Electric Compressor Cluster Assembly Insulation Design
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Solution Overview
Problem
Conventional electric compressors face insulation weaknesses and increased packaging size due to exposed terminals, leading to potential refrigerant contact and current leakage, which complicates assembly and increases manufacturing costs.
Innovation Solution
A cluster assembly with a detachable cluster and cluster body design, featuring spaced insertion holes and terminal accommodating parts filled with insulating molding, heat shrinkable tubes, and a compact configuration that minimizes refrigerant exposure and eliminates the need for separate fixing means, enhancing insulation and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If terminals are exposed outside the housing body for easy connection, then ease of operation is improved, but insulation reliability deteriorates due to refrigerant contact and current leakage risks
Solution Approach 1:
The terminal housing is nested within the cluster assembly, which is then inserted into the hollow cylindrical space of the stator. This nested arrangement allows terminals to be connected externally while being protected internally by multiple insulating layers (terminal housing, cluster assembly, stator structure), preventing refrigerant contact while maintaining ease of connection.
Solution Approach 2:
The terminal housing and cluster assembly act as intermediary insulating structures between the exposed terminals and the refrigerant environment. These intermediaries provide physical barrier protection while allowing terminal functions to remain accessible, resolving the conflict between exposure and insulation.
2Ease of manufacture
If terminal housing is formed as a single integrated member, then manufacturing simplicity is improved, but insulation performance deteriorates due to exposed terminal slots
Solution Approach 1:
The cluster assembly is divided into multiple functional segments: the terminal housing (accommodating terminals), the cluster body (fixed to stator), and the detachable cluster (with coil fixing parts). This segmentation allows each part to be optimized for its specific function while maintaining overall manufacturing efficiency and improved insulation through the distributed structure.
Solution Approach 2:
The terminal slots are positioned in a specific spatial arrangement within the terminal housing, and the entire cluster assembly is inserted into the hollow cylindrical space of the stator along the shaft direction. This dimensional arrangement creates additional insulating barriers without complicating the basic housing structure.
3Reliability
If cluster assembly size is increased to accommodate insulation structures, then insulation reliability is improved, but packaging space requirements increase
Solution Approach 1:
The cluster assembly utilizes the existing hollow cylindrical space of the stator by nesting within it. The terminal housing and other insulating structures are arranged concentrically and compactly within this available space, providing enhanced insulation without increasing the overall compressor package size.
Solution Approach 2:
The insulating structures are arranged in the radial and axial dimensions within the available hollow cylindrical space, rather than extending the length in the shaft direction. This efficient use of available volume provides improved insulation while maintaining compact packaging.
Data Source
AI summary
The present invention relates to a cluster assembly and an electric compressor comprising the same and, more particularly, to a cluster assembly which has an improved insulation structure and is convenient to install, and an electric compressor comprising the same. More specifically, the cluster assembly comprises: three terminals; a detachable cluster including first to third coil fixing portions each having a coil insertion hole into which a coil end is insertedly formed therein, and first to third terminal receiving portions having a space formed therein so as to be spaced apart from the first to third coil fixing portions by a predetermined distance in the longitudinal direction of the coil and receive the terminals; and a cluster body which is coupled to one side surface of an electric motor in an axial direction and is formed hollow in the center thereof along the outer circumferential surface of a stator and which includes a cluster insertion portion formed corresponding to the shape of the detachable cluster so that the detachable cluster can be inserted in a horizontal direction.