Technical Field
[0001] The present invention relates to an outdoor unit of an air-conditioning apparatus
(hereinafter referred to as "air-conditioning outdoor unit") that prevents wiring
mistakes in the assembly process.
Background Art
[0002] A compressor included in an air-conditioning outdoor unit has a configuration where
a container of the compressor contains an electric motor including a stator and a
rotor, a compression mechanism configured to compress refrigerant, and a main shaft
configured to transmit torque of the electric motor to the compression mechanism.
The compressor of this type has a glass terminal that is disposed to pass through
the container. The glass terminal is for supplying power from outside the container
to the rotor of the electric motor (see, e.g., Patent Literature 1). In the technique
disclosed in Patent Literature 1, a plurality of lead wires connected to the glass
terminal are connected through a cluster block to respective conductive pins in the
glass terminal. Cluster blocks of different colors are used here to prevent wiring
mistakes.
Citation List
Patent Literature
[0003] Patent Literature 1: Japanese Unexamined Patent Application Publication No.
2011-229221
Summary of Invention
Technical Problem
[0004] Even though the cluster blocks of different colors are used, it is still possible
to connect the cluster blocks to any conductive pins. That is, the technique described
above requires improvement because it is not good enough to reliably prevent wiring
mistakes.
[0005] The present invention has been made to address the issue described above. An object
of the present invention is to provide an air-conditioning outdoor unit that can physically
prevent wiring mistakes.
Solution to Problem
[0006] An air-conditioning outdoor unit according to an embodiment of the present invention
is an air-conditioning outdoor unit that includes a compressor having a plurality
of terminals each including a plurality of conductive pins. The air-conditioning outdoor
unit includes a plurality of lead wire groups provided for the respective terminals
and each including a plurality of lead wires connecting a control board to the plurality
of conductive pins, and a plurality of different end connectors provided for the respective
lead wire groups and each attached to an end portion of the lead wire group adjacent
to the plurality of conductive pins. The lead wire groups are each connected by the
end connector to the plurality of conductive pins and cut into two parts at a given
point in a longitudinal direction. The two parts of the lead wire group are detachably
coupled together at the given point by a pair of relay connectors. A length from the
control board to the given point and a length from the given point to the end connector
differ from one lead wire group to another. Advantageous Effects of Invention
[0007] The present invention makes it possible to physically prevent wiring mistakes. Brief
Description of Drawings
[Fig. 1] Fig. 1 is an exploded perspective view of an air-conditioning outdoor unit
according to Embodiment 1 of the present invention.
[Fig. 2] Fig. 2 is a perspective view of an upper part of a compressor included in
the air-conditioning outdoor unit according to Embodiment 1 of the present invention.
[Fig. 3] Fig. 3 is an explanatory diagram illustrating how the compressor and a control
board included in the air-conditioning outdoor unit according to Embodiment 1 of the
present invention are connected to each other.
[Fig. 4] Fig. 4 is an enlarged perspective view of the compressor illustrated in Fig.
3.
[Fig. 5] Fig. 5 is a diagram illustrating a modification example of the air-conditioning
outdoor unit according to Embodiment 1 of the present invention.
[Fig. 6] Fig. 6 is an explanatory diagram illustrating how the compressor and the
control board included in an air-conditioning outdoor unit according to Embodiment
2 of the present invention are connected to each other.
Description of Embodiments
Embodiment 1
[0008] Fig. 1 is an exploded perspective view of an air-conditioning outdoor unit according
to Embodiment 1 of the present invention.
[0009] As illustrated in Fig. 1, a housing of an air-conditioning outdoor unit 1 is composed
of a bottom 2, a front shell 3 having an L-shape in plan view and extending from the
front to the left side, an upper shell 5 forming a top face, and a side shell 4 forming
the right side. The front shell 3 has an air outlet 3a opening at the front and an
air inlet (not shown) opening on the left side. The housing contains, in the internal
space above the bottom 2, a heat exchanger 8, a compressor 10, and a fan 6 that sends
air into the heat exchanger 8. The heat exchanger 8 is disposed on the bottom 2 in
such a manner as to cover substantially the entire back-side opening of the housing.
The housing also contains a motor (not shown) that drives the fan 6, a motor mount
7 that secures the motor in place, and a connecting pipe 9. The connecting pipe 9
is configured to connect the heat exchanger 8 to the compressor 10. A control board
20 that controls the overall operation of the outdoor unit 1 is disposed above the
compressor 10.
[0010] Fig. 2 is a perspective view of an upper part of the compressor included in the air-conditioning
outdoor unit according to Embodiment 1 of the present invention.
[0011] The compressor 10 includes therein a compressor motor (not shown). The compressor
motor is a three-phase motor that includes windings of three phases, U-phase, V-phase,
and W-phase. The upper part of a container 10a of the compressor 10 has, at two points,
a glass terminal 11a and a glass terminal 11b that pass through the container 10a
of the compressor 10. Hereinafter, the glass terminal 11a and the glass terminal 11b
may be collectively referred to as glass terminals 11. The glass terminals 11 are
for supplying power from the control board 20 outside the container 10a to a stator
of the compressor motor.
[0012] The glass terminal 11a includes three conductive pins 12. The three conductive pins
12 are each connected to one end portion of a corresponding one of the windings of
U-phase, V-phase, and W-phase of the compressor motor in the container 10a. The glass
terminal 11a thus includes a total of three conductive pins 12 for the respective
U-phase, V-phase, and W-phase as a set. The glass terminal 11b similarly includes
three conductive pins 13, and the three conductive pins 13 are each connected to one
end portion of a corresponding one of the windings of U-phase, V-phase, and W-phase
of the compressor motor in the container 10a. The glass terminal 11b thus includes
a total of three conductive pins 13 for the respective U-phase, V-phase, and W-phase
as a set. This configuration enables supply of power to the compressor motor.
[0013] The conductive pins 12 of the glass terminal 11a have a cylindrical pin shape. The
conductive pins 13 of the glass terminal 11b are each composed of a cylindrical pin
and a terminal connecting plate 13a attached to the cylindrical pin.
[0014] Fig. 3 is an explanatory diagram illustrating how the compressor and the control
board included in the air-conditioning outdoor unit according to Embodiment 1 of the
present invention are connected to each other. Fig. 4 is an enlarged perspective view
of the compressor illustrated in Fig. 3.
[0015] A lead wire group 31 and a lead wire group 32, each including three lead wires, are
each connected at one end portion thereof to the control board 20. A cluster block
14 serving as an end connector is attached to the other end portion of the lead wire
group 31. The cluster block 14 is detachably connected to the conductive pins 12 of
the glass terminal 11a. Flag-shaped terminals 15, serving as an end connector, are
attached to the respective other end portions of the lead wires of the lead wire group
32. The flag-shaped terminals 15 are detachably connected to the respective conductive
pins 13 of the glass terminal 11b. The configuration described above enables electrical
connection between the control board 20 and the compressor 10. While not illustrated
in detail in Fig. 3 and Fig. 4, the flag-shaped terminals 15 each have an insertion
portion into which the terminal connecting plate 13a is inserted. Inserting the terminal
connecting plate 13a into the insertion portion enables connection between the flag-shaped
terminal 15 and the conductive pin 13.
[0016] The cluster block 14 is made of resin, and the flag-shaped terminals 15 are made
of metal. As illustrated in Fig. 4, a terminal sleeve 16 is mounted on the flag-shaped
terminal 15. To prevent fires caused by spark discharge resulting from poor contact
between the conductive pin 13 and the flag-shaped terminal 15, a flame-resistant material
is used to form the terminal sleeve 16. Although Fig. 4 only shows the terminal sleeve
16 mounted on one of the flag-shaped terminals 15, every flag-shaped terminal 15 has
the terminal sleeve 16 mounted thereon.
[0017] The air-conditioning outdoor unit of Embodiment 1 is configured such that by a winding
switching unit (not shown) on the control board 20, the connection of the compressor
motor can be switched between a Y-connection and a Δ-connection. The Y-connection
is a connection structure that provides better efficiency when the rotation speed
of the compressor motor is low, whereas the Δ-connection is a connection structure
that provides better efficiency when the rotation speed of the compressor motor is
high. Specifically, the winding switching unit is formed by a relay. With the winding
switching unit that switches the connection of the compressor motor in accordance
with the operating condition as described above, the outdoor unit of Embodiment 1
can improve energy saving performance. The technique that allows the connection of
the compressor motor to be switched between the Y-connection and the Δ-connection
is a known technique, and the winding switching unit can be configured using this
known technique.
[0018] In the type of compressors where no switching of the connection mode takes place,
a total of three conductive pins that are connected to the respective windings of
U-phase, V-phase, and W-phase of the compressor motor are arranged together in a single
glass terminal. In the type of compressors where the connection mode is switched as
in Embodiment 1, however, the windings of U-phase, V-phase, and W-phase of the compressor
motor each need to be connected at both end portions of the winding to the winding
switching unit of the control board 20. Since this requires a total of six conductive
pins, two glass terminals, each having a set of three conductive pins connected to
the U-phase, V-phase, and W-phase as described above, are arranged in the upper part
of the container 10a.
[0019] The lead wire group 31 is determined, in the circuit configuration, to be connected
to the glass terminal 11a. Similarly, the lead wire group 32 is determined, in the
circuit configuration, to be connected to the glass terminal 11b. The lead wire group
31 is connected, on one side thereof adjacent to the control board 20, to the U-phase,
V-phase, and W-phase through the winding switching unit, and is connected, on the
other side thereof adjacent to the compressor 10, to the glass terminal 11a using
the cluster block 14. The lead wire group 32 is connected, on one side thereof adjacent
to the control board 20, to the U-phase, V-phase, and W-phase through the winding
switching unit, and is connected, on the other side thereof adjacent to the compressor
10, to the glass terminal 11b using the flag-shaped terminals 15.
[0020] If the lead wire group 31 and the lead wire group 32 are too long, it is difficult
to assemble them. Therefore, as illustrated in Fig. 3, the lead wire group 31 and
the lead wire group 32 are each cut into two parts at a given point in the longitudinal
direction. The lead wire group 31 has, at the given point, a pair of relay connectors
33 detachable from each other, and the two parts of the lead wire group 31 can be
detachably coupled together by the pair of relay connectors 33. The pair of relay
connectors 33 is composed of a male connector 33a and a female connector 33b. The
lead wire group 32 is similarly cut into two parts at a given point in the longitudinal
direction. The lead wire group 32 has, at the given point, a pair of relay connectors
34 detachable from each other, and the two parts of the lead wire group 32 can be
detachably coupled together by the pair of relay connectors 34. The pair of relay
connectors 34 is composed of a male connector 34a and a female connector 34b.
[0021] If the lead wire group 31 and the lead wire group 32 are mistakenly connected to
the glass terminal 11b and the glass terminal 11a, respectively, the switching between
the Y-connection and the Δ-connection is not properly made. Embodiment 1 provides
the following configuration to prevent such a wiring mistake. Of the two parts into
which the lead wire group 31 is cut, one adjacent to the control board 20 is referred
to as a lead wire group 31a, and the other adjacent to the compressor 10 is referred
to as a lead wire group 31b. Similarly, of the two parts into which the lead wire
group 32 is cut, one adjacent to the control board 20 is referred to as a lead wire
group 32a, and the other adjacent to the compressor 10 is referred to as a lead wire
group 32b.
[0022] The lead wire group 31 and the lead wire group 32 are now compared. Of the lead wire
groups adjacent to the control board 20, the lead wire group 31a is longer in length
than the lead wire group 32a. Of the lead wire groups adjacent to the compressor 10,
the lead wire group 31b is shorter in length than the lead wire group 32b. That is,
the lead wires on both sides of the pair of relay connectors 33 for one lead wire
group differ in length from the lead wires on both sides of the pair of relay connectors
34 for the other lead wire group.
[0023] With this configuration, it is physically impossible to make wiring mistakes. That
is, assume that the lead wire group 31b and the lead wire group 32b, which are adjacent
to the compressor 10, are connected to the glass terminal 11a and the glass terminal
11b, respectively, and also assume that the coupling at the pair of relay connectors
33 and the coupling at the pair of relay connectors 34 are not yet made. The glass
terminal 11a and the glass terminal 11b differ in the shape of the conductive pins
12 and the conductive pins 13. Therefore, when connecting the lead wire group 31b
and the lead wire group 32b, which are adjacent to the compressor 10, to the glass
terminals, the assembly worker can uniquely identify, at a glance, which of the cluster
block 14 and the flag-shaped terminals 15 should be connected to which of the glass
terminals. That is, as illustrated in Fig. 4, the cluster block 14 for the lead wire
group 31b is connected to the glass terminal 11a, and the flag-shaped terminals 15
for the lead wire group 32b are connected to the glass terminal 11b.
[0024] Then assume, in this state, that the lead wire group 31a and the lead wire group
32a adjacent to the control board 20 are coupled, at the respective pairs of relay
connectors, to the lead wire group 31b and the lead wire group 32b adjacent to the
compressor 10. In this case, the male connector 33a for the lead wire group 31a can
be coupled to the female connector 34b for the lead wire group 32b. However, the lead
wire group 32a is too short to allow the male connector 34a to be coupled to the female
connector 33b for the lead wire group 31a. Thus, a wiring mistake is prevented here.
[0025] As described above, in Embodiment 1, the lead wire groups are each cut into two
parts at a given point in the longitudinal direction, and the two parts of the lead
wire group are detachably coupled together at the given point. Then, the length from
the control board 20 to the given point and the length from the given point to the
end connector in one lead wire group differ from those in the other lead wire group.
This makes it possible to physically prevent wiring mistakes.
[0026] Also, one lead wire group has the cluster block 14 as an end connector, whereas the
other lead wire group has the flag-shaped terminals 15 as an end connector. Accordingly,
the glass terminal 11a and the glass terminal 11b differ in the shape of the conductive
pins. This can prevent the cluster block 14 and the flag-shaped terminals 15 from
being connected to wrong glass terminals. Also, it is possible to uniquely identify
at a glance which of the cluster block 14 and the flag-shaped terminals 15 should
be connected to which of the glass terminals 11. This is effective in reducing the
assembly time.
[0027] The terminal sleeves 16, which are used to prevent fires as described above, also
serve the function of facilitating attaching and detaching of the flag-shaped terminals
15 to and from the conductive pins 13. That is, by varying at least the color or shape
of the terminal sleeve 16 for each of the flag-shaped terminals 15, it is possible
to prevent wiring mistakes in connecting the flag-shaped terminals 15 to the conductive
pins 13.
[0028] The air-conditioning outdoor unit according to the present invention is not limited
to the structure illustrated in the drawings mentioned above, and can be variously
modified without departing from the scope of the present invention. For example, the
lead wire group 31 and the lead wire group 32 may differ in the color of the lead
wires, or may differ in the color of the pair of relay connectors. With reference
to Fig. 5, a configuration will be described in which the colors of the lead wires
differ from one lead wire group to another.
[0029] Fig. 5 is a diagram illustrating a modification example of the air-conditioning outdoor
unit according to Embodiment 1 of the present invention. In Fig. 5, the lead wires
of different colors are represented by lines of different thicknesses and types.
[0030] In this modification example, each lead wire group has a different color combination
of lead wires. That is, for example, the lead wire group 31 is formed by a combination
of a black lead wire (thick solid line) 31A, a blue lead wire (thin solid line) 31B,
and a red lead wire (thick dotted line) 31C, whereas the lead wire group 32 is formed
by a combination of a black lead wire (thick solid line) 32A, a white lead wire (thin
dot-and-dash line) 32B, and a red lead wire (thick dotted line) 32C.
[0031] Thus, by varying the color combination of lead wires for each lead wire group, it
is possible to more visually identify a connection destination and prevent wiring
mistakes. In this example, the color combination of lead wires is varied for each
lead wire group. Alternatively, for example, the color of all the lead wires of the
lead wire group 31 may be black and the color of all the lead wires of the lead wire
group 32 may be red; that is, the color of lead wires all having the same color may
be varied for each lead wire group.
Embodiment 2
[0032] Embodiment 2 differs from Embodiment 1 in wiring-mistake preventing structure provided
at the pair of relay connectors. Differences between Embodiment 2 and Embodiment 1
will be primarily described here. Configurations not described in Embodiment 2 are
the same as those in Embodiment 1.
[0033] Fig. 6 is an explanatory diagram illustrating how the compressor and the control
board included in an air-conditioning outdoor unit according to Embodiment 2 of the
present invention are connected to each other.
[0034] In Embodiment 1 described above, the lead wire group 31 and the lead wire group 32
have the pair of relay connectors 33 and the pair of relay connectors 34, respectively,
that have the same placement of the male connector and the female connector. In Embodiment
2, on the other hand, the lead wire group 31 and the lead wire group 32 differ in
the placement of the male connector and the female connector. That is, as illustrated
in Fig. 6, the lead wire group 31 has the male connector and the female connector
placed adjacent to the control board 20 and the compressor 10, respectively, whereas
the lead wire group 32 has the male connector and the female connector placed adjacent
to the compressor 10 and the control board 20, respectively.
[0035] With this configuration, it is impossible to make such a wiring mistake as connecting
the lead wire group 31a to the lead wire group 32b connected to the glass terminal
11b, because their connectors are both male connectors. Also, by checking whether
the relay connector is of the male or female type, it is easy to identify which of
the lead wire group 31a and the lead wire group 32a should be connected to which of
the lead wire group 31b and the lead wire group 32b. This can reduce assembly time
and improve assembly performance.
[0036] As described above, in Embodiment 2, the lead wire group 31 and the lead wire group
32 differ in the placement of the male type and the female type in the pair of relay
connectors. With this configuration, it is physically impossible to make a wrong connection
in the pair of relay connectors, and it is possible to prevent wiring mistakes. Also,
the connection destination can be visually identified easily, and improved assembly
performance is achieved.
[0037] The configuration illustrated in Fig. 6 employs the technique of Embodiment 1, where
the lengths on both sides of the pair of relay connectors 33 in one lead wire group
differ from the lengths on both sides of the pair of relay connectors 34 in the other
lead wire group. However, the feature of Embodiment 2 is basically that the lead wire
group 31 and the lead wire group 32 differ in the placement of the male type and the
female type in the relay connectors, and Embodiment 2 does not necessarily need to
employ the technique of Embodiment 1. That is, the length from the control board 20
to a given point (where the lead wire group is cut) and the length from the given
point to the end connector in one lead wire group may be the same as those in the
other lead wire group. Even in this case, it is still possible, with the technique
of Embodiment 2, to prevent wiring mistakes. The configuration of varying the color
combination of three lead wires for each lead wire group, or the configuration of
varying the color of three lead wires of the same color for each lead wire group,
as described in the modification example of Embodiment 1, may be applied to Embodiment
2.
Reference Signs List
[0038] 1 outdoor unit, 2 bottom, 3 front shell, 3a air outlet, 4 side shell, 5 upper shell,
6 fan, 7 motor mount, 8 heat exchanger, 9 connecting pipe, 10 compressor, 10a container,
11 glass terminal, 11a glass terminal, 11b glass terminal, 12 conductive pin, 13 conductive
pin, 13a terminal connecting plate, 14 cluster block, 15 flag-shaped terminal, 16
terminal sleeve, 20 control board, 31 lead wire group, 31a lead wire group, 31b lead
wire group, 32 lead wire group, 32a lead wire group, 32b lead wire group, 33 relay
connector, 33a male connector, 33b female connector, 34 relay connector, 34a male
connector, 34b female connector
1. An air-conditioning outdoor unit including a compressor having a plurality of terminals
each including a plurality of conductive pins, the air-conditioning outdoor unit comprising:
a plurality of lead wire groups provided for the respective terminals, the lead wire
groups each including a plurality of lead wires connecting a control board to the
plurality of conductive pins; and
a plurality of different end connectors provided for the respective lead wire groups,
the end connectors each being attached to an end portion of the lead wire group adjacent
to the plurality of conductive pins,
wherein the lead wire groups are each connected by the end connector to the plurality
of conductive pins and cut into two parts at a given point in a longitudinal direction,
the two parts of the lead wire group are detachably coupled together at the given
point by a pair of relay connectors, and a length from the control board to the given
point and a length from the given point to the end connector differ from one lead
wire group to another.
2. The air-conditioning outdoor unit of claim 1, wherein the pair of relay connectors
includes a male connector and a female connector, and placement of the male connector
and the female connector differs from one lead wire group to another.
3. An air-conditioning outdoor unit including a compressor having a plurality of terminals
each including a plurality of conductive pins, the air-conditioning outdoor unit comprising:
a plurality of lead wire groups provided for the respective terminals, the lead wire
groups each including a plurality of lead wires connecting a control board to the
plurality of conductive pins; and
a plurality of different end connectors provided for the respective lead wire groups,
the end connectors each being attached to an end portion of the lead wire group adjacent
to the plurality of conductive pins,
wherein the lead wire groups are each connected by the end connector to the plurality
of conductive pins and cut into two parts at a given point in a longitudinal direction,
the two parts of the lead wire group are detachably coupled together at the given
point by a pair of relay connectors; and
the pair of relay connectors includes a male connector and a female connector, and
placement of the male connector and the female connector differs from one lead wire
group to another.
4. The air-conditioning outdoor unit of any one of claims 1 to 3, wherein a combination
of colors of the plurality of lead wires differs from one lead wire group to another,
or a color of the plurality of lead wires all having a same color differs from one
lead wire group to another.