Motor-Driven Compressor Cluster Block Radial Inward Arrangement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motor-driven compressors have a large axial and radial size due to the arrangement of the cluster block, which limits their compactness and efficiency.
Innovation Solution
The cluster block is arranged radially inward from the primary coil ends and coupled to the stator, with inserting projections that fit into existing gaps between the stator core and coil ends, reducing the axial and radial dimensions without disturbing the magnetic flux or requiring additional voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cluster block is arranged between the coil ends and the motor driving circuit in the axial direction, then the electrical connection is achieved, but the axial size of the motor-driven compressor is enlarged
Solution Approach 1:
The cluster block is repositioned from an axial arrangement (between coil ends and motor driving circuit) to a radial arrangement (inward from coil ends). This dimensional change allows the connection terminal to be accessible from the radial direction while maintaining electrical connection functionality, thereby reducing axial size without compromising manufacturing ease
2Volume of moving object
If the cluster block is arranged radially outward from the stator, then the electrical connection is achieved, but the radial size of the motor-driven compressor is enlarged
Solution Approach 1:
Instead of arranging the cluster block radially outward from the stator (conventional approach), the invention inverts this arrangement by placing the cluster block radially inward from the coil ends. This inversion allows the connection terminal to face the motor driving circuit while reducing radial size, and the inserting projection engages with the stator to maintain electrical connection
3Volume of moving object
If the cluster block is coupled to the outer circumferential surface of the stator core, then the coupling is achieved, but the axial and radial dimensions are enlarged
Solution Approach 1:
The inserting projection of the cluster block is nested into a groove formed on the outer circumferential surface of the stator core. This nesting arrangement allows the cluster block to be securely coupled to the stator while occupying minimal axial and radial space, as the connection is achieved through the groove engagement rather than external coupling structures
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A motor-driven compressor includes an electric motor including a stator and a rotor, wherein the stator includes a stator core and a coil end projecting from the stator core, a rotation shaft, a compression unit, a motor driving circuit, a housing accommodating the compression unit, the electric motor, and the motor driving circuit sequentially arranged in an axial direction of the rotation shaft, a conductor configured to electrically connect the motor driving circuit to the electric motor, a lead extending from the coil end, a connection terminal electrically connecting the conductor to the lead, and a cluster block accommodating the connection terminal. The cluster block is arranged in the housing. The cluster block is coupled to the stator with at least part of the cluster block located inward from the coil end in a radial direction of the rotation shaft.