Compressor Controller Cluster Assembly for Insect and Water Protection
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Solution Overview
Problem
Existing compressors face issues with insect infestation and complex assembly due to the exposure of the cluster outside the controller case, which complicates the assembly process and requires multiple steps.
Innovation Solution
The compressor design includes a controller case with a cluster assembly that secures the cluster inside, using hooks and a guide to facilitate assembly, and a flange to seal the cluster from external elements, ensuring the cluster is assembled within the case and sealed from the outside.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cluster is exposed outside the controller case, then the assembly process becomes simpler and requires fewer steps, but the cluster becomes vulnerable to insect infestation and water damage
Solution Approach 1:
The cluster is nested inside the controller case, specifically positioned within a recessed space formed by the guide structure. The cluster assembly is housed within the controller case body, protecting it from external harmful factors while maintaining assembly simplicity through the integrated guide structure that facilitates direct placement.
Solution Approach 2:
The guide structure acts as an intermediary element that bridges the cluster and the controller case. The guide provides a structured interface with hooks that secure the cluster while the recessed configuration protects it, mediating between the need for simple assembly and the need for protection.
2Ease of manufacture
If the cluster is exposed outside the controller case, then the assembly process requires fewer steps, but the controller case structure becomes more complex
Solution Approach 1:
The guide structure combines multiple functions into a single integrated component: it provides the recessed protective space, incorporates securing hooks for the cluster, and forms the interface for assembly. This merging reduces the need for separate protective covers, mounting brackets, and fastening mechanisms, thereby simplifying the overall controller case structure while maintaining protection and assembly simplicity.
3Object-affected harmful factors
If the cluster is secured inside the controller case using hooks and guide, then the cluster is protected from external elements, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The guide structure is pre-formed with the recessed configuration and integrated hooks during the controller case manufacturing process. This preliminary preparation of the securing mechanism eliminates the need for complex assembly operations, as the cluster can be directly placed and secured in a single action, reducing assembly time while maintaining robust protection.
Solution Approach 2:
The guide structure with its recessed configuration and integrated hooks provides self-securing functionality. When the cluster is placed into the guide, the hooks automatically engage with the cluster, providing secure fixation without requiring additional fastening operations or complex assembly steps, thereby reducing assembly time while ensuring protection.
4Object-affected harmful factors
If the cluster is assembled within the controller case, then the cluster is protected from insects and water, but the assembly process requires multiple steps and is more complex
Solution Approach 1:
The guide structure merges the protective recessed space and the securing mechanism into a single integrated component. This consolidation means that providing protection does not require separate protective covers or additional mounting structures, thereby avoiding increased assembly complexity while ensuring the cluster is securely housed and protected from harmful factors.
Data Source
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AI summary
Disclosed herein a compressor including a compressor case equipped with a BLDC motor therein and a connection terminal for receiving power from the BLDC motor, and a controller fastened to the compressor case to control the power supplied to the BLDC motor, wherein the controller includes a cluster connected to the connection terminal, and a controller case fastened to the compressor case and including a cluster assembly therein to which the cluster is assembled to prevent the cluster from being exposed to the outside, wherein the cluster assembly includes a plurality of hooks for securing the cluster, and a guide configured to guide so that the cluster is inserted horizontally based on a lower surface of the controller case and then rotated and secured vertically.