Electric Compressor Interlock Wire Fixing for Insulation Stability
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Solution Overview
Problem
Existing electric compressors face issues with insulation breakdown and reduced assembling efficiency due to the design of power terminals and interlock pins, which are prone to damage from vibration and require additional coatings or increased space, leading to cost, size, and weight increases.
Innovation Solution
The electric compressor incorporates a power terminal formed as a pin and an interlock wire formed as a bendable wire, with a fixing member supporting the interlock wire to prevent damage and improve insulation by securing the interlock wire at a position not facing the power terminal, and using a fixing member to stabilize the interlock wire's connection to the board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If both the power terminal and interlock pin are formed as pins extending in one direction, then the assembly structure is simple, but insulation breakdown occurs between the power terminal and interlock pin
Solution Approach 1:
A coating is applied as an intermediary layer between the power terminal and interlock pin to prevent insulation breakdown. The coating acts as a mediator that maintains electrical isolation while allowing the simple pin-based assembly structure to remain intact.
Solution Approach 2:
The interlock pin is repositioned in a different spatial dimension (not facing the power terminal) to eliminate the insulation breakdown issue. This dimensional rearrangement allows both pins to coexist without electrical interference while maintaining structural simplicity.
2Use of energy by moving object
If the interlock pin outer diameter and socket are formed small to match the small allowable current magnitude, then the current transmission is optimized, but assembly difficulty increases
Solution Approach 1:
The connection structure is divided into two distinct components: a pin for current transmission and a separate interlock mechanism for assembly. This segmentation allows the pin to be optimized for electrical performance while the interlock mechanism provides mechanical ease of assembly.
Solution Approach 2:
An interlock mechanism serves as a mediator between the small-diameter pin and the assembly process. This intermediary component enables easy assembly and disassembly without requiring larger pin dimensions, thus maintaining both electrical efficiency and manufacturing ease.
3Reliability
If the interlock wire is provided to deliver disconnection signals, then safety control is improved, but the wire is damaged by vibration
Solution Approach 1:
A coating is applied to the interlock wire as a protective intermediary layer that shields the wire from vibration damage. This coating maintains the wire's electrical function while enhancing its mechanical durability in vibrating environments.
Solution Approach 2:
The coating is applied beforehand to the interlock wire to provide preemptive protection against vibration damage. This prior cushioning prevents wire damage before it occurs, ensuring long-term reliability of the safety control system.
4Reliability
If a coating is provided to prevent insulation breakdown, then insulation reliability is improved, but cost and manufacturing complexity increase
Solution Approach 1:
The coating application process is merged with the existing manufacturing workflow, integrating insulation protection into the standard production sequence. This combination minimizes additional manufacturing complexity while ensuring reliable insulation coverage.
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 terminal extending from the connecter to the inverter so as to deliver power supplied from the external device to the inverter; and an interlock wire extending from the connector to the inverter so as to deliver a signal to the inverter when the connecter is detached from the external device, and a fixing member fixed to a board of the inverter while supporting the interlock wire may be provided, thereby it is possible to prevent the interlock wire from being damaged to an extent to which the cost, the size, and the weight are not dramatically increased.