Electric Compressor Inverter Housing Layout for Protected Connectors
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Solution Overview
Problem
Conventional electric compressors have connectors that protrude laterally, increasing the width of the inverter housing and making them susceptible to damage from external impacts, which is problematic for compact designs required in vehicle air conditioners.
Innovation Solution
The design integrates the high voltage and low voltage connectors within the axial width of the inverter housing, overlapping them with the bottom wall, reducing the radial and axial size expansion and protecting them from external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the high voltage connector and low voltage connector protrude laterally from the side surface of the inverter housing, then the connectors are easily accessible for connection, but the inverter housing increases its size in the width direction and the connectors are susceptible to damage from external impacts
Solution Approach 1:
The patent repositions the connectors from a lateral (radial) arrangement to an axial arrangement, extending them in the axial direction of the rotary shaft rather than protruding from the side surface. This dimensional change allows the connectors to be integrated within the axial footprint of the inverter housing, reducing the width direction dimensions while maintaining connection functionality.
Solution Approach 2:
The connectors are nested within the axial extent of the inverter housing by extending them in the axial direction. The extending portion of the inverter housing accommodates the connectors internally along the axial axis, effectively hiding them within the housing's projected area and preventing lateral protrusion.
2Ease of operation
If the high voltage connector and low voltage connector protrude laterally from the side surface of the inverter housing, then the connectors are easily accessible for connection, but the connectors are easily damaged by external impact
Solution Approach 1:
By changing the connector orientation from radial (lateral) to axial, the connectors are positioned within the protected envelope of the inverter housing. This dimensional repositioning removes them from vulnerable lateral exposure to impacts while maintaining their electrical connection function.
Solution Approach 2:
The inverter housing structure is designed with an extending portion that preemptively protects the connectors from external impacts. The housing acts as a protective barrier before any impact can reach the connectors, preventing damage in advance.
3Length of moving object
If the inverter housing is arranged radially on the motor housing to reduce axial length, then the axial size is minimized, but the lateral size increases when connectors protrude from the side surface
Solution Approach 1:
The patent maintains the radial arrangement of the inverter housing on the motor housing to minimize axial length, but simultaneously repositions the connectors to extend in the axial direction rather than protruding radially. This allows the connectors to utilize the axial dimension for their placement, preventing additional lateral expansion of the inverter housing.
Solution Approach 2:
The extending portion of the inverter housing that accommodates the connectors is merged with the main body of the inverter housing, integrating the connector housing space within the existing structural envelope. This integration ensures that the connectors do not create additional lateral dimensions beyond the inverter housing's radial boundaries.
Data Source
AI summary
An electric compressor includes a rotary shaft, a compression part, a motor, an inverter that has an inverter circuit, and a housing. The housing includes a motor housing having a peripheral wall extending in an axial direction of the rotary shaft and a bottom wall, an inverter housing that is provided on the peripheral wall, a compression part housing, a shaft support member that has an insertion hole. The inverter housing has an extending portion extending in the axial direction away from the peripheral wall and having a high voltage connector and a low voltage connector. The high voltage connector and the low voltage connector are overlapped with the bottom wall as viewed in the axial direction and disposed within a width of the extending portion.