Sealed Motor Controller Housing with Fastener Grommet Seal
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Solution Overview
Problem
Electric motors in outdoor condenser units of air conditioners are prone to moisture and contaminant ingress, which can damage internal components like the stator and controller due to their orientation and configuration, leading to potential mechanical and electrical failures.
Innovation Solution
The design includes a housing with a first endshield, a shell, and a controller can, where the stator is positioned axially between these components, and fasteners extend through and interconnect them, projecting beyond one end for machine mounting, with a seal assembly and grommet to prevent moisture and contaminant ingress, and a water slinger to direct fluids away from the motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the motor is mounted in outdoor condenser units with the stator and controller in the described orientation, then the motor can be installed in standard configurations, but moisture and contaminants can ingress into the controller compartment causing damage
Solution Approach 1:
The housing is divided into separate sealed compartments: the controller can is separated from the stator compartment by an endshield, with each compartment sealed independently. This segmentation allows the controller to be protected from moisture while maintaining standard mounting configurations.
Solution Approach 2:
A seal assembly including a grommet and endshield acts as an intermediary barrier between the controller compartment and the external environment. The grommet seals around fasteners penetrating the endshield, preventing moisture ingress while allowing mechanical connection.
2Ease of operation
If fasteners extend through the stator and housing for machine connection, then mounting is enabled, but pathways for moisture and contaminant ingress are created
Solution Approach 1:
A grommet is positioned at the interface between the endshield and controller can, sealing around the fasteners that extend through the housing. This intermediary sealing element prevents moisture and contaminants from traveling along the fastener pathways while maintaining the mounting capability.
Solution Approach 2:
The grommet is made of flexible sealing material that conforms to the fastener surfaces and housing interfaces, creating an effective seal around penetrating elements. This flexible seal prevents contaminant ingress while allowing the fasteners to maintain their structural and mounting functions.
3Reliability
If the controller compartment is sealed to prevent moisture ingress, then reliability is improved, but heat dissipation may be compromised
Solution Approach 1:
The housing is segmented into separately sealed compartments, with the controller can isolated from the stator compartment by the endshield. This segmentation allows independent sealing of the controller compartment while maintaining thermal management pathways for the stator, enabling both protection and heat dissipation.
Data Source
AI summary
An electric motor is provided. The motor is mountable to a machine. The motor includes a rotor rotatable about an axis, a stator, a housing, and a fastener. The housing includes a first endshield and a controller can, with the stator being positioned axially between the endshield and the can. The fastener extends through and interconnects the first endshield, the stator, and the can. The fastener projects axially beyond at least one of the first endshield and the can for connection to the machine.