

[0032] Optimized heat dissipation efficiency: The low-temperature refrigerant flowing in the air intake chamber 8 directly flushes the stator 5 after potting. Compared with the traditional closed motor structure, the winding temperature rise is reduced, avoiding insulation aging caused by high temperature.

[0033] Improved structural reliability: The cured potting compound 7 forms a rigid support, which can suppress the vibration of the windings when the motor is running, and at the same time compensate for the micro deformation of the cylinder 1 under the R290 high pressure condition, ensuring the stability of the air gap between the stator and rotor.

[0034] One end of the rotor 6 is fixedly connected to the stationary disc 3. The stationary disc 3 and the moving disc mesh with each other to form a compression chamber 4. The stationary disc 3 is connected to the rear cover 9 by bolts, and a sealing structure 10 is provided between the stationary disc 3 and the cylinder body 1. The rear cover 9 and the cylinder body 1 are detachably connected.

[0035] The direct connection between the rotor and the stationary disc eliminates transmission chain errors, and the stationary disc, as an integrated load-bearing frame, improves the axial stiffness of the system. The detachable design of the rear cover 9 can improve maintenance efficiency, avoid the cost waste caused by traditional whole scrapping, and reduce maintenance costs.

[0036] A front cover 2 is provided on the side of the moving plate facing the drive motor. The front cover 2 is fixedly connected to the cylinder body 1. The drive shaft connected to the stator 5 passes through the front cover 2 and is connected to the moving plate for transmission.

[0037] By fixing the front cover 2 to the cylinder body 1 and using it as a through support structure for the drive shaft, the transmission stability between the moving disc and the drive motor is ensured. The front cover 2 also enables the compact integration of the motor assembly and the cylinder body 1, while serving as a sealing and axial positioning function, thereby improving the rigidity and assembly accuracy of the overall structure.

[0038] The sealing structure 10 is a multi-stage sealing structure, consisting of at least two sealing grooves 11. The sealing grooves 11 are located on the inner wall of the cylinder body 1 or the outer wall of the stationary plate 3, and each sealing groove 11 is equipped with an O-ring seal. In the above scheme, a two-stage or multi-stage sealing design is adopted. By blocking the leakage path of the medium in layers, the sealing reliability is significantly improved. The synergistic effect of multiple O-ring seals can not only compensate for the wear of a single seal, but also enhance the adaptability to high pressure or high wear conditions, thereby extending the service life and reducing maintenance costs.

[0039] The vortex lines of the stationary disk 3 and the moving disk are spiral structures with equal pitch and equal wall thickness;

[0040] Both the stationary disk 3 and the moving disk adopt a scroll design with equal pitch and equal wall thickness, which makes the meshing process between the stationary disk and the moving disk smoother and reduces airflow pulsation and vibration noise. At the same time, the equal wall thickness structure optimizes the processability, reduces manufacturing difficulty and cost, and ensures the uniformity of the strength of the scroll teeth, thereby improving the operating efficiency, reliability and life of the compressor.

[0041] The end of the cylinder body 1 away from the rear cover 9 is fixedly connected to the controller 12 by bolts, and the controller 12 is electrically connected to the drive motor.

[0042] The controller 12 is fixed to the end of the cylinder 1 away from the rear cover 9 by bolts, which optimizes the spatial layout, facilitates centralized assembly and maintenance, shortens the wiring distance between the controller and the motor, and reduces signal interference and energy consumption. At the same time, the rigid connection method enhances the overall structural stability and facilitates heat dissipation management, thereby improving the system integration and operational reliability.

[0043] The drive motor shaft extends axially and passes through the bearing support between the cylinder 1 and the front cover 2;

[0044] By extending the motor shaft axially and adopting a through-bearing support structure, the drive shaft is supported by both the cylinder block and the front cover, significantly improving the shaft system rigidity and rotational accuracy. This layout effectively reduces shaft end deflection and yaw vibration, ensures the meshing stability of the moving disc and the stationary disc, and optimizes the utilization of axial space, making the overall structure more compact and reliable.

[0045] Working principle: Before using the vehicle-mounted R290 electric compressor, it is necessary to check the overall condition of the device to ensure it can operate normally. Figure 1 - Figure 3 As shown:

[0046] Power transmission system

[0047] After receiving the vehicle command, the controller 12 outputs three-phase AC power to the stator 5 winding to generate a rotating magnetic field. The rotor 6 drives the motor shaft to rotate under the action of the magnetic field, and the motor shaft drives the moving plate to move directly through the eccentric mechanism.

[0048] Gas compression process

[0049] R290 gas flows from the intake port of cylinder 1, carries away heat from the outer surface of the stator, and after being rectified by the intake chamber 8, it enters the compression chamber 4 through the intake port on the outer edge of the stationary disc 3. The vortex lines of the moving disc and the stationary disc 3 mesh to form three continuous crescent-shaped cavities 4 (basic volume). As the moving disc moves, the basic volume moves towards the center, and the volume gradually decreases. The pressure is converted from intake pressure to exhaust pressure. The compressed high-pressure gas enters the sealing structure 10 through the exhaust port in the center of the stationary disc 3.

[0050] Key security mechanisms

[0051] The potting compound 7 forms a continuous insulating layer on the winding surface, blocking the contact between R290 and the winding, preventing the enameled wire from being damaged by the impact of the refrigerant, and avoiding sparks caused by leakage. The dual structure of inner-side locking and outer-side sealing on the outside of the stationary plate 3 can effectively reduce the leakage of R290.

[0052] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An R290 electric compressor for vehicles, comprising a cylinder block (1) and a drive motor located within the cylinder block (1), characterized in that: The drive motor includes a stator (5) fixedly connected to the inner wall of the cylinder (1) and a rotatable rotor (6). The stator (5) is located in the air intake chamber (8), and its windings and core gaps are completely covered by a cured potting compound (7). One end of the rotor (6) is fixedly connected to the stationary disk (3), and the stationary disk (3) and the moving disk mesh with each other to form a compression chamber (4); The stationary disc (3) is connected to the rear cover (9) by bolts, and a sealing structure (10) is provided between the stationary disc (3) and the cylinder (1). The rear cover (9) and the cylinder (1) are detachably connected. The moving plate is provided with a front cover (2) on the side facing the drive motor. The front cover (2) is fixedly connected to the cylinder (1). The drive shaft connected to the stator (5) passes through the front cover (2) and is connected to the moving plate for transmission.

2. The R290 electric compressor for vehicle according to claim 1, characterized by: The sealing structure (10) is a multi-stage sealing structure, which consists of at least two sealing grooves (11). The sealing grooves (11) are located on the inner wall of the cylinder body (1) or the outer wall of the stationary plate (3). Each sealing groove (11) is provided with an O-ring seal.

3. The R290 electric compressor for vehicle according to claim 1, characterized by: The vortex lines of the stationary disk (3) and the moving disk are spiral structures with equal pitch and equal wall thickness.

4. The R290 electric compressor for vehicle according to claim 1, characterized by: The cylinder (1) is fixedly connected to the controller (12) at the end away from the rear cover (9) by bolts. The controller (12) is electrically connected to the drive motor.

5. The R290 electric compressor for vehicle according to claim 1, characterized in that: The drive motor shaft extends axially and passes through the bearing support between the cylinder (1) and the front cover (2).

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