Electric Compressor Connector Layout for Insulated Interlock Assembly
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Solution Overview
Problem
Existing electric compressors face issues of insulation breakdown and deteriorated assemblability due to power and interlock lines being configured as pins or wires extending in the same direction without sheaths, leading to poor assembly and increased risk of electrical interference.
Innovation Solution
The power line is configured as a pin extending in one direction, while the interlock line is designed as a bendable wire with a sheath, and the interlock connector is positioned apart from the socket on a separate surface of the printed circuit board, ensuring insulation and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If both the power line and interlock line are configured as pins extending in one direction, then the structure is simple, but insulation breakdown occurs between the power line and interlock line
Solution Approach 1:
The connector is segmented into distinct regions: the power line is configured as a pin extending in one direction, while the interlock line is configured as a wire extending in a different direction. This spatial segmentation prevents insulation breakdown by physically separating the high-voltage power line from the low-voltage interlock line, eliminating the harmful electrical interference while maintaining structural simplicity.
2Reliability
If the interlock line and socket have small diameters due to small allowable current, then current requirements are met, but assemblability deteriorates
Solution Approach 1:
Different line configurations are applied to different functional requirements: the power line uses a pin structure optimized for high-voltage current transmission, while the interlock line uses a wire structure with sufficient diameter for low-voltage signal transmission and easy assembly. This local differentiation allows each line to be optimized for its specific function without compromising overall system performance.
Data Source
AI summary
An electric compressor including a motor configured to generate power, a compression mechanism configured to compress a refrigerant by receiving power from the motor, an inverter configured to control the motor, a connector connected to an external device, a power line extending from the connector to the inverter to transmit electric power, which is supplied from the external device, to the inverter, and an interlock line extending from the connector to the inverter to transmit a signal to the inverter when the connector is separated from the external device, in which the power line and the interlock line are formed in different ways, thereby preventing insulation breakdown between the power line and the interlock line, easily assembling the power line and the inverter, and easily assembling the interlock line and the inverter.