Integrated Electric Compressor Bus Bar Resistance Welding
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Solution Overview
Problem
On-vehicle integrated electric compressors face reliability issues due to solder cracks and screw loosening caused by vibrations and heat changes, leading to impaired electrical continuity and variability in assembly quality.
Innovation Solution
The use of bus bars for electrical connections between the control board and motor, integrated with an insulator and positioning means, and joined via resistance welding, enhances reliability and workability by stabilizing the welding conditions and reducing worker variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or screwing is used to attach electrical and electronic parts, then assembly is simple and flexible, but the connections become unreliable under vibration and heat changes
Solution Approach 1:
The patent replaces mechanical connection methods (soldering and screwing) with resistance welding to join bus bars to terminals. This substitution eliminates the reliability issues of solder cracks and screw loosening under vibration, while maintaining manufacturing efficiency through automated welding processes.
Solution Approach 2:
The patent changes the connection method from low-strength mechanical joints to high-strength welded joints by controlling welding parameters (current value, welding time). This parameter change ensures stable electrical continuity under severe vibration and heat conditions while keeping the assembly process efficient.
2Reliability
If soldering or screw tightening is performed manually, then flexibility in assembly is maintained, but variations between workers reduce reliability
Solution Approach 1:
The patent replaces manual mechanical operations (soldering, screw tightening) with automated resistance welding. This eliminates worker variability and ensures consistent connection quality, while the automation system manages the complexity of process control.
3Reliability
If bus bars are used for electrical connections, then connection reliability improves, but assembly complexity increases
Solution Approach 1:
The patent merges multiple bus bars corresponding to different phases into a single integrated unit using an insulator with positioning means. This combining reduces the number of separate assembly operations, simplifies handling, and maintains the high reliability benefits of bus bar connections.
Solution Approach 2:
The patent introduces an insulator as an intermediary component that integrates multiple bus bars and provides positioning functionality. This mediator simplifies assembly by allowing the bus bars to be handled as a unit while ensuring proper positioning relative to the control board.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The bus bar connection and welding method improve the reliability of terminal joints, reduce variability in assembly, and enhance the overall workability of the integrated electric compressor.
Implementation Method 1
the bus bar and a terminal on the polyphase motor side can be joined to each other by resistance welding or the like. In resistance welding, if a welding current value and the like are controlled, the welding conditions can easily be kept constant
Data Source
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AI summary
There is provided an integrated electric compressor that is improved in reliability. Bus bar connection is employed for electrical connection between a power board 16 and the power source side and between the power board 16 and the motor side, and welding is employed for joining a bus bar to a capacitor 13 and a reactor 14, for joining board-side terminal parts of the bus bar to PN terminals 20a and 20b, and for joining UVW terminals 25a, 25b and 25c to housing-side terminals 28a, 28b and 28c. By employing resistance welding for the welding, the terminals can be joined to each other with stabilized quality. Further, since flat joint plates are provided on one end side of the housing-side terminals 28a, 28b and 28c, and the UVW terminals 25a, 25b and 25c are welded thereto, reliable joints between terminals can also be attained in these portions.