Compressor Stator Shrink-Fit Geometry to Reduce Resin Burrs
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Solution Overview
Problem
Existing methods for fixing a stator core to a barrel in compressors using resin members result in the generation of burrs and potential failures due to direct contact and uniform shrink fitting, which can compromise the integrity of the compressor and refrigeration apparatus.
Innovation Solution
A method involving insert molding of resin members on the stator core, followed by shrink fitting to the barrel, where the first joining surface with a larger curvature than the second joining surface allows for the formation of spaces that are gradually filled with melted resin, reducing burr formation and enhancing the fixing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If direct contact and uniform shrink fitting is used to fix the stator core to the barrel, then the fixing process is simple, but burrs are generated and potential failures occur
Solution Approach 1:
The resin member is designed with a curved outer peripheral surface that creates different contact characteristics at different locations. The curvature causes the intermediate portion to contact the barrel first during shrink fitting, while spaces are formed at the end portions, preventing uniform contact and burr generation throughout the entire interface.
Solution Approach 2:
The curved surface geometry is predetermined in the resin member design before the shrink fitting process. This preliminary geometric configuration ensures that during the shrink fitting operation, the intermediate portion makes contact first, gradually filling spaces with melted resin, thereby preventing burr formation before the end portions make contact.
2Ease of manufacture
If direct contact and uniform shrink fitting is used to fix the stator core to the barrel, then the manufacturing process is straightforward, but compressor integrity is compromised
Solution Approach 1:
The curved surface creates localized contact zones that progress from the intermediate portion to the end portions during shrink fitting. This localized, sequential contact prevents excessive stress concentration and resin overflow at any single location, thereby maintaining compressor integrity while keeping the manufacturing process straightforward.
3Manufacturing precision
If the first joining surface has a larger curvature than the second joining surface, then spaces are formed that reduce burr formation, but the joining geometry becomes more complex
Solution Approach 1:
The outer peripheral surface of the resin member is designed with a specific curvature radius that is larger than the curvature of the inner peripheral surface of the barrel. This curvature difference is the key geometric feature that enables spaces to be formed during shrink fitting, allowing melted resin to fill gradually from the intermediate portion and prevent burr formation, while the complexity is limited to a simple curved surface design.
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 method effectively reduces burr generation and improves the fixing process, enhancing the reliability and performance of the compressor and refrigeration apparatus by minimizing protrusions and potential failures.
Implementation Method 1
spaces between the first joining surface and the second joining surface are formed between the first end and the intermediate portion and between the second end and the intermediate portion
Implementation Method 2
fixing the stator core to the inside of the barrel via the resin member by shrink fit
Data Source
AI summary
A method for manufacturing a compressor includes fixing a stator core to an inside of a barrel via a resin member by shrink fit. An outer peripheral surface of the resin member is a first joining surface. A surface in contact with the first joining surface on an inner peripheral surface of the barrel is a second joining surface. The fixing the stator core to the inside of the barrel includes joining the first joining surface to the second joining surface. Upon joining, to the second joining surface, an intermediate portion of the first joining surface between a first end and a second end facing each other, spaces between the first joining surface and the second joining surface are formed between the first end and the intermediate portion and between the second end and the intermediate portion.