Electric Compressor Cover Reinforcement with Ribs
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Solution Overview
Problem
Electric compressors in vehicles have a weak cover that is prone to damage from shocks and generates significant vibration and noise, leading to increased maintenance costs and reduced riding comfort due to amplified resonance sounds.
Innovation Solution
The cover of the electric compressor is reinforced with straight ribs, ring ribs, or hexagonal ribs having a honeycomb structure on its inner or outer side, which disperses vibration and noise, enhancing the cover's strength and reducing resonance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a thin plate cover is used, then the compressor size is reduced, but the cover strength is insufficient and it is easily damaged by shock
Solution Approach 1:
The cover is segmented into multiple functional zones: a body portion, a flange portion with fastening holes, and multiple rib structures (straight ribs extending from fastening holes toward the center, ring ribs surrounding the fastening holes, and connection ribs forming a circular pattern around the center). This segmentation allows each zone to perform its specific function while collectively providing both strength and compactness.
Solution Approach 2:
The cover design transitions from a simple two-dimensional thin plate to a three-dimensional structured component by adding ribs that extend in multiple directions (straight ribs radially outward, ring ribs in concentric circles, connection ribs forming circular patterns). This dimensional enhancement provides structural strength without significantly increasing the overall footprint.
2Ease of manufacture
If a thin plate cover is used, then the manufacturing cost is reduced, but the maintenance time and cost increase due to easy damage
Solution Approach 1:
The cover is designed with pre-integrated rib structures (straight ribs, ring ribs, and connection ribs) that are formed as part of the cover body during manufacturing. These reinforcing features are built in advance rather than added later, ensuring the cover has sufficient strength to resist operational shocks and vibrations, thereby preventing damage and reducing maintenance needs.
3Weight of moving object
If the cover is a thin plate, then the weight is reduced, but vibration and noise from the compressor housing are transmitted to the cover, decreasing fatigue strength
Solution Approach 1:
The rib structures (straight ribs, ring ribs, and connection ribs) are strategically designed to act as vibration-damping elements. These ribs create a more rigid cover structure that can better withstand and dissipate vibrations from the compressor housing, preventing resonance and reducing fatigue accumulation while maintaining the lightweight characteristic of the thin plate base material.
4Volume of moving object
If the cover is a thin plate, then the compressor size is reduced, but resonance sound in specific frequency band is generated and amplified
Solution Approach 1:
The cover design incorporates asymmetric rib arrangements with different patterns: straight ribs extending radially from fastening holes, ring ribs forming concentric circles around the fastening holes, and connection ribs creating circular patterns around the center. This asymmetric multi-pattern structure disrupts resonance in specific frequency bands while maintaining overall compactness.
Data Source
AI summary
An electric compressor includes a cover. The cover is reinforced by forming straight ribs, ring ribs, connection ribs, or hexagonal ribs having a honeycomb structure. The straight ribs, rings ribs, connection ribs, or hexagonal ribs are formed on the inner side or the outer side of a body of the cover on a side of an inverter.