Linear Compressor Motor Cover Welding Assembly

Solution Overview

Problem

Conventional linear compressors require spacers for assembly, increasing assembly time and production costs due to the need for bolt assembly and material usage.

Innovation Solution

The motor cover and rear cover are directly surface-welded to each other, eliminating the need for spacers and unnecessary parts, and the welding positions are adjusted to account for design and tolerance variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If spacers and bolts are used to assemble the motor cover and rear cover, then the alignment and support are ensured, but the assembly time increases and production cost rises

Engineering Contradiction:

Improvealignment and supportVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The motor cover and rear cover are merged into a single welded structure, eliminating the need for separate spacers and bolts. The welding process directly joins the two covers, ensuring both alignment and structural integrity while significantly reducing assembly steps and time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical fastening system (spacers and bolts) is replaced with a welding process. This substitution eliminates the need for mechanical fasteners and their associated alignment features, achieving a permanent bond that ensures reliability while streamlining the assembly process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If spacers are used in the assembly, then the alignment is maintained, but the material cost increases

Engineering Contradiction:

ImprovealignmentVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The motor cover and rear cover are merged into a single welded structure, eliminating the need for separate spacers and bolts. The welding process directly joins the two covers, ensuring both alignment and structural integrity while significantly reducing assembly steps and time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spacers are extracted (removed) from the assembly system. By eliminating this component entirely and relying on the welded joint between the motor cover and rear cover, the design achieves alignment without requiring additional materials, thereby reducing material cost.

Inventive Principle:

Principle #2Taking out (Extraction)

3Stability of the object's composition

If multiple components (spacers, bolts, motor cover, rear cover) are assembled, then the structure is stable, but the device complexity increases

Engineering Contradiction:

Improvestructure stabilityVSAvoidnumber of components

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The motor cover and rear cover are merged into a single welded structure, eliminating the need for separate spacers and bolts. The welding process directly joins the two covers, ensuring both alignment and structural integrity while significantly reducing assembly steps and time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The welded joint serves multiple functions simultaneously: it provides structural stability, ensures alignment, and creates a permanent bond. This multi-functionality eliminates the need for separate components that would otherwise be required to achieve each of these objectives individually.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 approach reduces assembly time, lowers defect rates, and significantly cuts down material costs by eliminating the need for bolts and spacers, while maintaining the necessary alignment and support for the compressor components.

Implementation Method 1

fixedly welded to the supporting ends of the motor cover

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS8678788B2Linear compressor

Publication Date: 2014.03.25 LG ELECTRONICS INC

AI summary

A linear compressor is provided. Unnecessary parts of a motor cover of the compressor are bent toward a rear cover in an axis direction to form supporting ends of the motor cover, and the supporting ends of the motor cover are welded directly to the rear cover, thereby considerably cutting down the material cost.