Motor-Driven Compressor Cluster Block Attachment
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Solution Overview
Problem
The existing motor-driven compressors face issues with the cluster block detaching from the stator core due to slidable projections in dovetail grooves, leading to instability and potential disconnection of electrical connections.
Innovation Solution
A motor-driven compressor design featuring a cluster block with an insertion piece that engages with a cornered insertion hole on the stator core, combined with a method of attaching the cluster block to the stator core using an insertion piece that is elastically deformable and has a stopper portion to secure the connection, and a method of mounting the stator core by heating and expanding the motor housing to accommodate the cluster block and then cooling to secure the stator core in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a projection is used to engage with a dovetail groove to attach the cluster block to the stator core, then the attachment method is simple, but the cluster block can be displaced and detach from the stator core
Solution Approach 1:
The attachment structure is divided into multiple engagement points: the insertion piece has a tip that engages the insertion hole and a base that engages the groove, creating segmented attachment points that work together to prevent displacement while maintaining simple assembly
Solution Approach 2:
The attachment mechanism transitions from a single-direction sliding engagement (dovetail groove) to a multi-dimensional engagement system where the insertion piece engages both the insertion hole (radial direction) and the groove (axial direction), preventing displacement in multiple directions simultaneously
2Ease of operation
If the cluster block is made detachable for assembly purposes, then ease of assembly is improved, but the risk of detachment during operation increases
Solution Approach 1:
The insertion piece is designed with elastic deformation capability that creates a preliminary locking action when inserted, where the elastic recovery force continuously acts to maintain engagement, preventing accidental detachment while allowing controlled assembly and disassembly
Solution Approach 2:
The insertion piece acts as an intermediary element between the cluster block and stator core, providing a controlled attachment mechanism that allows easy assembly through insertion while preventing operational detachment through elastic locking and multi-point engagement
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 solution effectively prevents the cluster block from detaching from the stator core, ensuring stable electrical connections and improved assembly efficiency by maintaining the cluster block's posture relative to the stator core, enhancing the compressor's operational reliability and ease of assembly.
Implementation Method 1
heating the motor housing member to expand the whole motor housing radially outward
Implementation Method 2
cooling to secure the stator core in place
Data Source
AI summary
A stator core includes an insertion hole that has an opening in an outer peripheral surface of the stator core and a bent portion in the stator core. A cluster block includes an insertion piece, which is inserted into the insertion hole via the cornered portion. The cluster block is attached to the stator core by engaging the insertion piece with the insertion hole.