Compressor
09608490 ยท 2017-03-28
Assignee
Inventors
Cpc classification
F04C2240/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C29/0057
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K3/38
ELECTRICITY
F04C2210/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C29/0085
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K3/325
ELECTRICITY
F04C2240/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C2230/231
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K7/14
ELECTRICITY
F04C18/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K2203/06
ELECTRICITY
International classification
H02K3/50
ELECTRICITY
H02K7/14
ELECTRICITY
H02K3/34
ELECTRICITY
F04C18/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C29/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A compressor includes a casing, a compression mechanism arranged inside the casing, a motor arranged inside the casing, and an insulation sheet. The motor drives the compression mechanism. The motor is a concentrated-winding motor having a stator that has a plurality of teeth, and an insulator adjacent to the stator, with windings wound about the teeth with the insulator interposed between the windings and the teeth. The insulation sheet is arranged between the casing and crossover wires of the windings.
Claims
1. A compressor comprising: a casing; a compression mechanism arranged inside the casing; and a motor arranged inside the casing, the motor driving the compression mechanism, the motor being a concentrated-winding motor having a stator that has a plurality of teeth, and an insulator adjacent to the stator, with windings being wound about the teeth with the insulator interposed therebetween; and an insulation sheet arranged between the casing and crossover wires of the windings, the insulation sheet being tubular in shape, and being arranged between the insulator and the casing, and the insulation sheet having tabs sandwiched between the stator and the insulator.
2. The compressor according to claim 1, wherein the insulation sheet is molded from a heat-shrinkable material.
3. A compressor comprising: a casing; a compression mechanism arranged inside the casing; a motor arranged inside the casing, the motor driving the compression mechanism, the motor being a concentrated-winding motor having a stator that has a plurality of teeth, and an insulator adjacent to the stator, with windings being wound about the teeth with the insulator interposed therebetween; and an insulation sheet arranged between the casing and crossover wires of the windings, the insulation sheet being arranged between the insulator and the casing, and the insulation sheet having an annular part sandwiched between the stator and the insulator across an entire circumference of the stator.
4. A compressor comprising: a casing; a compression mechanism arranged inside the casing; a motor arranged inside the casing, the motor driving the compression mechanism, the motor being a concentrated-winding motor having a stator that has a plurality of teeth, and an insulator adjacent to the stator, with windings being wound about the teeth with the insulator interposed therebetween; and an insulation sheet arranged between the casing and crossover wires of the windings, the insulator having a protruding part protruding toward the casing, and the insulation sheet being arranged between the insulator and the casing, and the insulation sheet being arranged between the stator and the protruding part.
5. A compressor comprising: a casing; a compression mechanism arranged inside the casing; a motor arranged inside the casing, the motor driving the compression mechanism, the motor being a concentrated-winding motor having a stator that has a plurality of teeth, and an insulator adjacent to the stator, with windings being wound about the teeth with the insulator interposed therebetween; an insulation sheet arranged between the casing and crossover wires of the windings; and a sheet-securing member arranged between the insulator and the casing, the insulation sheet being arranged between the insulator and the casing, and the insulation sheet being arranged between the stator and the sheet-securing member.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
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(8)
(9)
(10)
(11)
(12)
(13)
DESCRIPTION OF EMBODIMENTS
(14) A compressor according to an embodiment of the present invention is described with reference to the drawings. The compressor according to the present embodiment is a rotary compressor. The rotary compressor is a compressor in which a piston is caused to rotate eccentrically inside a cylinder, and the volume of the space inside the cylinder is caused to vary, whereby a refrigerant circulating in a refrigerant circuit is compressed.
(1) Configuration of Compressor
(15)
(1-1) Casing
(16) The casing 10 has a substantially tubular barrel casing part 11, a bowl-shaped upper wall part 12 hermetically welded to an upper-end part of the barrel casing part 11, and a bowl-shaped bottom wall part 13 hermetically welded to a lower-end part of the barrel casing part 11. The casing 10 is molded from a rigid material that does not readily deform or break when the pressure and temperature on the inner part and outer part of the casing 10 change. The casing 10 is arranged such that the axial direction of the substantially tubular shape of the barrel casing part 11 runs vertically. The bottom part of the casing 10 is provided with an oil reservoir part 10a in which a lubricating oil is accumulated. The lubricating oil is a refrigerating oil used in order to lubricate sliding parts inside the rotary compressor 101.
(17) The casing 10 primarily accommodates a compression mechanism 15, a drive motor 16 disposed above the compression mechanism 15, and a crankshaft 17 disposed along the vertical direction. The compression mechanism 15 and the drive motor 16 are linked via the crankshaft 17. The intake tube 19 and the discharge tube 20 are hermetically joined to the casing 10.
(1-2) Compression Mechanism
(18) The compression mechanism 15 is primarily configured from a front head 23, a cylinder 24, a rear head 25, and a piston 21. The front head 23, the cylinder 24, and the rear head 25 are integrally fastened by laser welding. The space above the compression mechanism 15 is a high-pressure space S1 into which refrigerant compressed by the compression mechanism 15 is discharged.
(19) The compression mechanism 15 has a compression chamber 40, which is a space surrounded by the front head 23, the cylinder 24, and the rear head 25. The compression chamber 40 is partitioned by the piston 21 into an intake chamber communicating with the intake tube 19 and a discharge chamber communicating with the high-pressure space S1.
(20) The piston 21 is fitted onto an eccentric shaft part 17a of the crankshaft 17. Due to axial rotation of the crankshaft 17, the piston 21 performs an orbiting motion in the compression chamber 40 about the rotational axis of the crankshaft 17. The orbiting motion of the piston 21 causes the volumes of the intake chamber and discharge chamber constituting the compression chamber 40 to vary.
(1-3) Drive Motor
(21) The drive motor 16 is a brushless DC motor accommodated inside the casing 10 and arranged above the compression mechanism 15. The drive motor 16 is primarily configured from a stator 51 secured to an inner peripheral surface of the casing 10, and a rotor 52 rotatably accommodated on the inner side of the stator 51 with an air gap provided therebetween. The drive motor 16 is a three-phase motor having six concentrated-winding coils, and furthermore is an adjustable-speed motor driven by an inverter control. The configuration of the drive motor 16 is described in detail later.
(1-4) Crankshaft
(22) The crankshaft 17 is disposed such that the central axis thereof runs vertically. The crankshaft 17 has an eccentric shaft part 17a. The eccentric shaft part 17a of the crankshaft 17 is linked to the piston 21 of the compression mechanism 15. The end part on the vertical-direction upper side of the crankshaft 17 is linked to the rotor 52 of the drive motor 16. The crankshaft 17 is rotatably supported by the front head 23 and the rear head 25.
(1-5) Intake Tube
(23) The intake tube 19 passes through the barrel casing part 11 of the casing 10. The end part of the intake tube 19 that is inside the casing 10 is fitted into the compression mechanism 15. The end part of the intake tube 19 that is outside the casing 10 is connected to the refrigerant circuit. The intake tube 19 is a tube for supplying refrigerant from the refrigerant circuit to the compression mechanism 15.
(1-6) Discharge Tube
(24) The discharge tube 20 passes through the upper wall part 12 of the casing 10. The end part of the discharge tube 20 that is inside the casing 10 is positioned above the drive motor 16 in the high-pressure space S1. The end part of the discharge tube 20 that is outside the casing 10 is connected to the refrigerant circuit. The discharge tube 20 is a tube for supplying refrigerant compressed by the compression mechanism 15 to the refrigerant circuit.
(2) Configuration of Drive Motor
(25) The configuration of the drive motor 16 is described in detail here.
(2-1) Stator
(26) The stator 51 has a stator core 61, and a pair of insulators 62, 63 attached to the two vertical-direction end surfaces of the stator core 61, as shown in
(2-1-1) Stator Core
(27) The stator core 61 is secured to the casing 10. Specifically, the outer peripheral surface of the stator core 61 is welded to the inner peripheral surface of the casing 10. Three weld locations are provided to each of the two vertical-direction end parts of the stator core 61. The weld locations may be suitably determined in accordance with the weight and natural frequency of the stator core 61, and other such factors. The stator core 61 may be secured to the casing 10 by press-fitting and shrink-fitting.
(28) The stator core 61 has a tubular part 71, and six teeth 72, as shown in
(29) Six core cuts 73 are formed in the outer peripheral surface of the tubular part 71 of the stator core 61, as shown in
(30) Conducting wires are wound about the teeth 72 of the stator core 61, as well as the insulator 62, as shown in
(2-1-2) Insulator
(31)
(32) The insulator 62 has an annular part 62a and six projecting parts 62b, as shown in
(33)
(34)
(35) The insulation sheet 66 is arranged between the casing 10 and the insulator 62 attached to the upper-side end surface of the stator core 61; however, in cases in which the crossover wires 65 are arranged below the stator core 61, the insulation sheet 66 may be arranged between the casing 10 and the insulator 63 attached to the lower-side end surface of the stator core 61.
(2-2) Rotor
(36) The rotor 52 is linked to the crankshaft 17, which passes vertically through the rotational center of the rotor 52. The rotor 52 is connected to the compression mechanism 15 with the crankshaft 17 interposed therebetween. The rotor 52 has a rotor core 52a configured from a plurality of metal plates that are stacked in the vertical direction, and a plurality of magnets 52b embedded in the rotor core 52a, as shown in
(3) Operation of Compressor
(37) Driving of the drive motor 16 causes the rotor 52 to rotate and the crankshaft 17 to axially rotate. Due to the axial rotation of the crankshaft 17, the piston 21 of the compression mechanism 15 performs an orbiting motion in the compression chamber 40 about the rotational axis of the crankshaft 17. The orbiting motion of the piston 21 causes the volumes of the intake chamber and discharge chamber constituting the compression chamber 40 to vary. A low-pressure gas refrigerant is thereby taken into the intake chamber of the compression chamber 40 from the intake tube 19. The volume of the intake chamber is reduced by the orbiting motion of the piston 21; as a result, the refrigerant is compressed, and the intake chamber becomes a discharge chamber. The compressed, high-pressure gas refrigerant is discharged from the discharge chamber into the high-pressure space S1. The discharged compressed refrigerant passes vertically upward through the air gap, which is the space between the stator 51 and the rotor 52. The compressed refrigerant is then discharged outside the casing 10 from the discharge tube 20. The refrigerant compressed by the rotary compressor 101 is, e.g., R410A, R22, R32, or carbon dioxide.
(38) The lubricating oil that has accumulated in the oil reservoir part 10a at the bottom of the casing 10 is supplied to sliding parts of the compression mechanism 15, etc. The lubricating oil supplied to the sliding parts of the compression mechanism 15 flows into the compression chamber 40. In the compression chamber 40, the lubricating oil is formed into fine oil droplets that are mixed into the refrigerant gas. Therefore, the compressed refrigerant discharged from the compression mechanism 15 includes the lubricating oil. Some of the lubricating oil included in the compressed refrigerant separates from the refrigerant due to centrifugal force or the like caused by the flow of the refrigerant in the high-pressure space S1 above the drive motor 16, and adheres to the inner peripheral surface of the casing 10. The lubricating oil that has adhered to the inner peripheral surface of the casing 10 descends along the inner peripheral surface of the casing 10, and reaches a position at the height of the upper surface of the stator 51 of the drive motor 16. The lubricating oil then descends through the core cuts 73 of the stator core 61. The lubricating oil that has descended through the core cuts 73 finally returns to the oil reservoir part 10a.
(4) Features
(39) The rotary compressor 101 comprises the drive motor 16 having the concentrated-winding coils. The windings 64 of each of the coils 72a are connected to each other via the crossover wires 65. The crossover wires 65 are arranged so as to be wound about the insulator 62, which is positioned above the stator 51, while in contact with the outer peripheral surface 62d of the insulator 62.
(40) The insulation sheet 66 is arranged between the crossover wires 65 and the barrel casing part 11 of the casing 10. The tubular insulation sheet 66 is arranged by insertion between the outer peripheral surface 62d of the insulator 62 and the inner peripheral surface 11a of the barrel casing part 11. The insulation sheet 66 is an insulation member for preventing electrical connection between the crossover wires 65 and the casing 10.
(41) In cases in which no insulation sheet 66 is arranged, the distance between the crossover wires 65 and the casing 10 must be set equal to or greater than a legally stipulated distance, in order to suitably insulate the crossover wires 65 and the casing 10 from each other. In such a case, it is difficult to reduce the thickness of a back yoke, which is a toric portion on the outer side of the stator 51.
(42) However, in the rotary compressor 101, arranging the insulation sheet 66 between the crossover wires 65 and the casing 10 makes it possible to reduce the distance between the crossover wires 65 and the casing 10. This makes it possible to reduce the thickness of the back yoke of the stator 51, and to make the drive motor 16 more compact. Specifically, using the insulation sheet 66 makes it possible to make the rotary compressor 101 more compact. Even when the insulation sheet 66 is molded from a thin insulation member, and the temperature of the insulation sheet 66 rises during operation of the rotary compressor 101, the insulation sheet 66 does not have a large quantity of heat. Therefore, the insulation sheet 66 exerts substantially no adverse effect on the operation of the drive motor 16. Accordingly, the rotary compressor 101 can be made more compact without reducing the efficiency of the drive motor 16.
(43) Additionally, the insulation sheet 66 has a tubular shape having only a side surface, as shown in
(44) The insulation sheet 66 is preferably molded from a heat-shrinkable material. Specifically, the insulation sheet 66 is preferably molded from an insulating body having heat-shrinkage properties. In this case, heating and shrinking the tubular insulation sheet 66 after arranging the insulation sheet 66 by insertion between the crossover wires 65 and the casing 10 makes it possible to secure the insulation sheet 66 to the insulator 62. Accordingly, using the heat-shrinkable insulation sheet 66 makes it possible to readily secure the insulation sheet 66 to the drive motor 16.
(5) Modifications
(5-1) Modification A
(45) In the present embodiment, the insulation sheet 66 has a tubular shape having only a side surface, as shown in
(46) In the present modification, the insulation sheet 66 is arranged between the crossover wires 65 and the casing 10 while the tabs 66a of the insulation sheet 66 are inserted between the stator 51 and the insulator 62. Because the tabs 66a of the insulation sheet 66 are sandwiched between the stator 51 and the insulator 62, the tabs 66a prevent the insulation sheet 66 from separating from the stator 51. Accordingly, in the present modification, providing the tabs 66a to the insulation sheet 66 makes it possible to readily secure the insulation sheet 66 to the drive motor 16.
(5-2) Modification B
(47) In the present embodiment, the insulation sheet 66 has a tubular shape having only a side surface, as shown in
(48) In the present modification, the projecting parts 66c of the insulation sheet 66 are arranged between the crossover wires 65 and the casing 10 while the annular part 66b of the insulation sheet 66 is inserted between the stator 51 and the insulator 62, as shown in
(49) In the present modification, it is not necessary to form the notches 66d in the insulation sheet 66. Even in such a case, it is possible to secure the insulation sheet 66 to the drive motor 16 such that the annular part 66b is sandwiched between the stator 51 and the insulator 62, and such that the projecting parts 66c are arranged between the crossover wires 65 and the casing 10.
(5-3) Modification C
(50) In the present embodiment, the insulation sheet 66 is arranged between the insulator 62 and the barrel casing part 11 of the casing 10.
(51) In the present modification, the insulation sheet 66 is arranged between the insulator 62 and the barrel casing part 11. As shown in
(5-4) Modification D
(52) In the present embodiment, the insulation sheet 66 is arranged between the insulator 62 and the barrel casing part 11 of the casing 10.
(53) In the present modification, the insulation sheet 66 is arranged between the insulator 62 and the barrel casing part 11. As shown in
(5-5) Modification E
(54) In the present embodiment, the insulation sheet 66 is configured from a single sheet; however, the insulation sheet 66 may instead be configured from a plurality of sheets. For example, the insulation sheet 66 may be arranged such that a plurality of film-form insulation members constituting the insulation sheet 66 are inserted into a gap between the crossover wires 65 and the casing 10 from above the insulator 62, and the crossover wires 65 are insulated from the casing 10 through the entirety of the gap.
(5-6) Modification F
(55) In the present embodiment, the rotary compressor 101 is used as a compressor comprising the drive motor 16 in which the insulation sheet 66 is arranged between the crossover wires 65 and the casing 10; however, a scroll compressor and a reciprocating compressor, etc., may be used instead.
(56) Additionally, in the present embodiment, the drive motor 16 has concentrated-winding coils; however, distributed-winding coils in which coil windings are wound across a plurality of the teeth 72 may be used instead.
INDUSTRIAL APPLICABILITY
(57) The compressor according to the present invention can be made more compact while ensuring the efficiency of the motor.