Inverter-Integrated Compressor Coil Seat Design
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Solution Overview
Problem
The existing inverter-integrated electric compressors face challenges in efficiently attaching coil components due to the cumbersome process of inserting thick conductor wires into the motor drive circuit board and ensuring reliable electrical connections, which affects noise reduction and heat management.
Innovation Solution
A mechanism where a coil component with conductor wires wound in parallel is attached to the motor drive circuit using a seat with protrusions that fit into corresponding holes, allowing the wires to be inserted with widened intervals for easier connection and positioning, ensuring reliable electrical joints through TIG welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thick conductor wires are used to suppress heat generation in the coil component, then heat management is improved, but the process of inserting wires into the motor drive circuit board becomes cumbersome and productivity decreases
Solution Approach 1:
A seat component is introduced as an intermediary between the coil component and the motor drive circuit board. The seat has a body portion that receives the coil component and a protrusion that fits into a recess on the circuit board, providing a stable mounting position and facilitating wire insertion without requiring direct insertion into the circuit board holes
Solution Approach 2:
The mounting structure is divided into separate components: the coil component, the seat, and the motor drive circuit board. This segmentation allows the coil component to be mounted on the seat first, and then the entire assembly to be installed on the circuit board, simplifying the overall attachment process
2Reliability
If conductor wires are inserted one by one into the motor drive circuit board, then electrical connection is achieved, but the attachment process becomes time-consuming and productivity is reduced
Solution Approach 1:
The seat is prepared in advance with a recess that accommodates the coil component and positions the conductor wires. This preliminary preparation allows for easier and faster electrical connection during the assembly process, as the wires are already positioned correctly before being connected to the circuit board
3Device complexity
If the coil component is mounted directly on the motor drive circuit board, then the structure is simplified, but the positioning accuracy and connection reliability are compromised
Solution Approach 1:
The seat serves as a mediator between the coil component and the motor drive circuit board, providing a stable mounting position through its protrusion that fits into the recess on the circuit board. This intermediary structure ensures accurate positioning without significantly increasing overall device complexity
Solution Approach 2:
The seat has specific local features: a body portion with a recess for receiving the coil component and a protrusion for fitting into the circuit board recess. These localized structural qualities provide precise positioning at the mounting location without affecting the entire device structure
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
This approach simplifies the attachment process, enhances the reliability of electrical connections, and improves the efficiency of noise reduction by ensuring accurate positioning and secure welding, suitable for various compressors, including those in automotive air conditioning systems.
Implementation Method 1
an end of each conductor wire being connected electrically to the motor drive circuit
Implementation Method 2
ensuring reliable electrical connections, which affects noise reduction and heat management
Data Source
AI summary
Provided is an inverter-integrated electric compressor wherein the attachability of a coil component has been improved while reliability of a connection state at the electrical joints is ensured by simplifying a mechanism which electrically connects the coil component, such as one for removing electromagnetic noise, to a motor drive circuit. An inverter-integrated electric compressor, wherein a motor drive circuit including an inverter is surrounded by a compressor housing, is characterized in that a coil component comprising a plurality of conductor wires wound in parallel is attached to the motor drive circuit through a seat, the seat is provided with a protrusion which can be fitted into a seat affixing hole provided in a case member for housing the motor drive circuit, a plurality of terminal holes are arranged in the portion where the protrusion is provided, the plurality of conductor wires pulled out from the coil component are inserted, in a one-to-one correspondence, into the plurality of terminal holes in such a manner that the mutual interval between the wires is widened, and the end of each conductor wire is connected electrically to the motor drive circuit.