Thermally protected hermetic motor compressor
This invention relates to an arrangement for securing a thermal protection device and motor cover to the stator structure of a motor compressor. 
     A widely-used type of refrigeration compressor encloses a motor compressor assembly in a hermetically sealed container or shell. Representative of these motor compressor assemblies are &#34;Compressor Motor Protection&#34; U.S. Pat. No. 4,236,092 issuing Nov. 25, 1980 to Di Flora, &#34;Refrigeration Compressor Apparatus and Method of Assembly&#34; U.S. Pat. No. 4,412,791 issuing Nov. 1, 1983 to Lal and &#34;Thermally Protected Dynamoelectric Machine and Method of Assembly&#34; U.S. Pat. No. 4,503,347 issuing Mar. 5, 1985 to Bergman, the disclosures of which being incorporated by reference herein. 
     In assembling such motor compressors, the motor stator is positioned on top of and bolted to the frame of the compressor. The air gap between the rotor and stator is adjusted and fixed during assembly of the unit, then the bolts or machine screws which hold the stator in such position are tightened. For reasons connected with the operation of the refrigeration system a shroud or motor cover is secured to the upper end of the motor within the shell, overlying the end turns and the protector. 
     A thermally responsive motor protection device to provide for protection against burnout of the electric motor is secured to the end turns of the stator winding of the motor since this area heats quickly in the event of an overload, the motor protection device serving to interrupt the motor circuit in the event of overheating. Various protector mounting arrangements have been employed in an effort to achieve maximum efficiency while minimizing disadvantageous factors. 
     Inasmuch as the motor protector must be installed before the internal motor cover or shroud is secured, difficulty can be encountered in mounting the protector in the most advantageous position, and thereafter securing the shroud, without disturbing the air gap and without resorting to a plurality of smaller, separate screws or fasteners for the cover. It would be advantageous to secure this shroud or cover and the protector by means of the same fasteners which are used to secure the stator to the frame, not only for the sake of economy, but because the bolts or screws which secure the stator are heavy, well secured, and virtually free of any possibility of breakage or loosening under the recurrent vibration encountered during the long service life of these units. 
     The overall objective of the present invention is to provide an improved system for mounting a thermal protector and motor cover in a motor compressor unit of the type indicated. Another object is provision of a motor cover which functions to inhibit terminals interconnecting the motor wires to the protector from popping loose during operation. A related object is to provide such an improved mounting system which can be quickly and easily installed and supported in a positive manner after the gap between the rotor and stator of the motor has been adjusted and the stator has been permanently fixed in position. Another object is to provide an improved mounting means which reduces labor costs and minimizes the danger of improper installation by virtue of the fact that the protector unit and its supporting means can be easily, quickly and positively locked in place by the simple act of pushing the motor cover into position. 
     These and other objectives are achieved by a hermetic motor compressor having a retaining arrangement operably connectable to the motor for engagement by a molded cover to simultaneously fasten a heat sensitive circuit protector device within the cover and to the motor. The motor cover is specially configured to allow the user to orient a cooling gas suction inlet port at the top of the motor relative to the thermal protector device. Further, the motor cover is low cost and an effective support structure which will surmount the thermal protector arrangement and efficiently position overload wires relative to the compressor. 
    
    
     The foregoing and the other objects will become more apparent when viewed in light of the accompanying drawings and following detailed description wherein: 
     FIGS. 1 and 2 are front and side elevational views partially in section and with portions broken away of a hermetic motor compressor embodying the present invention. 
     FIG. 3 is a top plan view of the motor compressor with portions removed therefrom to show a motor cover and a thermal overload protection arrangement for the motor. 
     FIG. 4 is a top plan view of the motor cover. 
     FIG. 5 is an elevation view of the cover partially in section and taken along lines 5--5 of FIG. 4. 
     FIG. 6 is an elevation view of the cover in section and taken along lines 6--6 of FIG. 4. 
     FIG. 7 is a partial elevation view of the cover. 
     FIG. 8 is the elevation view of the cover in section taken along lines 8--8 of FIG. 7. 
     FIGS. 9 and 10 are plan and side views of a first retainer plate. 
     FIG. 11 is a plan view of a second retainer plate. 
     FIGS. 12-14 are plan, front and rear elevation views of a protector retainer. 
     FIGS. 15 and 16 are section views of the protector retainer taken along lines 15--15 and 16--16, respectively, of FIGS. 14 and 12. 
     FIG. 17 is a termination device used in the protector retainer. 
     FIGS. 18 and 19 show a representative termination. 
     FIG. 20 is an electrical schematic of the motor compressor. 
    
    
     Turning now to the drawings there is shown a hermetic refrigeration compressor indicated generally at 10 and comprising an outer shell 12 having at the top thereof a suction inlet 11 and defining an interior 13 within which is housed a compressor 14 of the reciprocating piston-type, a dynamoelectric motor 34 drivingly connected thereto, a shroud or motor cover 46 that overlies the top end of the motor, and a thermal protector or protection device 86 that protects the motor from overheating. A retention arrangement including a pair of arcuate retainer plates 64, 66 and a holder or connector block 70 advantageously secures the motor cover 46 and the protector 86 to the motor 34 such that the protector is proximate to the motor for electrical connection thereto and the motor cover supplies cooling gas to the protector. It should be noted that while the present invention is described with reference to a reciprocating piston-type compressor, it may be employed in connection with any type of motor compressor unit such as, for example, rotary or screw types. 
     The compressor 14 includes a lower housing 16 having an annular shoulder portion 17, a crankshaft 18 including an elongated drive shaft 19, a cylinder body 20 including a pair of pistons 22, 24 each disposed in a respective cylinder 21, 23, a valve plate 25 and a cylinder head 26 secured over the cylinders. The head 26 has chambers 27, 28 for conducting suction gas to the cylinders, chambers 29, 30 for receiving compressed discharge gas from the pistons and a central chamber 31. A muffler 32 receives heated discharge gas from the central chamber 31 and discharges the same through a discharge conduit 33 downwardly to a discharge exit and outwardly through shell (not shown). 
     The motor 34 is disposed above the lower housing 16 and includes a rotor 36 which is secured for rotation to the drive shaft 19 projecting from the crankshaft, a generally cylindrical stator structure 38 which encircles the rotor to define an air gap 37 therebetween and is secured to the shoulder portion 17, and coiled stator windings 39 describing an annular end turn portion 41, 43 adjacent each end, the motor cooperating with the crankshaft to drive the compressor. The stator includes a core structure 40 which has opposite ends defining generally flat annular end faces 42, 44 the lower end face 44 being supported on the shoulder portion 17, a series of bores (not shown) extending longitudinally between the end faces, and a fastener or bolt &#34;B&#34; disposed in each bore having a head adjacent to the upper end face 42 and a threaded body threadably engaged with the shoulder portion. The end turn portions 41, 43 extend generally perpendicularly upward from its respective annular end face 42, 44 to define around each a coil annulus encircled by its respective end face. 
     The motor cover 46 is integrally molded of a polymer and generally cup-shaped to form an interior chamber 47 which will overly and enclose the upper end of the motor structure to define an annulus 45 thereabout, the cover including a generally cylindrical side wall 48 having a peripheral bottom edge 49 and a generally planar top wall 50 provided with a centrally disposed cup-shaped recess 51. The side wall 48 includes an opening 52, an edge portion 53 adjacent the opening and spaced upwardly of the bottom edge 49, and latch fingers or flanges 58 extending generally longitudinally downward from the bottom edge. A cup-shaped wall portion 54 extends radially outward from the side wall 48 adjacent the opening therein to define an upper wall 56 and a reduced chamber 55 into which the thermal protector 86 is housed. The motor cover is provided with a suction gas inlet duct 57 to receive suction gas from the suction inlet 11 of the shell 12 whereby cooling gas is drawn into the interior chambers 47, 55 of the cover and directed at the end turn portion 41 of the stator and at the thermal protector 86. 
     Each flange 58 is resilient, laterally flexible, somewhat arcuate in cross-section and includes a shaped leg portion 59 terminating in a retention shoulder 60, each flange being adapted for insertion through a respective arcuate slot 67 in one of the retainer plates 64, 66 whereby the leg portion will resiliently deflect to allow the retention shoulder to pass through the slot whereupon the shoulder will seat against the bottom face of the receiving plate to inhibit reverse movement of the flange, thereby securing the cover 46 to the motor 34. 
     A wire retention finger 62 extends radially outward from one upper wall 56 to be exteriorly adjacent the cover circumference, the finger being integrally formed with one of the flanges and open at one end to define a slot 61 for receiving and keeping wire connections 94, 95, 96 extending from the connector block 70. A tooth 63 at the distal end of the finger constricts the slot opening to prevent unwanted removal of the wires therefrom. 
     A pair of thin, flat, arcuate retainer plates 64, 66 are bolted to the top annular end face 42 of the stator, each retainer plate being diametrically opposed to one another and including a pair of bolt holes 65 and one or more generally arcuate slots 67. Each bolt hole registers with one of the bores in the stator whereby to receive a bolt &#34;B&#34; and permit the respective plate 64, 66 to be secured to the top end face 42 of stator when the stator is secured to the shoulder portion 17. Each slot 67 is adapted to receive a resilient flange 58 from the motor cover. One retainer plate 64 is mounted adjacent the cover opening 52 and is sized to pass under the edge portion 53, the plate being provided with a pair of upwardly extending deformable ears 68. The free end of each ear is twisted to form a shoulder 69 for retaining the connector block 70. 
     The connector block 70 is provided for securing and positioning the thermal protector device 86 adjacent the end turn portion 41 and providing contact termination cavities 75, 76, 77, 78 for receiving a contact 90 and terminating wires in electrical communication with the end turn portion 41. The block comprises a generally planar body 71 having top and bottom surfaces 72, 74, a pair of openings 73 extending through the surfaces each opening 73 adapted to receive one respective ear 68, a cradle 84 for mounting the thermal protection device 86, and the insulation displacement cavities. One end portion of the block is adapted to position the cradle 84 with protector and the cavities 77, 78 interiorly of the cover. The other end portion of the block passes through and is adjacent the opening 52 and positions the cavities 75, 76 exteriorly of the cover. Each cavity defines a generally rectangular open at the top box-like structure and includes a pair of opposed end walls 81, a pair of opposed side walls 80, a wire receiving slot 82 extending downwardly from the top edge of each end wall, and an anvil 83 extending upwardly interiorly of the cavity. 
     As shown, the thermal protection device 86 is generally cylindrical and includes termination blades 87, 88, 89 each cooperating to complete an electrical interconnection between the protector, the stator and through 97 to an electrical power source. The protector device includes an interrupter switch 98 which serves to interrupt the operation of the motor (i.e., disable the motor) when the temperature exceeds a predetermined temperature. The device is purchased and forms no part of the invention. 
     The contacts 90 for completing an electrical termination are supplied by AMP Corporation and identified as Mag-mate terminals. Each contact includes an insulation displacement slot, a barb to bite into the cavity wall to retain the contact therein, a forward opening to seat about the anvil, a forward end to drive the wires to be connected inwardly of the slot and a rearward termination end portion extending from the cavity terminals. The portion of the connector block 70 disposed within the interior annulus 45 is positioned such that the wall 54 defining the chamber 55 prevents the terminals from upward movement thereby resulting in an unwanted disconnection during operation of the compressor. 
     The wires 94, 95, 96 extend from their terminations to terminals 90 and are prevented from moving outwardly of the cover by the retention finger 62 defining the slot 61, the finger describing a wire keeper and directing the wires longitudinally downwardly relative to the motor housing and upwardly through 97 to connect to a power source. Advantageously this orientation of the wires reduces strains. 
     FIG. 20 is an electrical schematic of the arrangement wherein the motor protector is connected to the stator windings comprising a pair of run windings 91, 92 and a start winding 93. The end turn portion 41 positions the coil ends 91A, 91B, 92A, 92B, 93A and 93B from the two run windings 91, 92 and the start winding 93 adjacent the protector for electrical connection to wires 94, 95 and 96 which connect through 97 to the power source. The termination is as follows: run windings 91, 92 have their ends 91A, 92A in cavity 78 and terminated to blade 87 interiorly of the cover and their other ends 91B, 92B in cavity 75 exteriorly of the cover and terminated to wire 94; start winding 93 has end 93A in cavity 77 and terminated to blade 88 interiorly of the cover and its other end 93B in cavity 76 exteriorly of the cover and terminated to wire 95; blade 89 of the protector is terminated interiorly of the cover to wire 96; and each of the wires 94, 95, 96 pass into the keeper slot 61 defined by finger 62 then downwardly and upwardly to the power source at 97 through the shell 12. 
     For assembly, the plates 64, 66 would be secured to the end face 42 using the bolts &#34;B&#34; through the holes 65 whereupon the block 70 would be positioned over retainer plate 64 and lowered whereby deformable ears 68 would pass through the openings 73. The ends of each ear would be twisted to form the retention shoulder 69. The cover 46 would be positioned such that flanges 58 would register with arcuate slots 67 on the two plates 64, 66 and lowered whereby leg portions 59 will flex to allow retention shoulders 60 to pass therebetween and engage the other side of the plate whereby to inhibit retrograde movement (i.e. unwanted removal of the motor cover) from the motor. It is to be understood that the motor cover 46 and the connector block 70 are generally fastened together by fingers and openings releasably interengaging to secure the cover to the plate and the block to the plate. Deformable fingers could extend from the block into holes in the plate, and the fingers instead of being deformable to form shoulders with their twisted ends could have shoulders like flanges 58. Similarly, the flange and openings for securing the cover relative to the plate could, respectively, include a flange finger extending from the plate for retaining receipt in an opening in the cover. 
     When mounted the protector 86 is disposed in the annulus 45 defined between the side wall 48 and the end turn portion 41, the protector being below the upwardmost extension of the annular end portion 41. The duct 57 is automatically positioned generally diametrically from the protector and supplies cooling suction gas to each end turn portion when the cover is mounted to the plates 64, 66. Should the motor overheat a switch 98 in the protector 86 opens to interrupts circuit path to the power source. 
     While it will be apparent that the preferred embodiments of the invention disclosed are well calculated to provide the advantages and features above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the subjoined claims.