Motor, scroll compressor and processing method of motor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost of copper windings in compressors and the inefficiency of existing connection methods between aluminum windings and copper lead wires, which result in low power output and reliability issues.
Innovation Solution
A motor for a compressor with an aluminum coil winding and a copper lead wire, where the connection between the winding and the lead wire is enhanced by using a crimp terminal filled with tin material, allowing for high current carrying capacity and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper windings are used in the motor, then the reliability and current carrying capacity are improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent employs a composite material structure where aluminum windings are combined with copper lead wires through a tin-filled crimp terminal connection. This composite approach allows the motor to utilize the cost advantage of aluminum while maintaining the high conductivity and reliability of copper at the critical connection points, thereby resolving the contradiction between manufacturing cost and connection reliability.
2Ease of manufacture
If aluminum windings are used to reduce cost, then the manufacturing cost decreases, but the current carrying capacity and power output are insufficient
Solution Approach 1:
The patent introduces tin as an intermediary material within the crimp terminal to facilitate the connection between aluminum windings and copper lead wires. The tin filling enhances the electrical conductivity and current carrying capacity of the aluminum-copper junction, allowing the motor to achieve high power output while maintaining the cost benefits of aluminum windings.
3Device complexity
If simple crimping is used to connect aluminum windings and copper lead wires, then the manufacturing process is simplified, but the connection reliability and maximum operating power are limited
Solution Approach 1:
The patent uses tin as an intermediary substance that is filled into the crimp terminal during or after the crimping process. This tin filling creates a metallurgical bond between the aluminum and copper components, significantly enhancing the connection reliability and maximum operating power capability while adding minimal complexity to the manufacturing 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
The solution increases the power output of the motor while reducing costs, achieving higher reliability and maximum operating power, with the motor capable of handling currents greater than or equal to 10 kilowatts.
Implementation Method 1
a space defined by the first crimp terminal is filled with a tin material, such that the connection between the winding and the lead wire can carry a large current
Implementation Method 2
the rotor rotating by means of electromagnetic induction of the coil
Data Source
AI summary
Provided are a motor, a scroll compressor, and a processing method of a motor. The motor includes: a stator provided with a plurality of stator slots, a toothed portion being formed between any two adjacent stator slots among the plurality of stator slots, and an aluminum coil being wound in the stator slots and/or around the toothed portions to form a winding, wherein the winding includes a first connecting portion; and a lead wire, which is a copper wire and has an end portion, the end portion being connected to the first connecting portion via a first crimp terminal so as to connect the winding to an external power supply, wherein the first crimp terminal wraps and presses the end portion and the first connecting portion in an axial direction of the lead wire, and a space defined by the first crimp terminal is filled with a tin material. In the present application, the coil forming the winding in the motor is provided as an aluminum coil, and the first connecting portion of the winding and the end portion of the lead wire are crimped together by means of the first crimp terminal, and then the first crimp terminal is filled with the tin material, such that the connection between the winding and the lead wire can carry a large current, and thus the power of the motor is increased while the cost of the motor is reduced.