Compressor Stator Welding Structure to Protect Slot Insulation
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Solution Overview
Problem
The formation of a concave portion in the back yoke portion of a compressor's stator core to prevent insulating film melting during welding increases magnetic resistance, leading to reduced motor and compression efficiency.
Innovation Solution
A compressor design that includes a stator core with a yoke portion, teeth portions, and slots, where an insulating film separates the winding from the stator core, and a sheet is sandwiched between the yoke portion and the insulating film at the welding portion to reduce heat transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a concave portion is formed in the back yoke portion facing the slot to prevent insulating film melting during welding, then insulation between stator core and winding is maintained, but magnetic resistance increases and motor efficiency is reduced
Solution Approach 1:
The patent applies local quality by placing the insulating sheet only at the specific location where welding is performed on the back yoke portion, rather than forming a concave portion throughout the entire back yoke. This localized approach provides heat insulation precisely where needed during welding while preserving the magnetic flux path and minimizing impact on motor efficiency.
Solution Approach 2:
The patent introduces an insulating sheet as an intermediary material between the back yoke portion and the insulating film in the slot. This intermediary sheet acts as a heat barrier during welding, protecting the insulating film from melting while avoiding the need to modify the stator core structure, thereby maintaining magnetic efficiency.
2Reliability
If a concave portion is formed in the back yoke portion to protect insulating film from welding heat, then insulation is maintained, but compression efficiency is reduced
Solution Approach 1:
The insulating sheet is applied locally at the welding position on the back yoke portion, providing heat protection only where welding occurs. This localized protection avoids the need for a concave portion that would reduce the overall magnetic flux path, thereby maintaining motor efficiency and compression efficiency.
Solution Approach 2:
The insulating sheet serves as a mediator that absorbs and blocks welding heat, preventing it from reaching and melting the insulating film in the slot. This protective intermediary allows welding to proceed without compromising the insulating film, maintaining both insulation reliability and compression efficiency.
3Strength
If welding is performed on the back yoke portion to fix stator core to container, then assembly is secured, but insulating film may melt due to heat
Solution Approach 1:
The insulating sheet acts as a thermal intermediary placed between the back yoke portion and the insulating film. During welding, this sheet absorbs and blocks heat transmission, protecting the insulating film from melting while allowing the welding process to securely fix the stator core to the container.
Solution Approach 2:
The insulating sheet is pre-positioned in the slot before welding is performed on the back yoke portion. This preliminary placement ensures that the insulating film is already protected when welding heat is applied, preventing melting and maintaining insulation reliability throughout the assembly process.
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
This design effectively prevents the reduction in motor efficiency and ensures appropriate electrical insulation between the stator core and the winding, while also reducing the risk of insulating film melting during welding.
Implementation Method 1
a sheet that is sandwiched between the yoke portion and the insulating film is arranged in the slot that corresponds to the welding portion
Data Source
AI summary
A compressor includes a stator core that includes a yoke portion and a teeth portion, a rotor that is arranged inside the stator core, a compression unit that compresses a refrigerant along with rotation of the rotor relative to the stator core, a container that has an internal space in which the stator core and the compression unit are arranged, a winding that is wound around the teeth portion, and an insulating film that is arranged in the slot so as to separate the winding from the stator core, wherein a welding portion that is fixed to the container by welding is formed on a side surface of the yoke portion on an outer diameter side, and a sheet that is sandwiched between the yoke portion and the insulating film is arranged in the slot that corresponds to the welding portion in a circumferential direction of the stator core.