Inverter-Integrated Electric Compressor Assembly Simplification
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Solution Overview
Problem
Inverter-integrated electric compressors face challenges with complex configurations, increased cost and size due to numerous components, and complicated assembly processes, particularly with the use of terminal blocks and bus bars in the direct current power input system.
Innovation Solution
The inverter-integrated electric compressor simplifies the configuration by integrating high-voltage electric components directly onto the main substrate, eliminating the need for terminal blocks and bus bars, and using fitting parts and positioning means to securely mount components on the substrate, allowing for direct cable connections and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal blocks and bus bars are used in the direct current power input system, then reliable electrical connections are achieved, but device complexity and assembly complexity increase
Solution Approach 1:
The patent combines the terminal block and bus bar into a single integrated terminal block structure. The bus bar is embedded within or integrated with the terminal block housing, eliminating the need for separate bus bar components and reducing the number of assembly steps while maintaining reliable electrical connections.
Solution Approach 2:
The terminal block is designed to serve multiple functions: it provides electrical connection terminals, houses the bus bar for current conduction, and offers mounting structures for securing cables. This multi-functional design reduces the overall component count and simplifies the power input system.
2Reliability
If multiple high-voltage electric components are individually mounted on the substrate, then proper electrical connections are established, but assembly time and production cost increase
Solution Approach 1:
Multiple high-voltage electric components are integrated into a single modular assembly. The components are pre-assembled and interconnected as one unit, which is then installed on the substrate as a complete module. This reduces the number of individual mounting operations and accelerates the assembly process.
Solution Approach 2:
The high-voltage electric components are pre-assembled and pre-connected in a modular configuration before being installed on the substrate. This preliminary assembly allows for quality control and connection verification to be performed beforehand, reducing on-site assembly time and improving overall productivity.
3Adaptability or versatility
If numerous components are used in the inverter device, then functional requirements are met, but size and weight of the device increase
Solution Approach 1:
The patent merges multiple functional components into integrated assemblies. The terminal block incorporates bus bars, mounting structures, and insulation elements into a single component. Similarly, high-voltage electric components are grouped into modular assemblies, reducing the total number of discrete parts and thereby reducing overall device weight.
Solution Approach 2:
The terminal block utilizes composite construction combining conductive materials (for electrical connections) with insulating materials (for safety and structural support). This composite approach allows for optimized weight while maintaining both electrical functionality and mechanical integrity, reducing the overall weight compared to using solid metal constructions.
Data Source
AI summary
Provided is an inverter-integrated electric compressor which has improved assembly properties and assembly precision, and improved productivity. In this inverter-integrated electric compressor, a P-N terminal is provided on the inverter device main substrate, and a power source-side cable can be connected to the P-N terminal by inserting a connector provided at one end; by arranging and mounting multiple high-voltage electric components on the back of the main substrate in the area where the P-N terminal is arranged, a filter circuit is provided on the main substrate. The multiple high-voltage electric components are integrally coupled via fitting units provided on the housing cases of one another and are arranged in a prescribed position on the back of the main substrate with a positioning means provided on one of the housing cases.