Electric Compressor Stator Cover Layout for Coil Cooling and Insulation
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Solution Overview
Problem
Existing electric compressors face challenges in securing insulation between leads and coil ends while minimizing axial size and ensuring efficient cooling of coils, particularly when a cover member is positioned opposite the coil ends, which can obstruct fluid flow and complicate the insulation process.
Innovation Solution
The design incorporates a cover member with an accommodation portion for the neutral connection portion, where leads have covered and non-covered portions, and includes through holes in the cover end surface to allow fluid flow, ensuring insulation while reducing axial size and enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a cover member is disposed relative to the coil ends on a side opposite from the core end surface to downsize the electric compressor in the radial direction, then the radial size is reduced, but the fluid flow to the coil ends is obstructed
Solution Approach 1:
The cover end surface is segmented into a first surface and a second surface positioned at different radial distances from the coil ends. The first surface is farther away and provides insulation for extension portions, while the second surface is closer and allows fluid flow through through holes to reach the coil ends for cooling.
Solution Approach 2:
Different regions of the cover member are assigned different functions: the first surface region provides insulation with greater axial clearance from coil ends, while the second surface region provides cooling access with smaller axial clearance and includes through holes for fluid flow.
2Reliability
If the first surface is positioned farther from the coil ends than the second surface to ensure insulation of extension portions, then insulation is secured, but the axial size increases
Solution Approach 1:
The cover member utilizes the radial dimension by having surfaces at different radial distances from the coil ends, rather than only varying axial position. This allows insulation and cooling functions to be differentiated radially while maintaining compact axial dimensions.
Solution Approach 2:
The cover end surface is divided into multiple surfaces at different radial positions, with the first surface providing insulation clearance and the second surface providing cooling access, thereby resolving the contradiction between insulation distance and compact size.
3Productivity
If through holes are formed in the cover end surface to allow fluid flow to coil ends, then cooling efficiency is improved, but the insulation between extension portions and coil ends becomes more difficult to secure
Solution Approach 1:
The cover member provides different axial clearances at different radial positions: the first surface is positioned farther from coil ends to provide insulation clearance for extension portions, while the second surface is positioned closer and contains through holes for fluid flow, thus locally optimizing both insulation and cooling functions.
Solution Approach 2:
The cover end surface is segmented into multiple surfaces with different functions: one surface dedicated to insulation with greater clearance, and another surface dedicated to cooling access with through holes and smaller clearance.
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 configuration maintains insulation between leads and coil ends, reduces the compressor's axial size, and facilitates effective cooling of coils by allowing fluid flow, thus optimizing the electric compressor's performance and compactness.
Implementation Method 1
at least the first surface having a through hole through which the fluid introduced into the motor chamber flows to the coil ends
Data Source
AI summary
An electric compressor includes a rotary shaft, a compression part, a motor including a stator, and a housing. The stator includes a stator core, coils corresponding to a plurality of phases, an insulator, coil ends, first leads of the winding wires, a neutral connection portion, and a cover member. The cover member has a cover end surface opposite from the coil ends. The cover end surface has an accommodation portion in which the neutral connection portion is accommodated. The first leads each include a covered portion, and a non-covered portion. The non-covered portion includes an extension portion continuous with the neutral connection portion extending out from the accommodation portion by a predetermined length. The cover end surface includes a first surface, and a second surface. At least the first surface has a through hole. The first surface is positioned farther from the coil ends than the second surface is.