Motor Compressor Cluster Block Assembly Fixation
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Solution Overview
Problem
In motor-driven compressors, the cluster block is not securely fixed, leading to potential contact and damage with coil ends during assembly, resulting in deformation or breakage when conductive members are connected to connection terminals.
Innovation Solution
A method of assembling the motor-driven compressor involves positioning the cluster block between the housing end wall and coil ends such that conductive member insertion holes are radially outer, using a pressing jig to hold the cluster block in place and prevent movement towards the stator core, allowing secure connection of conductive members to connection terminals without contacting the coil ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cluster block is not fixed in the housing, then the assembly process is simpler and the cluster block is easier to install, but the cluster block may move toward the electric motor and contact or damage the coil ends during assembly
Solution Approach 1:
The patent applies preliminary action by positioning the cluster block in a predetermined location between the end wall and coil ends before the conductive members are inserted. The cluster block is pre-positioned such that its conductive member insertion holes are radially outer, which prevents it from moving toward the electric motor during subsequent assembly steps.
Solution Approach 2:
The patent uses a pressing jig as an intermediary tool to hold the cluster block in place during the assembly process. The pressing jig temporarily restrains the cluster block's movement toward the stator core, allowing secure connection of conductive members without direct contact between the cluster block and coil ends.
2Ease of operation
If the cluster block is pressed toward the end wall during assembly, then the connection of conductive members is facilitated, but the cluster block may be deformed or broken due to stress concentration
Solution Approach 1:
The patent applies local quality by positioning the conductive member insertion holes in the radially outer portion of the cluster block, away from the pressed portion. This ensures that stress is distributed to stronger structural areas during assembly pressing, preventing deformation or breakage of the cluster block while facilitating easy connection of conductive members.
3Volume of moving object
If the conductive member insertion holes are positioned radially inner, then the cluster block can be more compact, but the cluster block is more susceptible to deformation and breakage when pressed during assembly
Solution Approach 1:
The patent positions the conductive member insertion holes in the radially outer portion of the cluster block, creating a functional separation where the pressed portion (radially inner) handles mechanical stress while the hole portion (radially outer) handles electrical connections. This local differentiation prevents stress concentration at the insertion holes.
Solution Approach 2:
The patent resolves the spatial conflict by utilizing the radial dimension to separate the functions: the radially inner portion accommodates pressing forces while the radially outer portion contains the conductive member insertion holes. This dimensional separation allows both compactness and structural integrity to be achieved.
Data Source
AI summary
The cluster block accommodates connection terminals and has conductive member insertion holes, into which the conductive members are inserted. The cluster block is disposed between the bottom wall of the housing and second coil ends. The conductive member insertion holes are located on the radially outer side of the inner circumferential surface of the stator core. The cluster block includes a second wall portion in the vicinity of the electric motor and a first wall in the vicinity of the bottom wall of the housing. The second wall portion has a pressed surface on the radially inner side of the inner circumferential surface of the stator core. The outer surface of the first wall portion has a contact surface that is lined up with the pressed surface in the axial direction of the stator core. The contact surface is allowed to contact the bottom wall of the housing.