Electric Compressor Stator Terminal Structure for Faster Assembly
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Solution Overview
Problem
Conventional electric compressors require complex and time-consuming assembly processes such as stripping winding coils, welding lead wires, and additional impregnation steps, leading to reduced productivity and increased production costs.
Innovation Solution
An electric compressor design featuring a cluster integrally formed on the stator with connection terminals that directly connect the winding coil to a sealing terminal, eliminating the need for stripping and welding processes, and incorporating a connection pin system for simplified electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection structure with sealing terminal is used to electrically connect inverter and electric motor, then electrical connection and airtightness are achieved, but assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines the sealing terminal structure with the electrical connection structure into an integrated unit. The connection terminal is directly formed on the sealing terminal body, eliminating the need for separate welding operations between lead wires, female terminals, and sealing terminals. This merging of functions achieves both reliable electrical connection and airtightness while significantly reducing assembly complexity and time.
Solution Approach 2:
The connection terminal is pre-formed as an integral part of the sealing terminal structure during manufacturing. This preliminary action eliminates the need for subsequent welding or connection operations during assembly, as the electrical connection path is already established through the integrally formed connection terminal that directly contacts the winding coil.
2Reliability
If multiple welding and connection processes are performed to connect winding coil, lead wire, and terminal, then stable electrical connection is achieved, but production cost increases
Solution Approach 1:
The patent merges multiple separate components (sealing terminal, female terminal, connection terminals) into a single integrally formed sealing terminal structure with built-in connection terminals. This eliminates the need for multiple welding operations and separate assembly steps, thereby reducing manufacturing complexity and production cost while maintaining stable electrical connection through the direct contact design.
Solution Approach 2:
The patent extracts and eliminates the unnecessary lead wire and separate female terminal components from the conventional connection structure. By taking out these redundant elements and replacing them with an integrally formed connection terminal, the design simplifies the manufacturing process and reduces production costs associated with multiple welding and assembly operations.
3Reliability
If additional processes like impregnation and lacing are performed on winding coil, then stable coupling in vibration environment is achieved, but assembly time increases
Solution Approach 1:
The patent combines the electrical connection function with the mechanical mounting function through the integrally formed connection terminal. The connection terminal serves both as the electrical conductor and as the mechanical element that directly contacts and secures the winding coil, eliminating the need for separate impregnation and lacing processes. This integrated design maintains vibration resistance while significantly reducing assembly time.
4Reliability
If complex assembly processes are required for electrical connection, then reliable connection is achieved, but product assembly complexity increases
Solution Approach 1:
The patent merges the sealing terminal, female terminal, and connection terminals into a single integrally formed structure. This unified design eliminates multiple separate assembly steps including stripping, welding, and connection operations, thereby reducing assembly process complexity while maintaining connection reliability through the direct contact design of the built-in connection terminals.
Data Source
AI summary
Proposed is an electric compressor for a vehicle configured such that an electrical connection structure between a winding coil of an electric motor and a sealing terminal that connects an inverter unit to the electric motor is improved, thereby being capable of increasing assemblability of a product and reducing a production cost. The electric compressor includes an electric motor provided with a stator, a rotor, and a rotary shaft, a compression unit configured to compress a refrigerant according to a rotation of the rotary shaft, an inverter configured to control driving of the electric motor, a sealing terminal electrically connecting the electric motor to the inverter, and a cluster integrally formed on a portion of the stator, the cluster having an inner portion thereof provided with multiple connection terminals for electrically connecting a coil wound on the stator to multiple connection pins provided at the sealing terminal.