Hermetic motors with windings coupled to on-winding motor protectors via welded terminals
A hermetic motor includes a stator having at least one winding formed by a winding wire, and an on-winding motor protector having at least one contact. To improve the reliability and reduce the cost of the hermetic motor, the winding wire is directly coupled (without a lead wire) to the motor protector contact. Additionally, a common wire extending from the motor protector to a cluster block (if applicable) can be the same type of wire as the winding wire.
1. A hermetic motor comprising a stator having at least one winding formed by a winding wire, and an on-winding motor protector having a housing and at least one contact extending from an external side of the motor protector housing, wherein the winding wire is coupled to the motor protector by a terminal that is directly coupled to the winding wire without lead wire, and wherein said terminal is welded to the at least one contact on the external side of the motor protector housing.
2. The hermetic motor of claim 1 wherein the terminal is a splice terminal and the splice terminal is welded to the at least one contact.
3. The hermetic motor of claim 2 wherein the splice terminal is crimped to the winding wire.
4. The hermetic motor of claim 3 wherein the winding wire includes a coating and a substantially solid conductor, and wherein the crimped splice terminal extends through the coating and contacts the conductor.
5. The hermetic motor of claim 4 wherein the splice terminal includes internal serrations for penetrating the winding wire coating.
6. The hermetic motor of claim 1 further comprising a cluster block and a common wire having opposite first and second ends, wherein the first end of the common wire is coupled to the motor protector housing, and the second end of the common wire is coupled to the cluster block.
7. The hermetic motor of claim 6 wherein the common wire is a same type of wire as the winding wire.
8. The hermetic motor of claim 7 wherein the common wire and the winding wire each comprise copper.
9. The hermetic motor of claim 1 wherein the motor protector is a line break automatic reset control device.
10. The hermetic motor of claim 9 wherein the hermetic motor is a permanent split capacitor (PSC) motor.
11. A method of assembling a hermetic motor, the hermetic motor including a stator having at least one winding formed by a substantially solid winding wire and an on-winding motor protector having a housing and at least one contact extending from an external side of the housing, the method comprising coupling the substantially solid winding wire to the motor protector by coupling the substantially solid winding wire directly to a terminal without lead wire, and welding said terminal to the at least one contact on the external side of the motor protector housing.
12. The method of claim 11 wherein coupling the winding wire to a terminal includes crimping a splice terminal to the winding wire, and wherein welding the terminal to the motor protector includes welding the splice terminal to the at least one contact.
13. The method of claim 11 wherein the hermetic motor includes a cluster block and a common wire having opposite first and second ends, the method further comprising coupling the first end of the common wire to the motor protector housing and coupling the second end of the common wire to the cluster block.
14. The method of claim 13 wherein the common wire is a same type of wire as the winding wire.
15. A hermetic motor comprising a stator having a plurality of windings formed by at least a first substantially solid winding wire and a second substantially solid winding wire, and an on-winding motor protector having a housing and at least a first contact and a second contact extending from an external side of the housing, the first winding wire and the second winding wire directly coupled to a first terminal and a second terminal, respectively, without lead wire, and wherein said first terminal and said second terminal are welded to the first contact and the second contact, respectively, on the external side of the motor protector housing.
16. The hermetic motor of claim 15 wherein the hermetic motor is a single-phase PSC motor having a main winding formed by the first winding wire and an auxiliary winding formed by the second winding wire, and wherein the motor protector is a single-phase on-winding motor protector.
17. The hermetic motor of claim 15 wherein the motor is a three-phase motor and the motor protector is a three-phase on-winding motor protector.