CN116569454A

CN116569454A - Motor with a motor housing

Info

Publication number: CN116569454A
Application number: CN202180078987.7A
Authority: CN
Inventors: H·里博特; H·巴努穆西; M·瓦里隆; P·加尼森; B·拉亚
Original assignee: Valeo Japan Co Ltd
Current assignee: Valeo Japan Co Ltd
Priority date: 2020-11-27
Filing date: 2021-11-24
Publication date: 2023-08-08
Also published as: WO2022113974A1; EP4252338A1; JP2023553306A

Abstract

An electric motor for a vehicle air conditioner is provided. The motor includes a first housing, a second housing, a sealing element, and a plurality of tension-loaded members. A first housing having a first mating surface is adapted to house the electric motor and a second housing having a second mating surface is adapted to house the inverter assembly. Furthermore, the first mating surface and the second mating surface are complementary and are opposite to each other. The sealing element is disposed between the first mating surface and the second mating surface, and the second housing is adapted to couple with the first housing. Further, when the first housing is coupled with the second housing, a plurality of tension-loaded members are disposed in holes formed on the first mating surface and the second mating surface.

Description

Motor with a motor housing

Technical Field

The present invention relates generally to an electric machine, and more particularly to a connection between a motor housing and an inverter housing of an electric machine to reduce leakage of electromagnetic noise from the housing of the electric machine.

Background

Typically, an electric machine, particularly an electric compressor, is disposed in an Alternating Current (AC) circuit of the vehicle. The electric compressor includes a compression unit for compressing a refrigerant, an electric motor driving the compression unit, and an inverter assembly driving the electric motor in a controlled manner. In addition, the housing is configured to house the various components of the motor-driven compressor and is mechanically coupled together by various fasteners. In one example, the motor housing is configured to house an electric motor and the inverter housing is configured to house an inverter assembly. An electric motor provided in the compressor enables the compression unit to suck refrigerant from an inlet formed on the motor housing to cool the electric motor by circulating the refrigerant through the motor housing. Typically, the motor housing is formed of an aluminum material in a cylindrical shape having openings on both sides. Further, the refrigerant enters the compression unit to be compressed, and flows out of the electric compressor through a discharge port formed on a rear cover connected to one end of the motor housing. From the other end of the motor housing, an electric motor is inserted and connected with the inverter housing. Conventionally, the mating portion of each housing is sealed with a gasket to prevent leakage of refrigerant. In general, a gasket provided between a motor case and an inverter case has three layers, such as a substrate made of a metal material as a first layer, and rubber coated on both sides of the substrate forms a second layer and a third layer. The inverter housing also includes High Voltage (HV) connector terminals and Low Voltage (LV) connector terminals. Conventionally, electromagnetic noise is generated by active components of an electric motor in a motor housing. Since the gasket is a rubber-coated metal gasket, electromagnetic noise is likely to be transmitted from the motor housing to the inverter case. Furthermore, electromagnetic noise transmitted from the motor housing may interfere with HV and LV connector terminals. Such electromagnetic noise interference on the connector terminals may enter the inverter housing and cause the control circuit enclosed in the inverter housing to malfunction.

Accordingly, there remains a need for an electric machine provided with features that avoid leakage of electromagnetic noise from the housing of the electric machine. Further, there is still another need for a connection formed between a motor housing and an inverter housing of an electric machine to reduce a leakage path of electromagnetic noise by grounding the electromagnetic noise. Furthermore, there remains a need for an electric machine provided with features that protect the inverter circuit from electromagnetic noise.

Disclosure of Invention

In this specification, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless otherwise indicated, such references are used merely to distinguish and name similar but not identical elements. The concept of priority should not be inferred from such an index, as these terms may be interchanged without departing from the invention. Furthermore, such indexing does not imply any order of installation or use of the elements of the invention.

In view of the foregoing, embodiments of the present invention herein provide an electric machine, particularly an electric compressor for a vehicle air conditioner. The motor includes a first housing, a second housing, a sealing element, and a plurality of tension-loaded members. A first housing having a first mating surface is adapted to house the electric motor and a second housing having a second mating surface is adapted to house the inverter assembly. Furthermore, the first mating surface and the second mating surface are complementary and are opposite to each other. The sealing element is disposed between the first mating surface and the second mating surface, and the second housing is adapted to couple with the first housing. Further, the plurality of tension-loaded members are disposed in holes formed on the first mating surface and the second mating surface when the first housing is coupled with the second housing.

Further, a sealing element having an aperture is aligned with the apertures formed on the first and second mating surfaces to receive the tension-loaded member therethrough.

In one example, the second housing includes an extension portion that extends outwardly in a radial direction relative to the second housing, and at least one of the first and second connectors is disposed on a sidewall of the extension portion of the second housing.

In one example, the plurality of tension-loaded members are disposed in a circumferential region of the second mating surface corresponding to at least one of the first and second connectors.

The motor further includes a plurality of bosses formed on one side of the outer circumferences of the first and second mating surfaces, corresponding to at least one of the first and second connectors, wherein the hole is formed on the boss.

In one embodiment, the holes are formed on the first and second mating surfaces at a predetermined distance.

In one example, at least one distance between adjacent holes formed on the first mating surface and the second mating surface is less than 30mm.

Furthermore, the sealing element is a rubber-coated metal gasket.

Furthermore, the plurality of tension-loaded members are spring pins.

In another example, the motor further includes at least two pins formed on the second housing to position the first housing in alignment with the second housing.

Drawings

Other features, details and advantages of the invention may be inferred from the description of the invention which follows. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1 shows a block diagram of an electric machine according to an embodiment of the invention;

FIG. 2 shows a schematic view of a first housing of the motor of FIG. 1;

FIG. 3 illustrates a cross-sectional view of the motor of FIG. 1 taken along a longitudinal axis of the motor;

fig. 4 shows a schematic view of a second housing of the motor of fig. 1 in a plane perpendicular to the longitudinal axis of the second housing;

FIG. 5 illustrates an exploded view of a second housing of the motor of FIG. 1 having an inverter assembly;

FIG. 6 shows an exploded view of the motor of FIG. 1; and is also provided with

Fig. 7 shows an enlarged cross-sectional view of one of the plurality of tension-loaded members coupled between the first housing and the second housing of fig. 1.

Detailed Description

It must be noted that the figures disclose the invention in a manner that is sufficiently detailed to practice, and that they help to better define the invention if desired. However, the invention should not be limited to the embodiments disclosed in the specification.

The present invention relates to an electric motor, and more particularly, to an electric compressor provided in an air conditioning circuit of a vehicle. Generally, an electric compressor includes a motor housing provided with an electric motor and an inverter housing provided with an inverter assembly. The motor housing and the inverter housing are coupled together to enable connection between the electric motor and the inverter. Further, an electric motor is connected to the compression unit to compress the refrigerant flowing therein. In order to achieve a fluid-tight connection between the motor housing and the inverter housing, a rubber-coated metal gasket is arranged between the motor housing and the inverter housing. Such rubber coated gasket allows transmission of electromagnetic noise generated by the electric motor disposed in the motor housing. Such gaskets can therefore transmit electromagnetic noise to the inverter assembly and cause the inverter assembly to fail. To avoid this, a physical connection between the inverter housing and the motor housing is established. This physical connection interacts with the external body of the motor, which is connected to the ground of the vehicle. Thus, electromagnetic noise is restricted from entering the inverter case. Further, the location and function of this physical connection will be explained with reference to the following drawings.

Fig. 1 shows a block diagram of an electric machine 100 according to an embodiment of the invention. In the present embodiment, the electric motor 100 is an electric compressor, and in particular, the electric compressor 100 driven by a motor, which is integrated with an inverter. The motor 100 is disposed in a refrigerant circuit of the vehicle. Generally, the motor 100 is disposed in a refrigerant circuit of a vehicle to compress a refrigerant flowing therein. The electric machine 100 comprises a first housing 110 adapted to house an electric motor 112, a second housing 120 adapted to house an inverter assembly 122, and a third housing 130 adapted to house a compression unit 132. Further, the first, second and third housings 110, 120 and 130 are integrally fastened by fastening means (not shown) such as bolts, thereby forming the housing of the motor 100. In one embodiment, the first, second and third housings 110, 120, 130 are formed from metal, particularly from aluminum die casting.

The electric motor 112 provided in the first housing 110 includes a stator and a rotor (not shown in fig. 1). Further, a rotation shaft 134 is connected to the rotor, and the rotation shaft 134 extends into the third housing 130 to be coupled with the compression unit 132. The first housing 110, which is a motor housing, is formed in a cylindrical shape having openings on both sides to accommodate the electric motor 112. In addition, one end of the first housing 110 is coupled to the third housing 130 having the compression unit 132. From the other end of the first housing 110, the electric motor 112 is inserted and connected with the second housing 120 having the inverter assembly 122. When the electric motor 112 is energized, the rotary shaft 134 drives the compression unit 132 provided in the third housing 130.

The compression unit 132 provided in the third housing 130 includes a fixed scroll (scroll) and an orbiting scroll (orbiting) for compressing a refrigerant flowing therein. In one embodiment, the fixed scroll is fixedly integrally formed with the third housing 130. The orbiting scroll member is rotatably coupled to an eccentric pin formed by a rotation shaft 134 extending from the first housing 110. The orbiting scroll member is adapted to compress a refrigerant in a compression space defined between the fixed scroll member and the orbiting scroll member when the rotary shaft 134 is rotated by the electric motor 112. In other words, the refrigerant in the compression space is compressed by the orbiting motion of the orbiting scroll member relative to the fixed scroll member. Further, a suction port 136 is integrally formed with the first housing 110 for sucking the refrigerant into the motor 100. The refrigerant sucked from the suction port 136 at the first housing 110 may flow through the electric motor 112 to cool or absorb heat generated by the electric motor 112, and enter the third housing 130 to perform a compression process. Thereafter, the compressed refrigerant is discharged from the motor 100 through the discharge port 150 integrally formed with the third housing 130.

The inverter assembly 122 housed in the second housing 120, which is an inverter housing, is adapted to drive the electric motor 112 in a controlled manner. The inverter assembly 122 includes a plurality of electronic components mounted on a circuit board to perform desired operations. The circuit board is powered by an external power source, such as a battery of the vehicle. The circuit board is shown in fig. 5. Further, a seal terminal 142 is provided on an end wall of the second housing 120 and is adapted to be coupled with the electric motor 112. Inverter assembly 122 generates controlled inputs for electric motor 112 and transmits these inputs to electric motor 112 through sealed terminals 142. Further, the input generated by inverter assembly 122 may control the speed of electric motor 112.

Fig. 2 shows a schematic view of the first housing 110 of the motor 100 of fig. 1. The electric motor 112 is not shown in fig. 2. In one embodiment, the first housing 110 includes an annular wall 208, the annular wall 208 extending a distance to form the first housing 110 into a cylindrical shape. Further, the first housing 110 comprises a first mating surface 202 defined on a longitudinal end of the first housing 110 in the direction a. In one example, the first housing 110 is hollow cylindrical, and an inner peripheral surface of the first housing 110 defines an opening in the direction a. Further, the first housing 110 has openings on both sides to be coupled with the second housing 120 and the third housing 130, respectively. In one example, the opening formed in the first housing 110 in the direction a is adapted to align with the second housing 120, and the opening formed in the first housing 110 in the direction B is aligned with the third housing 130. Furthermore, the third housing 130 is mechanically coupled to the first housing 110 at an opening defined in the direction B by any connection means. The connection means may be a plurality of threads and bolts. In one embodiment, the electric motor 112 is inserted into the first housing 110 through an opening defined in the first housing 110 in the direction a.

Further, the suction port 136 protrudes from the annular wall 208 of the first housing 110, as shown in fig. 2. In one embodiment, the first housing 110 may further include mounting means on an outer surface thereof to allow for mounting of the motor 100 to a vehicle body.

In addition, at least two positioning holes 210A, 210B are provided on the outer circumference and/or the inner circumference of the first mating surface 202 at a predetermined distance to receive any connection means, such as a positioning pin, so that efficient positioning can be achieved between the first housing 110 and the second housing 120. In particular, on the outer periphery of the first mating surface 202, the positioning holes 210A, 210B are provided on opposite sides with respect to the central axis of the first housing 110.

The first housing 110 also includes a plurality of apertures 204A-D formed in the first mating surface 202 at a predetermined distance. In one embodiment, the plurality of holes 204A-D are formed on the outer periphery of the first mating surface 202. According to the foregoing embodiment, as shown in fig. 2, a plurality of bosses 206A-D are provided on the outer peripheral surface of the opening. In other words, the plurality of bosses 206A-D are formed on the outer surface of the first housing 110 at the outer periphery of the opening defined in the first housing 110. In addition, the plurality of apertures 204A-D are formed in the plurality of bosses 206A-D.

Fig. 3 shows a cross-sectional view of the motor 100 of fig. 1 in a plane perpendicular to the longitudinal axis of the motor 100. The second housing 120 has a base plate 302 and a peripheral wall 306 extending from an outer edge of the base plate 302 to define a space accommodating the inverter assembly 122. In one embodiment, the shape of the substrate 302 is concave-convex to correspond to the electronic components 320 of the inverter assembly 122.

Further, as shown in fig. 3, the second housing 120 includes an extension 316, which extension 316 extends outwardly beyond the outer diameter of the first housing 110 in the radial direction. In one embodiment, the base plate 302 of the second housing 120 includes a bottom 308A that is complementary to the opening provided in the first housing 110 and an upper portion 308B that forms the sidewall 304 of the extension 316. Further, the bottom 308A of the second housing 120 is annular and is adapted to couple with the first housing 110.

In one embodiment, as shown in fig. 1 and 4, the hermetic terminal 142 is disposed on the bottom 308A of the substrate 302 of the second housing 120. The inverter assembly 122 and the electric motor 112 are electrically connected via the seal terminal 142. The bottom 308A of the second housing 120 includes a second mating surface 310 that is complementary to and opposite the first mating surface 202 of the first housing 110.

In addition, the second mating surface 310 includes a plurality of apertures 312A-D disposed on the second mating surface 310. In one embodiment, the plurality of apertures 312A-D formed in the second mating surface 310 are complementary to the plurality of apertures 204A-D formed in the first mating surface 202. In addition, a plurality of bosses 314A-D are provided on the second mating surface 310. In one embodiment, the plurality of bosses 314A-D are disposed on the outer periphery of the second mating surface 310.

As shown in fig. 3 and 4, the second housing 120 is also provided with at least two connectors 318A-B on the side wall 304 of the extension 316. The two connectors 318A-B include at least a first connector 318A and a second connector 318B for providing power and signals to the inverter assembly 122. In one embodiment, the first connector 318A is a high voltage terminal and the second connector 318B is a low voltage terminal.

As shown in fig. 3 and 5, the inverter assembly 122 also includes the plurality of electronic components 320 mounted on the circuit board 138 for controlling operation. As shown in fig. 5, the circuit board 138 is located in the inverter assembly accommodation space and is fixed to the base plate 302 by a plurality of bolts/screws 228. The first connector 318A and the second connector 318B are electrically connected to an electronic component 320 disposed on the circuit board 138 of the inverter assembly 122 via bus bars and/or wires. In one example, high voltage terminal 318A provides a high voltage to an inverter designed with electronic components 320. Such an inverter converts the high-voltage DC power into three-phase AC power and transfers the power to the electric motor 112 provided in the first housing 110. In addition, the low voltage terminal 318B supplies low voltage DC power to a control unit designed by the electronic part 320 to control the electric motor 112, such as the rotation speed, the number of rotor revolutions, the turning on and off, and the like of the electric motor 112.

In a preferred embodiment, the plurality of bosses 206A-D, 314A-D are formed on one side of the outer perimeter of the first mating surface 202 of the first housing 110 and the second mating surface 310 of the second housing 120, corresponding to the connectors 318A-B. In one example, the bosses 206A-D formed on the first mating surface 202 are complementary to the bosses 314A-D formed on the second mating surface 310.

Fig. 6 shows an exploded view of the motor 100 of fig. 1, wherein the connection between the first housing 110 and the second housing 120 is depicted. As described above, the first mating surface 202 of the first housing 110 is complementary to and adapted to couple with the second mating surface 310 of the second housing 120. Further, a sealing element 402 is disposed between the first mating surface 202 and the second mating surface 310 to configure a fluid-tight connection between the first housing 110 and the second housing 120. In one embodiment, the sealing element 402 is a gasket configured with three layers, such as a first layer made of a metallic material, and second and third layers formed of rubber coated on both sides of the first layer. When the first housing 110 is coupled with the second housing 120, the sealing element 402 is in contact with the first mating surface 202 and the second mating surface 310.

The sealing element 402 also includes apertures 404A-D formed in the outer periphery of the sealing element 402. In one embodiment, the apertures 404A-D are aligned with the apertures 204A-D, 312A-D formed on the first mating surface 202 of the first housing 110 and the second mating surface 310 of the second housing 120.

The motor 100 also includes a plurality of tension-loaded members 406A-D disposed in the apertures 204A-D, 312A-D formed in the first mating surface 202 and the second mating surface 310 when the first housing 110 is coupled with the second housing 120. In one example, the plurality of tension-loaded members 406A-D are spring pins. In addition, the plurality of tension-loaded members 406A-D are made of a metallic material.

In one embodiment, the plurality of tension loaded members 406A-D are disposed at a circumferential region of the second mating surface 310 corresponding to at least one of the first connector 318A and the second connector 318B. As shown in fig. 4 and 6, the holes 312A-D and the tension-loaded members 406A-D inserted into the holes 312A-D are disposed at an area between the connectors 318A-B and the inside of the second mating surface 310 that generates electromagnetic noise.

In another embodiment, the plurality of tension-loaded members 406A-D are adapted to elastically deform in their radial directions when the plurality of tension-loaded members 406A-D are inserted into the apertures 204A-D, 312A-D formed in the first and second mating surfaces 202, 310. In one example, the outer diameter of the plurality of tension-loaded members 406A-D is equal to or greater than the inner diameter of the apertures 204A-D, 312A-D. Since the diameter of the holes 204A-D, 312A-D is the same as the diameter of the plurality of tension-loaded members 406A-D, the plurality of tension-loaded members 406A-D need to be elastically deformed in a radial direction along the plurality of tension-loaded members 406A-D, the plurality of tension-loaded members 406A-D can be easily inserted into the holes 204A-D, 312A-D. In this example, one end of the plurality of tension loaded members 406A-D is inserted into holes 312A-D formed in the second mating surface 310. Thereafter, the sealing member 402 is disposed on the second mating surface 310 of the second housing 120 such that the plurality of tension-loaded members 406A-D disposed in the apertures 312A-D of the second mating surface 310 pass through the apertures 404A-D formed in the sealing member 402. In addition, when the first housing 110 is coupled to the second housing 120, the other ends of the plurality of tension-loaded members 406A-D are inserted into the holes 204A-D formed on the first mating surface 202, thereby forming a housing for the motor 100. Since the plurality of tension-loaded members 406A-D are disposed between the first housing 110 and the second housing 120, the plurality of tension-loaded members 406A-D achieve physical contact between the first housing 110 and the second housing 120. Further, the main body of the second housing 120 is connected to the ground of the vehicle. Since the plurality of tension-loaded members 406A-D achieve physical contact between the first housing 110 and the second housing 120, electromagnetic noise generated by the electric motor 112 of the first housing 110 is grounded through the second housing 120.

The plurality of tension-loaded members 406A-D disposed between the first housing 110 and the second housing 120 at the areas corresponding to the connectors 318A-B may prevent electromagnetic noise from being transferred to the connectors 318A-B, thereby preventing electromagnetic noise from interfering with the electronic components 320 disposed in the inverter assembly 122.

Fig. 7 shows an enlarged cross-sectional view of one of the plurality of tension-loaded members 406A-D secured between the first housing 110 and the second housing 120. In addition, the plurality of tension-loaded members 406A-D are made of a metallic material having high electrical conductivity and EMC/EMI shielding characteristics, such as copper, iron, steel, aluminum, and the like. In one embodiment, each of the tension loaded members 406A-D includes a pin body extending in a cylindrical shape with a slot formed in a longitudinal direction of the pin body. Further, both ends of the pin body are provided with inclined surfaces so that the tension-loaded members 406A-D can be easily inserted into the holes 204A-D, 312A-D when the first housing 110 is assembled with the second housing 120. In one embodiment, one of the distances between adjacent tension members 406A-D of the plurality of tension members 406A-D is less than 30mm. In another embodiment, at least two solid metal pins 408 are inserted into positioning holes 410A and 410B formed on the second housing 120 to position the first housing 110 in alignment with the second housing 120, as shown in fig. 6. In addition, the positioning holes 410A-B formed in the second housing 120 are complementary to the positioning holes 210A-B formed in the first housing 110.

As described above, the outer diameter of the plurality of tension-loaded members 406A-D is equal to or greater than the inner diameter of the apertures 204A-D, 312A-D. Accordingly, the coefficient of friction between the outer body of the plurality of tension-loaded members 406A-D and the inner walls of the apertures 204A-D, 312A-D may be high, thereby retaining the plurality of tension-loaded members 406A-D within the apertures 204A-D, 312A-D. To insert the plurality of tension-loaded members 406A-D into the holes 204A-D, 312A-D, the plurality of tension-loaded members 406A-D are deformed in their radial directions such that both ends of the plurality of tension-loaded members 406A-D may be inserted into the respective holes 204A-D, 312A-D provided in the first and second housings 110, 120. In one embodiment, each tension-loaded member 406A-D has a length of 14 mm. In one example, the pin portions of the plurality of tension-loaded members 406A-D inserted into the apertures 204A-D provided in the first housing 110 are larger than the pin portions of the plurality of tension-loaded members 406A-D inserted into the apertures 312A-D provided in the second housing 120.

All the above embodiments are only intended to explain the invention and many more embodiments and combinations thereof are possible. Therefore, the present invention should not be limited to the above-described embodiments.

Claims

1. An electric machine (100), comprising:

a first housing (110) having a first mating surface (202) and adapted to house an electric motor (112);

a second housing (120) having a second mating surface (310) and adapted to house an inverter assembly (122), wherein the first mating surface (202) and the second mating surface (310) are complementary and opposite each other;

-a sealing element (402) arranged between the first mating surface (202) and the second mating surface (310), wherein the second housing (120) is adapted to be coupled with the first housing (110); and

a plurality of tension-loaded members (406A-D) disposed in apertures (204A-D, 312A-D) formed in the first and second mating surfaces (202, 310) simultaneously couple the first housing (110) with the second housing (120).

2. The electric machine (100) of claim 1, wherein the sealing element (402) has apertures (404A-D) aligned with apertures (204A-D, 312A-D) formed on the first and second mating surfaces (202, 310) to receive the tension-loaded members (406A-D) therethrough.

3. The electric machine (100) of claim 1 or 2, wherein the second housing (120) comprises an extension (316) extending outwardly in a radial direction relative to the second housing (120) and at least one of a first and a second connector (318A, 318B) respectively provided on a side wall (304) of the extension (316) of the second housing (120).

4. The electric machine (100) of claim 3, wherein the plurality of tension-loaded members (406A-D) are disposed at a circumferential region of the second mating surface (310) corresponding to at least one of the first and second connectors (318A, 318B).

5. The electric machine (100) of claim 3, further comprising a plurality of bosses (206A-D, 314A-D) formed on one side of the outer perimeter of the first and second mating surfaces (202, 310), corresponding to the at least one of the first and second connectors (318A, 318B), wherein apertures (204A-D, 312A-D) are formed on the bosses (206A-D, 314A-D).

6. The electric machine (100) of any of claims 1 to 5, wherein the apertures (204A-D, 312A-D) are formed on the first mating surface (202) and the second mating surface (310) at a predetermined distance.

7. The electric machine (100) of any of claims 1 to 6, wherein at least one distance between adjacent holes (204A-D, 312A-D) formed on the first mating surface (202) and the second mating surface (310) is less than 30mm.

8. The electric machine (100) of any of claims 1 to 7, wherein the sealing element (402) is a rubber coated metal gasket.

9. The electric machine (100) of any of claims 1 to 8, wherein the plurality of tension-loaded members (406A-D) are spring pins.

10. The electric machine (100) of any of claims 1 to 9, further comprising at least two pins (408) formed on the second housing (120) to position the first housing (110) in alignment with the second housing (120).