Compressor Motor Busbar Assembly for Reliable Winding Interconnection
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Solution Overview
Problem
Existing compressors face challenges in efficiently arranging windings for small-sized motors, leading to potential incorrect interconnections and reduced reliability due to the limited number of input terminals compared to the number of coils.
Innovation Solution
A motor design featuring a stator assembly with a hollow structure, insulator, and a busbar assembly that includes busbars with different radii and a winding coupling unit to connect coils to an external driving circuit, ensuring proper phase interconnection and insulation, while a method for fabricating this assembly involves bending and welding the windings onto a folded plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of windings constructing each coil increases to match the number of teeth, then the motor can generate sufficient magnetic field, but the number of input terminals remains limited to 2 or 3, requiring manual interconnection of windings which reduces reliability
Solution Approach 1:
The patent divides the winding interconnection system into modular segments using busbars. Each busbar connects to specific coils and phases, breaking down the complex manual interconnection task into manageable, pre-configured modules. This segmentation eliminates manual wiring errors while maintaining the required magnetic field generation capability through proper phase distribution.
Solution Approach 2:
The busbar assembly acts as an intermediary component between the coils and the input terminals. Instead of directly connecting numerous coil windings to limited input terminals, the busbars serve as intermediate connection points that automatically interconnect windings of the same phase, reducing the risk of manual interconnection errors and improving reliability.
2Ease of manufacture
If manual interconnection of windings is used to connect coils of the same phase, then flexibility in assembly is maintained, but user mistakes lead to wrong interconnections and reduced reliability
Solution Approach 1:
The busbar assembly is pre-configured with connection points and geometries that correspond to specific coil positions and phases before assembly. This preliminary preparation ensures that during the assembly process, workers simply need to connect coils to the appropriate busbar terminals, eliminating complex manual interconnection decisions and preventing user mistakes while maintaining assembly flexibility.
Solution Approach 2:
The busbar assembly structure itself provides the interconnection function automatically through its design. The geometric configuration and positioning features of the busbars enable them to self-align and self-connect with the appropriate coils, reducing reliance on manual judgment and minimizing the potential for human error in winding interconnection.
3Reliability
If a busbar assembly with multiple busbars of different radii is used to connect coils, then automated connection and improved reliability are achieved, but the device complexity increases
Solution Approach 1:
The busbar assembly, despite having multiple busbars of different radii, performs a single unified function: connecting coils of the same phase to the appropriate input terminals. The different radii are not arbitrary but are optimized for specific mounting positions and connection requirements, allowing the assembly to handle various coil configurations with a single standardized component design that reduces overall system complexity.
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
The solution enhances the reliability of small-sized motor windings by ensuring accurate phase interconnection and insulation, improving the motor's efficiency and reducing noise and vibration.
Implementation Method 1
a busbar assembly configured to connect the plurality of coils to an external driving circuit
Implementation Method 2
an insulator for insulating the stator from the coils
Implementation Method 3
a method for fabricating the motor includes welding the winding to a folded plate
Data Source
AI summary
A compressor includes a motor which includes a stator assembly configured to include a stator in which a hollow is formed, a plurality of coils formed by a winding wound on the stator, and an insulator for insulating the stator from the coils, and a rotor inserted into the hollow, configured to rotate about a rotation axis. The rotor includes a plurality of poles, and a curvature radius of an outer circumference of a center part of the poles is different from a curvature radius of an outer circumference of an edge part of the poles. A method for fabricating a motor includes coupling a stator hook formed in a busbar assembly having a plurality of busbars to a hook engaging part formed in the stator assembly having the plurality of coils, and fusing a winding onto a folded plate connected to the plurality of busbars.