Inverter-Integrated Compressor Control Board Vibration Mitigation
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Solution Overview
Problem
Inverter-integrated vehicle air-conditioner electric compressors face issues with board vibration and deformation due to vehicle vibrations, leading to device detachment, solder/weld rupture, and short circuits, which existing countermeasures like increasing board thickness or screwing locations compromise the compressor's compact and lightweight design.
Innovation Solution
A vehicle-air-conditioner electric compressor design that includes a base supporting the control board at multiple locations within the inverter accommodating section, with an elastic member and reinforcing members to absorb shocks and enhance rigidity, and a bus bar assembly formed by insert molding using insulating resin, minimizing vibration and deformation while preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the board is increased to enhance rigidity and minimize vibration deformation, then the reliability is improved, but the volume and weight of the inverter accommodating section increase
Solution Approach 1:
The patent applies preliminary action by providing reinforcing members and bases that support the board at positions where vibration and deformation are most likely to occur. These reinforcing structures are pre-installed to prevent vibration-induced damage before it occurs, allowing the use of thinner, lighter boards while maintaining reliability.
Solution Approach 2:
The patent applies local quality by strategically placing reinforcing members and bases at specific locations on the board (such as near mounting holes or high-stress areas) rather than uniformly thickening the entire board. This localized reinforcement provides the necessary rigidity to prevent vibration damage while minimizing the overall weight increase.
2Reliability
If the number of screwing locations is increased to minimize board vibration and deformation, then the reliability is improved, but the volume and weight of the inverter accommodating section increase
Solution Approach 1:
The patent uses preliminary action by pre-positioning bases and reinforcing members at strategic locations within the inverter accommodating section. These pre-positioned structures provide support and reduce vibration at critical points, allowing for effective vibration mitigation without requiring an increased number of screwing locations or additional space.
Solution Approach 2:
The patent applies local quality by concentrating reinforcement at specific high-stress or high-vibration areas rather than uniformly distributing support structures throughout the entire inverter accommodating section. This localized approach provides effective vibration control while minimizing the overall volume required.
3Reliability
If the thickness of the bus bar is increased to enhance rigidity and prevent resonance, then the reliability is improved, but the volume and weight of the inverter accommodating section increase
Solution Approach 1:
The patent applies preliminary action by providing bases and reinforcing members that support the bus bar at positions where resonance and vibration are most likely to occur. These supporting structures are pre-installed to prevent vibration-induced damage before it occurs, allowing the use of thinner, lighter bus bars while maintaining reliability and preventing short circuits.
Solution Approach 2:
The patent applies local quality by strategically placing reinforcing members and bases at specific locations on the bus bar (such as near connection points or high-stress areas) rather than uniformly thickening the entire bus bar. This localized reinforcement provides the necessary rigidity to prevent resonance and vibration damage while minimizing the overall volume increase.
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 reduces vibration and deformation of boards and bus bars, preventing device detachment, solder/weld rupture, and short circuits, thereby enhancing the reliability and maintaining the compressor's compact and lightweight nature.
Implementation Method 1
an elastic member and reinforcing members to absorb shocks and enhance rigidity
Data Source
AI summary
An object is to provide a highly reliable vehicle-air-conditioner electric compressor of an inverter-integrated type that minimizes vibration and deformation of a board and a bus bar caused by vibration of a vehicle so as to prevent devices from becoming detached, to prevent soldered sections and welded sections from rupturing, and to prevent short circuits from occurring. In a vehicle-air-conditioner electric compressor (1) in which an inverter accommodating section (11) is provided at a periphery of a housing (2) and an inverter (20) is accommodated inside the inverter accommodating section (11), a control board (26) constituting the inverter (20) is screwed to fixing-screw base surfaces (29) provided at a plurality of locations of the inverter accommodating section (11), and a base (40) that has the same height as the fixing-screw base surfaces (29) and supports the control board (26) near substantially a midpoint of a fixing-screw pitch on the control board (26) and/or near a position where a large component is disposed on the control board (26) is provided at one or more locations of the inverter accommodating section (11).