Motor Compressor Busbar Vibration Stress Mitigation
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Solution Overview
Problem
Motor-driven compressors experience vibration-induced stress on busbars due to relative movement between the circuit board and connector, leading to potential bending and damage at the connection points.
Innovation Solution
The design includes a resin case that accommodates busbars, allowing them to move within the case when the circuit board vibrates, and incorporates projections to restrict movement in intersecting directions, reducing stress on the busbars and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the circuit board and connector are rigidly fixed to the housing, then the electrical connection is stable, but the busbar is subjected to stress and may bend or damage during vibration
Solution Approach 1:
The connector is divided into a fixed portion (resin case attached to housing) and a movable portion (busbar that can move independently). This segmentation allows the electrical connection to remain stable while the busbar can accommodate vibrations without transmitting stress to the solder joints.
Solution Approach 2:
The busbar's positional parameter is changed from fixed to movable within the resin case. By allowing the busbar to move in response to vibrations, the system absorbs mechanical stress without compromising the electrical connection integrity.
2Strength
If the busbar is allowed to move freely in the case, then vibration stress is reduced, but the busbar may move excessively and cause other problems
Solution Approach 1:
The resin case provides different local properties: it allows movement in the direction of vibration while restraining movement in other directions. This localized quality control enables the busbar to accommodate vibrations without excessive displacement that could cause other issues.
Data Source
AI summary
A motor-driven compressor includes a compression unit, an electric motor, a motor controller, a housing, and a connector. The motor controller includes a circuit board. The housing includes an inverter accommodation chamber, and the inverter accommodation chamber accommodates the motor controller. The connector is accommodated in the inverter accommodation chamber and electrically connects the circuit board and a member located outside the inverter accommodation chamber. The connector includes one or more busbars and a case. The one or more busbars are electrically connected to the circuit board. The case is formed from a resin and accommodates the one or more busbars. The circuit board and the connector are fastened to the housing. The one or more busbars are allowed to move in the case when the circuit board vibrates.