US20040208760A1 - Terminal block assembly for a hermetic compressor - Google Patents
Terminal block assembly for a hermetic compressor Download PDFInfo
- Publication number
- US20040208760A1 US20040208760A1 US10/675,313 US67531303A US2004208760A1 US 20040208760 A1 US20040208760 A1 US 20040208760A1 US 67531303 A US67531303 A US 67531303A US 2004208760 A1 US2004208760 A1 US 2004208760A1
- Authority
- US
- United States
- Prior art keywords
- terminal block
- housing wall
- assembly
- housing
- aperture
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
- H02K5/225—Terminal boxes or connection arrangements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01C—ROTARY-PISTON OR OSCILLATING-PISTON MACHINES OR ENGINES
- F01C21/00—Component parts, details or accessories not provided for in groups F01C1/00 - F01C20/00
- F01C21/10—Outer members for co-operation with rotary pistons; Casings
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/12—Casings; Cylinders; Cylinder heads; Fluid connections
- F04B39/121—Casings
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C23/00—Combinations of two or more pumps, each being of rotary-piston or oscillating-piston type, specially adapted for elastic fluids; Pumping installations specially adapted for elastic fluids; Multi-stage pumps specially adapted for elastic fluids
- F04C23/008—Hermetic pumps
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C29/00—Component parts, details or accessories of pumps or pumping installations, not provided for in groups F04C18/00 - F04C28/00
- F04C29/0042—Driving elements, brakes, couplings, transmissions specially adapted for pumps
- F04C29/0085—Prime movers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C18/00—Rotary-piston pumps specially adapted for elastic fluids
- F04C18/30—Rotary-piston pumps specially adapted for elastic fluids having the characteristics covered by two or more of groups F04C18/02, F04C18/08, F04C18/22, F04C18/24, F04C18/48, or having the characteristics covered by one of these groups together with some other type of movement between co-operating members
- F04C18/34—Rotary-piston pumps specially adapted for elastic fluids having the characteristics covered by two or more of groups F04C18/02, F04C18/08, F04C18/22, F04C18/24, F04C18/48, or having the characteristics covered by one of these groups together with some other type of movement between co-operating members having the movement defined in group F04C18/08 or F04C18/22 and relative reciprocation between the co-operating members
- F04C18/356—Rotary-piston pumps specially adapted for elastic fluids having the characteristics covered by two or more of groups F04C18/02, F04C18/08, F04C18/22, F04C18/24, F04C18/48, or having the characteristics covered by one of these groups together with some other type of movement between co-operating members having the movement defined in group F04C18/08 or F04C18/22 and relative reciprocation between the co-operating members with vanes reciprocating with respect to the outer member
- F04C18/3562—Rotary-piston pumps specially adapted for elastic fluids having the characteristics covered by two or more of groups F04C18/02, F04C18/08, F04C18/22, F04C18/24, F04C18/48, or having the characteristics covered by one of these groups together with some other type of movement between co-operating members having the movement defined in group F04C18/08 or F04C18/22 and relative reciprocation between the co-operating members with vanes reciprocating with respect to the outer member the inner and outer member being in contact along one line or continuous surfaces substantially parallel to the axis of rotation
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2230/00—Manufacture
- F04C2230/20—Manufacture essentially without removing material
- F04C2230/23—Manufacture essentially without removing material by permanently joining parts together
- F04C2230/231—Manufacture essentially without removing material by permanently joining parts together by welding
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2230/00—Manufacture
- F04C2230/60—Assembly methods
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S417/00—Pumps
- Y10S417/902—Hermetically sealed motor pump unit
Definitions
- the present invention pertains to hermetically sealed compressors and, more particularly, for terminal block assemblies for such compressors.
- the compressor assembly will include a hermetically sealed housing containing a motor and a compression mechanism.
- the motor is typically connected to a power source via a terminal assembly that is mounted in the housing.
- Prior terminal assemblies generally, include a terminal body and a plurality of conductor pins.
- the terminal body is typically cup-shaped and is mounted within an aperture defined in the wall of the compressor housing.
- the terminal body has a plurality of holes each defined by a collar or annular lip.
- the conductor pins extend through and are secured within the holes by the annular lip and an insulating glass seal, which electrically insulates the pins from the terminal body.
- the interior ends of the conductor pins are connected to lead wires running to the stator, while the exterior ends of the conductor pins protrude from the terminal body and are connected to a source of electrical power.
- a fence is often provided to protect the exterior ends of the pins protruding from the terminal body.
- the fence typically comprises a wall that extends outwardly from the compressor housing and surrounds the terminal body and protruding pins.
- One end of the fence is often attached to, or integrally formed with, the terminal body.
- the free end of the fence is usually open and a plug or cap may fit into, or fasten onto, the free end to close the opening.
- terminal assemblies are assembled prior to mounting and welding the terminal body to the housing.
- the cup-shaped terminal body of prior terminal assemblies are often unable to withstand the high heat of welding or brazing. Consequently, the subsequent welding of the pre-assembled terminal assembly to the housing often results in damage to the terminal body, insulators and/or the conductive pins.
- the interior of compressors using carbon dioxide as a working fluid may reach substantially high temperatures and pressures.
- Prior terminal assemblies, particularly the mountings of the conductive pins within the holes of the terminal body are often unable to withstand the high pressures created in carbon dioxide compressors.
- the assembly of the fence and plug onto the terminal body is often complicated and adds additional parts and manufacturing time.
- prior compressors often required extensive machining of the housing and the housing aperture to achieve a tight fit between the terminal body and the aperture of the housing. Such extensive machining adds difficulty, time and expense to the assembly process.
- the present invention provides a hermetic compressor assembly that includes a terminal body that may be easily mounted on and hermetically sealed with the compressor housing without requiring the terminal body and an aperture in the housing to be manufactured using tight tolerances.
- the present invention comprises, in one form thereof, an assembly for use with a hermetic compressor that includes a hermetically sealed housing defining an interior space and including a housing wall with an interior surface and an exterior surface.
- the housing wall defines an aperture extending through the housing wall and in communication with the interior space.
- a motor and a compressor mechanism operably coupled with the motor are disposed within the interior space.
- a terminal block is mounted on the housing wall proximate the aperture and forms a hermetic seal with the exterior surface of the housing wall.
- the hermetic seal encircles the aperture and at least one terminal pin is mounted in the terminal block and extends through the aperture.
- the terminal block may include a mating surface that is flushly engaged with the exterior surface of the housing wall and that encircles the aperture wherein the exterior surface is cylindrical and the mating surface is a concave surface.
- the terminal block may be disposed entirely outwardly of the exterior surface of the housing wall or include a portion disposed within the aperture.
- the invention comprises, in another form thereof, a hermetic compressor assembly that includes a hermetically sealed housing defining an interior space and including a housing wall having an interior surface and an exterior surface.
- the housing wall defines an aperture in communication with the interior space.
- a motor, and a compressor mechanism operably coupled with said motor, are disposed within said interior space.
- a terminal block is positioned over the aperture and is welded to the exterior surface of the housing at a location spaced radially outwardly of the aperture with at least one terminal pin being mounted in the terminal block and extending through the aperture.
- the invention comprises, in yet another form thereof, a hermetic compressor assembly that includes a hermetically sealed housing defining an interior space and including a housing wall with an interior surface and an exterior surface.
- the housing wall defines an aperture that extends through the wall and is in communication with the interior space.
- a motor and a compressor mechanism operably coupled with the motor are disposed within the interior space.
- a terminal block is mounted on the housing covering the aperture and forming a hermetic seal with the housing wall.
- the terminal block defines an annular groove and at least one terminal pin extends through the terminal block and has an end projecting outwardly from the terminal block.
- the assembly also includes a cover having a plurality of radially inwardly projecting tabs engageable with the groove to thereby mount the cover to the terminal block with the cover substantially enclosing the outwardly projecting end of the at least one terminal pin.
- the cover may include a plurality of resilient mounting members extending therefrom with the tabs being disposed on respective distal ends of the plurality of resilient mounting members.
- the terminal block may also include a guide surface disposed between said annular groove and a distal end of said terminal block wherein the guide surface tapers radially inwardly as the guide surface projects from the latching surface to the distal end.
- a guide surface may have a frustroconical shape.
- the present invention comprises, in still another form thereof, a method of assembling a hermetic compressor.
- the method includes providing a housing having a housing wall with an interior surface and an exterior surface, forming an aperture in the housing wall, and installing at least one terminal pin in a terminal block.
- the method also involves mounting the terminal block on the housing wherein the terminal block covers the aperture and forming a hermetic seal between the terminal block and the exterior surface of the housing wall wherein said hermetic seal circumscribes the aperture.
- the steps of mounting the terminal block to the housing and forming the hermetic seal between the terminal block and the exterior surface of the housing wall may both comprise welding the terminal block to the exterior surface of the housing wall.
- the step of installing at least one terminal pin assembly in the terminal block may include threadingly engaging the terminal pin assembly with the terminal block and such step may occur either after or prior to mounting the terminal block on the housing.
- FIG. 1 is a first sectional view of a hermetic compressor according to the present invention
- FIG. 2 is a second sectional view of the hermetic compressor of FIG. 1;
- FIG. 3 is a top view of the compressor of FIG. 1;
- FIG. 4 is a sectional view of the compressor sub-assembly of FIG. 1;
- FIG. 5 is a top view of a two-piece separator plate according to one embodiment of the present invention.
- FIG. 5A is an interior side view of either piece of the separator plate of FIG. 5;
- FIG. 6 is a top view of a two-piece separator plate according to another embodiment of the present invention.
- FIG. 6A is an interior side view of a first piece of the separator plate of FIG. 6;
- FIG. 7 is a top perspective view of a crankcase according to the present invention.
- FIG. 8 is bottom perspective view of the crankcase of FIG. 7;
- FIG. 9 is a bottom view of the crankcase of FIG. 7;
- FIG. 10 is a sectional view taken along line 10 - 10 of FIG. 9;
- FIG. 11 is a top view of the crankcase of FIG. 7;
- FIG. 12 is an enlarged view of the encircled region of FIG. 9;
- FIG. 13 is an enlarged, fragmentary sectional view taken along line 13 - 13 of FIG. 12;
- FIG. 14 is a perspective view of a terminal block assembly according to the present invention.
- FIG. 15 is a side view of the terminal block assembly of FIG. 14;
- FIG. 16 is an exploded view of the terminal block assembly of FIG. 14 in relation with the housing of a hermetic compressor according to the present invention
- FIG. 17 is a front view of the terminal block assembly of FIG. 14;
- FIG. 18 is an enlarged sectional view of a pin assembly according to the present invention.
- FIG. 19 is an end view taken along line 19 - 19 of FIG. 18;
- FIG. 20 is a perspective view of a second embodiment terminal assembly and protective cover according to the present invention.
- FIG. 21 is a sectional view of the terminal assembly and protective cover of FIG. 20;
- FIG. 22 is a top view of the terminal assembly and protective cover of FIG. 20 installed on a compressor housing according to the present invention
- FIG. 23 is a sectional view taken along line 23 - 23 of FIG. 22;
- FIG. 24 is a plan view of the terminal block of the terminal assembly FIG. 20;
- FIG. 25 is a sectional view taken along line 25 - 25 of FIG. 24;
- FIG. 26 is a bottom view of the protective cover of FIG. 22.
- FIG. 27 is a sectional view taken along line 27 - 27 of FIG. 26.
- hermetic compressor 20 comprises housing 22 which includes upper housing 24 , lower housing 26 , and cylindrical main housing 28 . As better illustrated in FIG. 16, aperture 64 is defined in wall 62 of main housing 28 .
- housing portions 24 , 26 and 28 are formed of sheet steel having a thickness of between about 0.2 inches (0.508 cm) and 0.4 inches (1.02 cm). Housing portions 24 , 26 , and 28 are hermetically sealed by a method such as welding, brazing, or the like. Alternatively, either upper housing 24 or lower housing 26 may be integrally-formed with main housing 28 .
- motor 30 and compression mechanism 40 Disposed within housing 22 is motor 30 and compression mechanism 40 .
- Motor 30 includes rotor 36 , which is surrounded by stator 32 and fixed to crankshaft 38 .
- Stator 32 includes windings 34 , which are connected by lead wires (not shown) to a power source (not shown) via terminal assembly 60 .
- Stator 32 is secured at one end to legs 53 of crankcase or main bearing 46 and at the opposite end to lower outboard bearing 47 .
- Discharge muffler 51 is disposed between main bearing 46 and motor 30 .
- Compression mechanism 40 includes first cylinder 42 and second cylinder 44 , each having a cylindrical chamber 43 and 45 , respectively.
- First and second cylinders 42 , 44 are separated by separator plate 50 , which has a central bore 57 .
- Chamber 43 of first cylinder 42 receives gas, which may be, for example, carbon dioxide or any other suitable refrigerant, at substantially suction pressure, through intake tube 77 .
- Intermediate pressure muffler 49 is disposed on upper outboard bearing 48 and upper outboard bearing 48 is disposed adjacent first cylinder 42 .
- Upper outboard bearing 48 includes intermediate discharge tube 78 , which is in communication with chamber 43 of first cylinder 42 .
- Intermediate discharge tube 78 is also in communication with chamber 45 of second cylinder 44 through intermediate suction tube 79 (FIGS. 2 and 3).
- Intermediate discharge tube 78 and intermediate suction tube 79 are in fluid communication with each other externally of housing 22 , and may comprise a common conduit.
- Second cylinder 44 is disposed adjacent to main bearing 46 and chamber 45 is in communication with discharge muffler 51 through valve opening 98 in main bearing 46 (FIGS. 9, 12 and 13 ).
- valve opening 98 is equipped with a valve assembly 100 that includes resilient valve 102 sealing valve opening 98 and valve stop 104 .
- Valve assembly 100 is secured to main bearing 46 by fastener 106 .
- discharge tube 81 is in communication with discharge muffler 51 .
- Crankshaft 38 extends through chamber 45 , bore 57 , and chamber 43 , and includes two eccentric portions 37 , 39 mounted thereon which are disposed inside chambers 43 and 45 , respectively.
- Roller bearings 108 provide radial support to eccentric portions 37 , 39 and further seal any space between the wall of bore 57 and crankshaft 38 .
- Crankshaft 38 is radially supported at either end in lower outboard bearing 47 and upper outboard bearing 48 by needle roller bearings 110 , 112 , which prevent deflection of crankshaft 38 .
- compressor 20 receives suction pressure gas into first compression chamber 43 through tube 77 , where it is compressed to an intermediate pressure and discharged into intermediate pressure muffler 49 .
- the intermediate pressure gas is then discharged externally from compressor 22 through intermediate discharge tube 78 , which extends from outboard bearing 48 and through housing 22 .
- the intermediate pressure gas is then introduced into the motor compartment through intermediate pressure suction tube 79 , and is drawn into second compression chamber 45 and compressed to discharge pressure.
- the discharge pressure gas is discharged into discharge muffler 51 from second compression chamber through valve opening 98 in main bearing 46 .
- valve 102 when pressure reaches a certain pre-determined limit, the pressure of the discharge pressure gas forces valve 102 to deflect away from main bearing 46 , thereby exposing valve opening 98 to discharge muffler 51 .
- the deflection of valve 102 is limited by valve stop 104 .
- the discharge gas is then expelled from the compressor assembly through discharge tube 81 , which extends from main bearing 46 and through housing 22 .
- the displacement volume ratio of intermediate pressure gas to discharge pressure gas is approximately 1:10.
- separator plate 50 is a two-piece separator plate having a first piece 52 and a second, complementary piece 54 .
- each of first and second pieces 52 , 54 includes planar surface 58 having semi-circular central recess 59 .
- First and second pieces 52 , 54 may be paired by joining planar surfaces 58 and fastening first and second pieces using dowel 96 , the ends of which are received within dowel holes 95 .
- semi-circular recesses 59 form bore 57 , which is sized to closely surround crankshaft 38 at a location between the eccentrics.
- Two-piece separator plate 50 also includes bolt clearance holes 56 . The two-piece plate design allows the separator plate 50 to be fitted more closely around the portion of crankshaft 38 located between eccentrics 37 , 39 and sealably separate compression chambers 43 and 45 .
- separator plate 250 is a two-piece separator plate having a first piece 252 and a second, complementary piece 254 .
- each of first and second pieces 252 , 254 includes annular surface 260 and planar surface 258 having semi-circular central recess 259 .
- First and second pieces 252 , 254 may be paired by joining planar surfaces 258 and fastening first and second pieces 252 , 254 using dowel 296 , the ends of which are received within dowel holes 295 .
- first and second pieces 252 , 254 may be secured using fasteners 262 , which extend through clearance apertures 266 in second piece 254 and engage threaded apertures 268 defined in interior surface 258 of first piece 252 .
- Notches 264 may be defined in annular surface 260 of second piece 254 for receiving fasteners 262 and for housing the head of fasteners 262 within the diametric perimeter of annular surface 260 .
- Two-piece separator plate 250 also includes bolt clearance holes 256 .
- main bearing 46 is placed on a holding device with the upper side 33 facing up.
- Second cylinder 44 is then placed on the upper side 33 of main bearing 46 and crankshaft 38 is inserted into main bearing 46 and second cylinder 44 .
- Roller bearing 108 is mounted on crankshaft 38 within chamber 45 .
- First and second pieces 52 , 54 of separator plate 50 are then positioned on top of second cylinder 44 and paired such that semi-circular central recesses 59 closely capture the portion of crankshaft 38 located between eccentrics 37 , 39 .
- First and second pieces 52 , 54 are connected to one another using dowels 96 , the ends of which are inserted into holes 95 (FIG. 5).
- first and second pieces 252 , 254 of separator plate 250 may be positioned on top of second cylinder 44 and paired such that semi-circular central recesses 259 closely capture the portion of crankshaft 38 located between eccentrics 37 , 39 .
- First and second pieces 252 , 254 may then be connected to one another using dowels 296 and/or fasteners 262 .
- Roller bearing 108 is mounted on crankshaft 38 and first cylinder 42 is then positioned on separator plate 50 such that roller bearing is disposed within chamber 43 .
- Outboard bearing 48 and intermediate discharge muffler 49 are then positioned atop first cylinder 42 and five bolts (represented by dashed lines 154 in FIG. 1) are placed through clearance holes in intermediate discharge muffler 49 , outboard bearing 48 , first cylinder 42 , two-piece separator plate 50 , and second cylinder 44 , and engage threaded holes 41 (FIG. 7) in the upper side 33 of main bearing 46 .
- main bearing 46 is removed from the holding device and annular discharge muffler 51 is positioned on the underside 35 of main bearing 46 between legs 53 .
- Five bolts are then inserted through clearance holes in discharge muffler 51 and engage one end of threaded holes 41 at the underside 35 of main bearing 46 (FIG.
- Crankshaft 38 is then affixed to rotor 36 by heat-shrinking.
- Stator 32 is then placed over rotor 36 , and outboard bearing 47 is positioned over the end of stator 32 and rotor 36 .
- Four threaded bolts or like fasteners (not shown) are inserted into clearance holes (not shown) provided in outboard bearing 47 and stator 32 .
- Bolts are then threaded into four threaded holes 158 provided in the ends of legs 53 of main bearing 46 (FIG. 8).
- the resulting compressor sub-assembly 21 shown in FIG. 4, is then installed in housing 22 by, first, heat-expanding main housing 28 , and inserting compressor sub-assembly 21 into main-housing 28 (FIG. 1).
- Main housing 28 is then allowed to cool thereby shrink-fitting housing 28 onto sub-assembly 21 , such that sub-assembly 21 is in contact with the housing at the peripheries of main bearing 46 and outboard bearing 47 .
- the upper and lower housing portions are then welded to the main housing portion 28 to hermetically seal compressor 20 .
- Tubes 77 , 78 , 79 , and 81 are then inserted into openings (not shown) in housing 28 such that the inner portion of tubes 77 , 78 , 79 and 81 extend into openings (not shown) in first cylinder 42 , outboard bearing 48 , outboard bearing 47 and main bearing 46 , respectively.
- the openings in first cylinder 42 , outboard bearing 48 , outboard bearing 47 and main bearing 46 are provided with a seal, such as an o-ring, to sealingly receive tubes 77 , 78 , 79 and 81 .
- the outer portion of tubes 77 , 78 , 79 and 81 are then sealed to housing 38 by welding, brazing or the like.
- terminal assembly 60 generally includes machined metallic disk 66 and three pin assemblies 80 .
- Disk 66 includes three equally spaced-apart, threaded holes extending therethrough. Referring particularly to FIGS. 15 and 16, interior side 68 of disk 66 defines a first diameter portion 76 having diameter D 1 sized to snugly fit within aperture 64 in wall 62 of housing 22 . Disk 66 also includes a second diameter portion 74 adjacent first diameter portion 76 and having diameter D 2 , which is larger in diameter than both D 1 and aperture 64 . As shown in FIGS. 3 and 16, first diameter portion 76 of disk 66 fits into aperture 64 .
- Second diameter portion 74 abuts wall 62 , thereby restricting further movement of disk 66 into aperture 64 and providing a sealing region 71 between the surface of second diameter portion 74 and housing wall 62 .
- Disk 66 is hermetically sealed to the exterior surface of housing wall 62 at sealing region 71 located at the radially outer edge of larger diameter portion 74 of disk 66 by welding, brazing or other means that fully encircles aperture 64 .
- each pin assembly 80 includes an elongate conductive pin 82 , electrical insulator 88 disposed about pin 82 , annular collar 84 disposed about a portion of electrical insulator 88 , and tabs 90 positioned at both the interior end 92 and exterior end 94 of pin 82 .
- Electrical insulator 88 includes Teflon® sleeve 114 extending along a length of pin 82 at interior end 92 , sintered glass portions 116 , and a fused glass portion 118 .
- annular collar 84 includes hexagonal head portion 85 and shaft portion 87 , which includes threaded outer surface 86 .
- Each pin assembly 80 is received in a corresponding one of threaded holes 72 in disk 66 and is secured in hole 72 via a threaded engagement between threaded collar surface 86 and threaded surface of hole 72 . In this threaded engagement, pin assemblies 80 are more securely fixed in holes 72 , and therefore, are capable of withstanding the high pressures created in carbon dioxide compressors.
- the interior end 92 of pin 82 may be connected to lead wires (not shown) extending from stator windings 34 via a connector clip, cluster block or other electrical connecting means.
- the exterior end 94 of pin 82 is appropriately connected to a power source (not shown) to provide power to pin 82 and, ultimately, to stator 32 .
- Disk 66 is a metal casting, such as steel, that is capable of enduring the heat of welding and/or brazing, and is machined to final shape. Disk 66 is of substantial thickness, the overall thickness of disk 66 as measured between exterior side 70 and interior side 68 is, preferably, about one inch. However, thickness can vary, provided that disk 66 is thick enough to endure the heat of hermetic sealing and the pressures of carbon dioxide compression without damage or deformity to disk 66 or pin assemblies 80 . Second diameter portion 74 , particularly, should be of substantial thickness, preferably, about 0.300 inches. First diameter portion 76 should have sufficient thickness to securely fit into aperture 64 , preferably, about 0.200 inches.
- the terminal assembly withstands the heat of welding and the pressures created in a carbon dioxide compressor, and therefore, provides a more robust compressor assembly design.
- the terminal assembly is assembled by, first, mounting metallic disk 66 on housing 22 by inserting first diameter portion 76 into aperture 64 until second larger diameter portion 74 of metallic disk 66 engages outer wall 62 of housing 22 . Then second diameter portion 74 is hermetically sealed to housing outer wall 62 by welding, brazing or the like around the perimeter of second diameter portion 74 . Finally, terminal pin assemblies 80 are inserted into holes 72 and annular collars 84 are secured to hole 72 in a threaded engagement.
- terminal assembly 60 is assembled by, first, installing terminal pin assemblies 80 within holes 72 , as described above. With the pin assemblies 80 threadedly secured in holes 72 , metallic disk 66 is mounted in aperture 64 and second diameter portion 74 is hermetically sealed to outer wall 62 without causing damage to disk 66 or pin assemblies 80 .
- terminal block 160 is a solid, metallic cylindrical block having mating end 163 and distal or projecting end 165 .
- terminal block 160 also includes three equally-spaced, tapped and threaded holes 172 extending through terminal block 160 from mating end 163 to projecting end 165 . Holes 172 receive terminal pin assemblies 180 in a threaded-engagement as described above with respect to pin assemblies 80 .
- Terminal block 160 is a metal casting, e.g., steel, that is capable of enduring the heat of welding and brazing, and is machined to form the final shape.
- Terminal block 160 is of substantial thickness, the overall thickness of terminal block 160 as measured along the axis between mating end 163 and projecting end 165 is, preferably, between about 0.5 inches (1.27 cm) to about 1 inch (2.54 cm). However, the thickness can vary, provided that terminal block 160 is thick enough to endure the heat of hermetic sealing and the pressures of carbon dioxide compression without damage or deformity to terminal block 160 or pin assemblies 180 .
- mating end 163 has a concave mating surface 164 having a radius of curvature that corresponds to the curvature of exterior surface 161 of housing wall 162 , such that mating surface 164 of terminal block 160 lies flush against housing wall 162 .
- Housing wall 162 may be substantially identical to housing wall 62 described above and has an exterior surface 161 facing outwardly and an interior surface 159 that faces the hermetically sealed interior space 193 defined by the housing and containing the motor/compressor subassembly 21 .
- FIGS. 20-27 show the housing wall as having a substantially cylindrical shape, it should be understood that housing wall 162 may have alternative shapes.
- mating surface 164 can take other shapes to engage such alternatively shaped housings. Furthermore, the entirety of mating surface 164 need not be shaped to conform to the housing. Instead, mating surface 164 may be formed such that only an outer perimeter portion of mating surface 164 is shaped to conform to the housing and contacts exterior surface 161 of housing wall 162 to sealingly encircle aperture 164 .
- Terminal block 160 is mounted on the exterior surface of housing wall 162 such that terminal block 160 is disposed entirely outside of exterior surface 161 of housing wall 162 , as shown in FIG. 23.
- Terminal block 160 is hermetically sealed to exterior surface 161 of housing wall 162 by welding, brazing or the like around the perimeter of mating end 163 . Because the hermetic seal between terminal block 160 and housing wall 162 is spaced radially outwardly of aperture 164 and not formed with the sidewalls of aperture 164 , terminal block 160 and aperture 164 do not have to form a tight fit and, when manufacturing the housing, aperture 164 may be located and formed using relatively loose tolerances.
- terminal block 160 may also include annular groove 166 , which is defined in perimetrical surface 167 of terminal block 160 and extends about the perimeter or circumference of terminal block 160 .
- Perimetrical surface 167 may include frustoconical guide surface 168 adjacent groove 166 .
- Guide surface 168 tapers inwardly moving from groove 166 to projecting end 165 .
- guide surface 168 slopes from a first diameter D 3 at projecting end 165 to a larger second diameter D 4 adjacent groove 166 .
- Both annular groove 166 and tapered guide surface 164 cooperate to receive a snap-fit protective cover, such as cover 190 illustrated in FIGS. 20, 21, 26 and 27 .
- Cylindrical cover 190 may be formed of a plastic such as polyurethane or other suitable material, and includes six, equally spaced-apart, resilient mounting members or legs 192 .
- Each leg 192 includes a radially inwardly projecting tab or lip 194 that is shaped and sized to fit within annular groove 166 .
- resilient legs 192 are urged along tapered guide surface 164 , causing resilient legs 192 to flex outward.
- resilient legs 192 spring inwards, snapping lip 194 into groove 164 , thereby locking cover 190 onto terminal block 160 .
- the more distal edge surface of groove 166 forms latching surface 195 that engages lips 194 and prevents cover 190 from being removed from the terminal body without prying lips 194 radially outwardly to disengage lips 194 from groove 166 .
- cover 190 When attached, cover 190 encloses the outwardly projecting ends 181 of the terminal pins. Cover 190 also includes a D-shaped hole 196 through which a wire assembly leading from the power source can extend. Cover 190 protects the terminal assembly from damage during operation and is relatively easy to install. Although cover 190 and terminal block 160 illustrated in FIGS. 20-27 both have a circular cross section where they are engaged, it should be understood that terminal block 160 and cover 190 can be any suitable shape, such as a generally rectangular shape.
- terminal block 160 shown in FIGS. 20-25 withstands both the heat of welding and the pressures created in a carbon dioxide compressor. Consequently, terminal block 160 provides a robust compressor assembly design.
- pin assemblies 180 are mounted in holes 172 prior to mounting of the terminal block to housing wall 162 , however, if desired, it would also be possible to mount pin assemblies 180 in holes 172 after securing terminal block 160 on housing wall 162 .
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Abstract
Description
- The present invention is a continuation-in part of pending patent application Ser. No. 10/414,332, filed Apr. 15, 2003 in the name of Zer Kai Yap and entitled “Terminal Block Assembly For A Hermetic Compressor.”
- 1. Field of the Invention
- The present invention pertains to hermetically sealed compressors and, more particularly, for terminal block assemblies for such compressors.
- 2. Description of the Related Art
- Various types of compressors are known, including reciprocating piston, rotary vane and scroll type compressors. Oftentimes, the compressor assembly will include a hermetically sealed housing containing a motor and a compression mechanism. The motor is typically connected to a power source via a terminal assembly that is mounted in the housing.
- Prior terminal assemblies, generally, include a terminal body and a plurality of conductor pins. The terminal body is typically cup-shaped and is mounted within an aperture defined in the wall of the compressor housing. The terminal body has a plurality of holes each defined by a collar or annular lip. The conductor pins extend through and are secured within the holes by the annular lip and an insulating glass seal, which electrically insulates the pins from the terminal body. The interior ends of the conductor pins are connected to lead wires running to the stator, while the exterior ends of the conductor pins protrude from the terminal body and are connected to a source of electrical power.
- A fence is often provided to protect the exterior ends of the pins protruding from the terminal body. The fence typically comprises a wall that extends outwardly from the compressor housing and surrounds the terminal body and protruding pins. One end of the fence is often attached to, or integrally formed with, the terminal body. The free end of the fence is usually open and a plug or cap may fit into, or fasten onto, the free end to close the opening.
- In order to prevent refrigerant leakage and accommodate the high pressures within the compressor, parts of the compressor are machined to extremely close tolerances and the compressor housing is hermetically sealed. In the case of the terminal assembly, the terminal body of the assembly is tightly fitted within an aperture of the compressor housing and is then sealed to the wall of the housing at the tightly fitting interface of the terminal body and the sidewalls of the aperture, typically by welding, brazing or the like. The terminal pins are installed in the holes of the terminal body and the fence is attached to the terminal body.
- Ideally, terminal assemblies are assembled prior to mounting and welding the terminal body to the housing. However, the cup-shaped terminal body of prior terminal assemblies are often unable to withstand the high heat of welding or brazing. Consequently, the subsequent welding of the pre-assembled terminal assembly to the housing often results in damage to the terminal body, insulators and/or the conductive pins. In addition, the interior of compressors using carbon dioxide as a working fluid may reach substantially high temperatures and pressures. Prior terminal assemblies, particularly the mountings of the conductive pins within the holes of the terminal body, are often unable to withstand the high pressures created in carbon dioxide compressors. Furthermore, the assembly of the fence and plug onto the terminal body is often complicated and adds additional parts and manufacturing time. In addition, prior compressors often required extensive machining of the housing and the housing aperture to achieve a tight fit between the terminal body and the aperture of the housing. Such extensive machining adds difficulty, time and expense to the assembly process.
- Therefore, a need remains for a terminal assembly that is relatively simple to assemble, can better endure the welding process by which the terminal assembly is fixed to the compressor housing, and is better able to withstand the higher pressures and temperatures experienced in a hermetic compressor using carbon dioxide as the refrigerant.
- The present invention provides a hermetic compressor assembly that includes a terminal body that may be easily mounted on and hermetically sealed with the compressor housing without requiring the terminal body and an aperture in the housing to be manufactured using tight tolerances.
- The present invention comprises, in one form thereof, an assembly for use with a hermetic compressor that includes a hermetically sealed housing defining an interior space and including a housing wall with an interior surface and an exterior surface. The housing wall defines an aperture extending through the housing wall and in communication with the interior space. A motor and a compressor mechanism operably coupled with the motor are disposed within the interior space. A terminal block is mounted on the housing wall proximate the aperture and forms a hermetic seal with the exterior surface of the housing wall. The hermetic seal encircles the aperture and at least one terminal pin is mounted in the terminal block and extends through the aperture.
- The terminal block may include a mating surface that is flushly engaged with the exterior surface of the housing wall and that encircles the aperture wherein the exterior surface is cylindrical and the mating surface is a concave surface. The terminal block may be disposed entirely outwardly of the exterior surface of the housing wall or include a portion disposed within the aperture.
- The invention comprises, in another form thereof, a hermetic compressor assembly that includes a hermetically sealed housing defining an interior space and including a housing wall having an interior surface and an exterior surface. The housing wall defines an aperture in communication with the interior space. A motor, and a compressor mechanism operably coupled with said motor, are disposed within said interior space. A terminal block is positioned over the aperture and is welded to the exterior surface of the housing at a location spaced radially outwardly of the aperture with at least one terminal pin being mounted in the terminal block and extending through the aperture.
- The invention comprises, in yet another form thereof, a hermetic compressor assembly that includes a hermetically sealed housing defining an interior space and including a housing wall with an interior surface and an exterior surface. The housing wall defines an aperture that extends through the wall and is in communication with the interior space. A motor and a compressor mechanism operably coupled with the motor are disposed within the interior space. A terminal block is mounted on the housing covering the aperture and forming a hermetic seal with the housing wall. The terminal block defines an annular groove and at least one terminal pin extends through the terminal block and has an end projecting outwardly from the terminal block. The assembly also includes a cover having a plurality of radially inwardly projecting tabs engageable with the groove to thereby mount the cover to the terminal block with the cover substantially enclosing the outwardly projecting end of the at least one terminal pin.
- The cover may include a plurality of resilient mounting members extending therefrom with the tabs being disposed on respective distal ends of the plurality of resilient mounting members. The terminal block may also include a guide surface disposed between said annular groove and a distal end of said terminal block wherein the guide surface tapers radially inwardly as the guide surface projects from the latching surface to the distal end. Such a guide surface may have a frustroconical shape.
- The present invention comprises, in still another form thereof, a method of assembling a hermetic compressor. The method includes providing a housing having a housing wall with an interior surface and an exterior surface, forming an aperture in the housing wall, and installing at least one terminal pin in a terminal block. The method also involves mounting the terminal block on the housing wherein the terminal block covers the aperture and forming a hermetic seal between the terminal block and the exterior surface of the housing wall wherein said hermetic seal circumscribes the aperture.
- The steps of mounting the terminal block to the housing and forming the hermetic seal between the terminal block and the exterior surface of the housing wall may both comprise welding the terminal block to the exterior surface of the housing wall. The step of installing at least one terminal pin assembly in the terminal block may include threadingly engaging the terminal pin assembly with the terminal block and such step may occur either after or prior to mounting the terminal block on the housing.
- The above-mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
- FIG. 1 is a first sectional view of a hermetic compressor according to the present invention;
- FIG. 2 is a second sectional view of the hermetic compressor of FIG. 1;
- FIG. 3 is a top view of the compressor of FIG. 1;
- FIG. 4 is a sectional view of the compressor sub-assembly of FIG. 1;
- FIG. 5 is a top view of a two-piece separator plate according to one embodiment of the present invention;
- FIG. 5A is an interior side view of either piece of the separator plate of FIG. 5;
- FIG. 6 is a top view of a two-piece separator plate according to another embodiment of the present invention;
- FIG. 6A is an interior side view of a first piece of the separator plate of FIG. 6;
- FIG. 7 is a top perspective view of a crankcase according to the present invention;
- FIG. 8 is bottom perspective view of the crankcase of FIG. 7;
- FIG. 9 is a bottom view of the crankcase of FIG. 7;
- FIG. 10 is a sectional view taken along line10-10 of FIG. 9;
- FIG. 11 is a top view of the crankcase of FIG. 7;
- FIG. 12 is an enlarged view of the encircled region of FIG. 9;
- FIG. 13 is an enlarged, fragmentary sectional view taken along line13-13 of FIG. 12;
- FIG. 14 is a perspective view of a terminal block assembly according to the present invention;
- FIG. 15 is a side view of the terminal block assembly of FIG. 14;
- FIG. 16 is an exploded view of the terminal block assembly of FIG. 14 in relation with the housing of a hermetic compressor according to the present invention;
- FIG. 17 is a front view of the terminal block assembly of FIG. 14;
- FIG. 18 is an enlarged sectional view of a pin assembly according to the present invention;
- FIG. 19 is an end view taken along line19-19 of FIG. 18;
- FIG. 20 is a perspective view of a second embodiment terminal assembly and protective cover according to the present invention;
- FIG. 21 is a sectional view of the terminal assembly and protective cover of FIG. 20;
- FIG. 22 is a top view of the terminal assembly and protective cover of FIG. 20 installed on a compressor housing according to the present invention;
- FIG. 23 is a sectional view taken along line23-23 of FIG. 22;
- FIG. 24 is a plan view of the terminal block of the terminal assembly FIG. 20;
- FIG. 25 is a sectional view taken along line25-25 of FIG. 24;
- FIG. 26 is a bottom view of the protective cover of FIG. 22; and
- FIG. 27 is a sectional view taken along line27-27 of FIG. 26.
- The embodiments disclosed herein are not intended to be exhaustive or limit the invention to the precise forms disclosed in the following description. Rather the embodiments are chosen and described so that others skilled in the art may utilize its teachings.
- Referring to FIG. 1,
hermetic compressor 20 compriseshousing 22 which includesupper housing 24,lower housing 26, and cylindricalmain housing 28. As better illustrated in FIG. 16,aperture 64 is defined inwall 62 ofmain housing 28. Returning now to FIG. 1,housing portions Housing portions upper housing 24 orlower housing 26 may be integrally-formed withmain housing 28. Disposed withinhousing 22 ismotor 30 andcompression mechanism 40.Motor 30 includesrotor 36, which is surrounded bystator 32 and fixed tocrankshaft 38.Stator 32 includeswindings 34, which are connected by lead wires (not shown) to a power source (not shown) viaterminal assembly 60.Stator 32 is secured at one end tolegs 53 of crankcase ormain bearing 46 and at the opposite end to loweroutboard bearing 47.Discharge muffler 51 is disposed betweenmain bearing 46 andmotor 30. -
Compression mechanism 40 includesfirst cylinder 42 andsecond cylinder 44, each having acylindrical chamber second cylinders separator plate 50, which has acentral bore 57.Chamber 43 offirst cylinder 42 receives gas, which may be, for example, carbon dioxide or any other suitable refrigerant, at substantially suction pressure, throughintake tube 77.Intermediate pressure muffler 49 is disposed on upperoutboard bearing 48 and upperoutboard bearing 48 is disposed adjacentfirst cylinder 42. Upperoutboard bearing 48 includesintermediate discharge tube 78, which is in communication withchamber 43 offirst cylinder 42.Intermediate discharge tube 78 is also in communication withchamber 45 ofsecond cylinder 44 through intermediate suction tube 79 (FIGS. 2 and 3).Intermediate discharge tube 78 andintermediate suction tube 79 are in fluid communication with each other externally ofhousing 22, and may comprise a common conduit. -
Second cylinder 44 is disposed adjacent tomain bearing 46 andchamber 45 is in communication withdischarge muffler 51 through valve opening 98 in main bearing 46 (FIGS. 9, 12 and 13). Referring to FIGS. 9, 12 and 13,valve opening 98 is equipped with avalve assembly 100 that includesresilient valve 102 sealingvalve opening 98 andvalve stop 104.Valve assembly 100 is secured tomain bearing 46 by fastener 106. Referring back to FIGS. 1-3,discharge tube 81 is in communication withdischarge muffler 51.Crankshaft 38 extends throughchamber 45, bore 57, andchamber 43, and includes twoeccentric portions chambers Roller bearings 108 provide radial support toeccentric portions bore 57 andcrankshaft 38.Crankshaft 38 is radially supported at either end in loweroutboard bearing 47 and upperoutboard bearing 48 byneedle roller bearings crankshaft 38. - Turning now to FIGS. 1-3, in operation,
compressor 20 receives suction pressure gas intofirst compression chamber 43 throughtube 77, where it is compressed to an intermediate pressure and discharged intointermediate pressure muffler 49. The intermediate pressure gas is then discharged externally fromcompressor 22 throughintermediate discharge tube 78, which extends fromoutboard bearing 48 and throughhousing 22. The intermediate pressure gas is then introduced into the motor compartment through intermediatepressure suction tube 79, and is drawn intosecond compression chamber 45 and compressed to discharge pressure. Referring now to FIGS. 1-3 and 13, the discharge pressure gas is discharged intodischarge muffler 51 from second compression chamber through valve opening 98 inmain bearing 46. More specifically, when pressure reaches a certain pre-determined limit, the pressure of the discharge pressuregas forces valve 102 to deflect away frommain bearing 46, thereby exposingvalve opening 98 to dischargemuffler 51. The deflection ofvalve 102 is limited byvalve stop 104. The discharge gas is then expelled from the compressor assembly throughdischarge tube 81, which extends frommain bearing 46 and throughhousing 22. The displacement volume ratio of intermediate pressure gas to discharge pressure gas is approximately 1:10. - According to one embodiment of the present invention shown in FIG. 5,
separator plate 50 is a two-piece separator plate having afirst piece 52 and a second,complementary piece 54. As illustrated in FIGS. 5 and 5A, each of first andsecond pieces planar surface 58 having semi-circularcentral recess 59. First andsecond pieces planar surfaces 58 and fastening first and second pieces using dowel 96, the ends of which are received within dowel holes 95. When first andsecond pieces semi-circular recesses 59 form bore 57, which is sized to closely surroundcrankshaft 38 at a location between the eccentrics. Two-piece separator plate 50 also includes bolt clearance holes 56. The two-piece plate design allows theseparator plate 50 to be fitted more closely around the portion ofcrankshaft 38 located betweeneccentrics separate compression chambers - According to another embodiment of the present invention shown in FIG. 6,
separator plate 250 is a two-piece separator plate having afirst piece 252 and a second,complementary piece 254. As illustrated in FIGS. 6 and 6A, each of first andsecond pieces annular surface 260 andplanar surface 258 having semi-circularcentral recess 259. First andsecond pieces planar surfaces 258 and fastening first andsecond pieces dowel 296, the ends of which are received within dowel holes 295. Alternatively, or additionally, first andsecond pieces fasteners 262, which extend throughclearance apertures 266 insecond piece 254 and engage threadedapertures 268 defined ininterior surface 258 offirst piece 252.Notches 264 may be defined inannular surface 260 ofsecond piece 254 for receivingfasteners 262 and for housing the head offasteners 262 within the diametric perimeter ofannular surface 260. Two-piece separator plate 250 also includes bolt clearance holes 256. - In assembling
compressor 20 according to the present invention,main bearing 46 is placed on a holding device with theupper side 33 facing up.Second cylinder 44 is then placed on theupper side 33 ofmain bearing 46 andcrankshaft 38 is inserted intomain bearing 46 andsecond cylinder 44.Roller bearing 108 is mounted oncrankshaft 38 withinchamber 45. First andsecond pieces separator plate 50 are then positioned on top ofsecond cylinder 44 and paired such that semi-circularcentral recesses 59 closely capture the portion ofcrankshaft 38 located betweeneccentrics second pieces second pieces separator plate 250 may be positioned on top ofsecond cylinder 44 and paired such that semi-circularcentral recesses 259 closely capture the portion ofcrankshaft 38 located betweeneccentrics second pieces dowels 296 and/orfasteners 262.Roller bearing 108 is mounted oncrankshaft 38 andfirst cylinder 42 is then positioned onseparator plate 50 such that roller bearing is disposed withinchamber 43. - Outboard bearing48 and
intermediate discharge muffler 49 are then positioned atopfirst cylinder 42 and five bolts (represented by dashedlines 154 in FIG. 1) are placed through clearance holes inintermediate discharge muffler 49,outboard bearing 48,first cylinder 42, two-piece separator plate 50, andsecond cylinder 44, and engage threaded holes 41 (FIG. 7) in theupper side 33 ofmain bearing 46. Next,main bearing 46 is removed from the holding device andannular discharge muffler 51 is positioned on the underside 35 ofmain bearing 46 betweenlegs 53. Five bolts are then inserted through clearance holes indischarge muffler 51 and engage one end of threadedholes 41 at the underside 35 of main bearing 46 (FIG. 8) to securedischarge muffler 51 tomain bearing 46. Alternatively, the fivebolts 154 extending throughintermediate discharge muffler 49,outboard bearing 48,first cylinder 42, two-piece separator plate 50,second cylinder 44, and holes 41 can be lengthened to further extend completely throughholes 41 anddischarge muffler 51 and can be secured with nuts. -
Crankshaft 38 is then affixed torotor 36 by heat-shrinking.Stator 32 is then placed overrotor 36, andoutboard bearing 47 is positioned over the end ofstator 32 androtor 36. Four threaded bolts or like fasteners (not shown) are inserted into clearance holes (not shown) provided inoutboard bearing 47 andstator 32. Bolts are then threaded into four threadedholes 158 provided in the ends oflegs 53 of main bearing 46 (FIG. 8). - The resulting compressor sub-assembly21, shown in FIG. 4, is then installed in
housing 22 by, first, heat-expandingmain housing 28, and inserting compressor sub-assembly 21 into main-housing 28 (FIG. 1).Main housing 28 is then allowed to cool thereby shrink-fittinghousing 28 onto sub-assembly 21, such that sub-assembly 21 is in contact with the housing at the peripheries ofmain bearing 46 andoutboard bearing 47. The upper and lower housing portions are then welded to themain housing portion 28 to hermetically sealcompressor 20.Tubes housing 28 such that the inner portion oftubes first cylinder 42,outboard bearing 48,outboard bearing 47 andmain bearing 46, respectively. The openings infirst cylinder 42,outboard bearing 48,outboard bearing 47 andmain bearing 46 are provided with a seal, such as an o-ring, to sealingly receivetubes tubes housing 38 by welding, brazing or the like. - With reference to FIGS. 14-19, according to one embodiment of the present invention,
terminal assembly 60 generally includes machinedmetallic disk 66 and threepin assemblies 80.Disk 66 includes three equally spaced-apart, threaded holes extending therethrough. Referring particularly to FIGS. 15 and 16,interior side 68 ofdisk 66 defines afirst diameter portion 76 having diameter D1 sized to snugly fit withinaperture 64 inwall 62 ofhousing 22.Disk 66 also includes asecond diameter portion 74 adjacentfirst diameter portion 76 and having diameter D2, which is larger in diameter than both D1 andaperture 64. As shown in FIGS. 3 and 16,first diameter portion 76 ofdisk 66 fits intoaperture 64.Second diameter portion 74 abutswall 62, thereby restricting further movement ofdisk 66 intoaperture 64 and providing a sealingregion 71 between the surface ofsecond diameter portion 74 andhousing wall 62.Disk 66 is hermetically sealed to the exterior surface ofhousing wall 62 at sealingregion 71 located at the radially outer edge oflarger diameter portion 74 ofdisk 66 by welding, brazing or other means that fully encirclesaperture 64. - Turning now to FIGS. 18 and 19, each
pin assembly 80 includes an elongateconductive pin 82,electrical insulator 88 disposed aboutpin 82,annular collar 84 disposed about a portion ofelectrical insulator 88, andtabs 90 positioned at both theinterior end 92 andexterior end 94 ofpin 82.Electrical insulator 88 includesTeflon® sleeve 114 extending along a length ofpin 82 atinterior end 92, sinteredglass portions 116, and a fusedglass portion 118. Between fusedglass portion 118 and one of the sinteredglass portions 116 is freon-proof epoxy resin 120, and parts of both fusedglass portion 118 and sinteredglass portion 116 are disposed betweenpin 81 andannular collar 84.Annular collar 84 includes hexagonal head portion 85 andshaft portion 87, which includes threadedouter surface 86. Eachpin assembly 80 is received in a corresponding one of threadedholes 72 indisk 66 and is secured inhole 72 via a threaded engagement between threadedcollar surface 86 and threaded surface ofhole 72. In this threaded engagement,pin assemblies 80 are more securely fixed inholes 72, and therefore, are capable of withstanding the high pressures created in carbon dioxide compressors. - As is typical in the art, the
interior end 92 ofpin 82 may be connected to lead wires (not shown) extending fromstator windings 34 via a connector clip, cluster block or other electrical connecting means. Theexterior end 94 ofpin 82 is appropriately connected to a power source (not shown) to provide power to pin 82 and, ultimately, tostator 32. -
Disk 66 is a metal casting, such as steel, that is capable of enduring the heat of welding and/or brazing, and is machined to final shape.Disk 66 is of substantial thickness, the overall thickness ofdisk 66 as measured betweenexterior side 70 andinterior side 68 is, preferably, about one inch. However, thickness can vary, provided thatdisk 66 is thick enough to endure the heat of hermetic sealing and the pressures of carbon dioxide compression without damage or deformity todisk 66 orpin assemblies 80.Second diameter portion 74, particularly, should be of substantial thickness, preferably, about 0.300 inches.First diameter portion 76 should have sufficient thickness to securely fit intoaperture 64, preferably, about 0.200 inches. - This terminal assembly withstands the heat of welding and the pressures created in a carbon dioxide compressor, and therefore, provides a more robust compressor assembly design. In one embodiment of the present invention, the terminal assembly is assembled by, first, mounting
metallic disk 66 onhousing 22 by insertingfirst diameter portion 76 intoaperture 64 until secondlarger diameter portion 74 ofmetallic disk 66 engagesouter wall 62 ofhousing 22. Thensecond diameter portion 74 is hermetically sealed to housingouter wall 62 by welding, brazing or the like around the perimeter ofsecond diameter portion 74. Finally,terminal pin assemblies 80 are inserted intoholes 72 andannular collars 84 are secured to hole 72 in a threaded engagement. - Alternatively, the terminal assembly can be assembled prior to
welding disk 66 to wall 62 ofhousing 22. In this case,terminal assembly 60 is assembled by, first, installingterminal pin assemblies 80 withinholes 72, as described above. With thepin assemblies 80 threadedly secured inholes 72,metallic disk 66 is mounted inaperture 64 andsecond diameter portion 74 is hermetically sealed toouter wall 62 without causing damage todisk 66 orpin assemblies 80. - According to another embodiment of the present invention exemplified in FIGS. 20-27,
terminal block 160 is a solid, metallic cylindrical block having mating end 163 and distal or projectingend 165. As can be seen in FIGS. 21 and 24,terminal block 160 also includes three equally-spaced, tapped and threadedholes 172 extending throughterminal block 160 frommating end 163 to projectingend 165.Holes 172 receiveterminal pin assemblies 180 in a threaded-engagement as described above with respect to pinassemblies 80.Terminal block 160 is a metal casting, e.g., steel, that is capable of enduring the heat of welding and brazing, and is machined to form the final shape.Terminal block 160 is of substantial thickness, the overall thickness ofterminal block 160 as measured along the axis betweenmating end 163 and projectingend 165 is, preferably, between about 0.5 inches (1.27 cm) to about 1 inch (2.54 cm). However, the thickness can vary, provided thatterminal block 160 is thick enough to endure the heat of hermetic sealing and the pressures of carbon dioxide compression without damage or deformity toterminal block 160 orpin assemblies 180. - Referring now to FIGS. 22, 23 and25,
mating end 163 has aconcave mating surface 164 having a radius of curvature that corresponds to the curvature ofexterior surface 161 ofhousing wall 162, such thatmating surface 164 ofterminal block 160 lies flush againsthousing wall 162.Housing wall 162 may be substantially identical tohousing wall 62 described above and has anexterior surface 161 facing outwardly and aninterior surface 159 that faces the hermetically sealedinterior space 193 defined by the housing and containing the motor/compressor subassembly 21. Although FIGS. 20-27 show the housing wall as having a substantially cylindrical shape, it should be understood thathousing wall 162 may have alternative shapes. Accordingly,mating surface 164 can take other shapes to engage such alternatively shaped housings. Furthermore, the entirety ofmating surface 164 need not be shaped to conform to the housing. Instead,mating surface 164 may be formed such that only an outer perimeter portion ofmating surface 164 is shaped to conform to the housing and contactsexterior surface 161 ofhousing wall 162 tosealingly encircle aperture 164. -
Terminal block 160 is mounted on the exterior surface ofhousing wall 162 such thatterminal block 160 is disposed entirely outside ofexterior surface 161 ofhousing wall 162, as shown in FIG. 23.Terminal block 160 is hermetically sealed toexterior surface 161 ofhousing wall 162 by welding, brazing or the like around the perimeter ofmating end 163. Because the hermetic seal betweenterminal block 160 andhousing wall 162 is spaced radially outwardly ofaperture 164 and not formed with the sidewalls ofaperture 164,terminal block 160 andaperture 164 do not have to form a tight fit and, when manufacturing the housing,aperture 164 may be located and formed using relatively loose tolerances. - As illustrated in FIG. 25,
terminal block 160 may also include annular groove 166, which is defined inperimetrical surface 167 ofterminal block 160 and extends about the perimeter or circumference ofterminal block 160.Perimetrical surface 167 may includefrustoconical guide surface 168 adjacent groove 166.Guide surface 168 tapers inwardly moving from groove 166 to projectingend 165. In other words, guidesurface 168 slopes from a first diameter D3 at projectingend 165 to a larger second diameter D4 adjacent groove 166. Both annular groove 166 and taperedguide surface 164 cooperate to receive a snap-fit protective cover, such ascover 190 illustrated in FIGS. 20, 21, 26 and 27. -
Cylindrical cover 190 may be formed of a plastic such as polyurethane or other suitable material, and includes six, equally spaced-apart, resilient mounting members orlegs 192. Eachleg 192 includes a radially inwardly projecting tab orlip 194 that is shaped and sized to fit within annular groove 166. To installcover 190 onterminal block 160,resilient legs 192 are urged along taperedguide surface 164, causingresilient legs 192 to flex outward. Whenlip 194 reachesgroove 164,resilient legs 192 spring inwards, snappinglip 194 intogroove 164, thereby lockingcover 190 ontoterminal block 160. The more distal edge surface of groove 166forms latching surface 195 that engageslips 194 and prevents cover 190 from being removed from the terminal body without pryinglips 194 radially outwardly to disengagelips 194 from groove 166. - When attached,
cover 190 encloses the outwardly projecting ends 181 of the terminal pins. Cover 190 also includes a D-shapedhole 196 through which a wire assembly leading from the power source can extend. Cover 190 protects the terminal assembly from damage during operation and is relatively easy to install. Althoughcover 190 andterminal block 160 illustrated in FIGS. 20-27 both have a circular cross section where they are engaged, it should be understood thatterminal block 160 and cover 190 can be any suitable shape, such as a generally rectangular shape. - Similar to
metallic disk 66 shown in FIGS. 14-19,terminal block 160 shown in FIGS. 20-25 withstands both the heat of welding and the pressures created in a carbon dioxide compressor. Consequently,terminal block 160 provides a robust compressor assembly design. In the illustrated embodiments,pin assemblies 180 are mounted inholes 172 prior to mounting of the terminal block tohousing wall 162, however, if desired, it would also be possible to mountpin assemblies 180 inholes 172 after securingterminal block 160 onhousing wall 162. - While this invention has been described as having an exemplary design, the present invention may be further modified within the scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.
Claims (28)
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US10/675,313 US20040208760A1 (en) | 2003-04-15 | 2003-09-30 | Terminal block assembly for a hermetic compressor |
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US10/414,332 US7108489B2 (en) | 2003-04-15 | 2003-04-15 | Terminal block assembly for a hermetic compressor |
US10/675,313 US20040208760A1 (en) | 2003-04-15 | 2003-09-30 | Terminal block assembly for a hermetic compressor |
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US10/675,313 Abandoned US20040208760A1 (en) | 2003-04-15 | 2003-09-30 | Terminal block assembly for a hermetic compressor |
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WO2016155781A1 (en) * | 2015-03-31 | 2016-10-06 | Arcelik Anonim Sirketi | Terminal assembly for use in a hermetic compressor |
US20180298914A1 (en) * | 2015-04-28 | 2018-10-18 | Denso Corporation | Blower |
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ITBO20120682A1 (en) * | 2012-12-18 | 2014-06-19 | Spal Automotive Srl | ELECTRIC MACHINE |
WO2014097109A1 (en) * | 2012-12-18 | 2014-06-26 | Spal Automotive S.R.L. | Electrical machine. |
US9997971B2 (en) | 2012-12-18 | 2018-06-12 | Spal Automotive S.R.L. | Electrical machine |
WO2016155781A1 (en) * | 2015-03-31 | 2016-10-06 | Arcelik Anonim Sirketi | Terminal assembly for use in a hermetic compressor |
US20180298914A1 (en) * | 2015-04-28 | 2018-10-18 | Denso Corporation | Blower |
CN109723641A (en) * | 2019-03-01 | 2019-05-07 | 珠海格力节能环保制冷技术研究中心有限公司 | Air conditioner and compressor |
US11953008B2 (en) | 2019-03-01 | 2024-04-09 | Gree Green Refrigeration Technology Center Co., Ltd. Of Zhuhai | Air conditioner and compressor |
CN111396312A (en) * | 2020-03-11 | 2020-07-10 | 东南大学 | Synchronous rotary compressor adopting external drive |
Also Published As
Publication number | Publication date |
---|---|
US20040208762A1 (en) | 2004-10-21 |
CA2464230C (en) | 2008-05-13 |
CA2464230A1 (en) | 2004-10-15 |
US7108489B2 (en) | 2006-09-19 |
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