Resolver and rotor bearing support system

Abstract

The present disclosure provides a resolver and rotor bearing support system. Systems and methods for integrating a resolver stator and a bearing support for a rotor bearing together are described. The system may electrically isolate the rotor bearing from the conductive material so that electrical arcing at the rotor bearing may be addressed. In one example, the resolver stator and the bearing support may be overmolded with plastic.

Description

Technical Field

[0001] The present disclosure relates to methods and systems for constructing a rotating electrical machine with electrical isolation. The methods and systems may be particularly useful for electric vehicles. Background Art

[0002] An electric motor may include a rotor that rotates within a stator. The rotor may include a shaft supported by bearings. Electrical noise may be conducted from the shaft and through the bearings to the housing of the electric motor. If the voltage across the bearings exceeds a threshold voltage, arcing may occur within the bearings. Arcing may be undesirable because it may cause pitting and degradation of the bearings. Therefore, it may be desirable to provide a method for reducing the likelihood of arcing within the bearings. Summary of the Invention

[0003] An electric vehicle or hybrid vehicle may include an electric motor that provides propulsion for the vehicle. The motor may include a stator and a rotor. The rotor may rotate within the stator, and the rotor may be supported via bearings. The bearings may be of metal construction so that the bearings can allow electricity (e.g., noise) generated by temperature changes, transistor switching, etc. to flow through the bearings. Therefore, it may be desirable to electrically isolate the bearings from the motor housing that supports the bearings (e.g., to prevent or significantly reduce the flow of electricity from one device to another). The position of the rotor may also be monitored via a rotary transformer so that current can be supplied to the stator windings of the motor at a specified timing based on the rotor position. The rotary transformer and the bearings may be close to each other, and since both the rotary transformer and the bearings are docked with the rotor shaft, it may be desirable for the rotary transformer and the bearings to be positioned concentrically. However, it may be difficult to secure the rotary transformer stator and the bearings to the motor housing so that the rotary transformer stator is concentric with the bearings and so that the center of the rotary transformer and the center of the bearings are not radially offset from each other. A rotary transformer stator that is concentric with the bearings that support the rotor shaft can allow for smooth rotation of the rotor shaft.

[0004] The inventors herein have recognized the aforementioned problems and have developed a support system comprising: a housing constructed of an electrically insulating material, the housing configured to support a resolver stator and a rotor bearing support cup, the resolver stator being concentric with the rotor bearing support cup when the resolver stator and the bearing support cup are integrated with the housing.

[0005] By integrating the resolver stator and bearing support cup into a single or unique housing comprised of electrically insulating material, the bearing is electrically isolated from the transmission / gearbox / power unit housing to prevent arcing and degradation of the rotor bearing. Additionally, the housing can facilitate concentric positioning of the bearing support cup with the resolver stator to allow unimpeded rotation of the rotor shaft within the bearing and resolver stator.

[0006] The present disclosure can provide several advantages. Specifically, the method can reduce the likelihood of arcing within the rotor bearing. Furthermore, the method can allow for concentric positioning of the rotor bearing and resolver stator, allowing the rotor shaft to rotate freely. Furthermore, the method can reduce the total number of fasteners that attach the rotor bearing and resolver stator to the motor housing, allowing for a reduction in the axial length of the motor. Furthermore, the method can reduce the number of guides on the motor housing, thereby reducing system financial costs and stress points within the system.

[0007] The above advantages and other advantages and features of the present specification will be readily apparent from the following detailed description when taken alone or in conjunction with the accompanying drawings.

[0008] It will be understood that the above summary is provided to introduce a series of concepts further described in the detailed description in a simplified form. It is not meant to identify key features of the claimed subject matter, the scope of which is solely defined by the claims appended to the detailed description. Furthermore, the claimed subject matter is not limited to implementations that address any disadvantages noted above or in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Advantages described herein will be more fully understood by reading the examples of embodiments herein referred to as the Detailed Description when read alone or with reference to the accompanying drawings, in which:

[0010] Figure 1 is a schematic view of an exemplary electric vehicle;

[0011] Figure 2 is a schematic diagram of an exemplary resolver stator;

[0012] Figure 3 is a schematic diagram of an exemplary integrated rotary transformer stator and rotor bearing support according to the present specification;

[0013] Figure 4 is a cross-sectional view of an exemplary integrated resolver stator and rotor bearing support;

[0014] Figure 5 is a cutaway perspective view of an exemplary integrated resolver stator and rotor bearing support; and

[0015] Figure 6 is a flow chart of an exemplary method for constructing an exemplary integrated resolver stator and rotor bearing support. DETAILED DESCRIPTION

[0016] The present disclosure relates to reducing degradation, complexity, and financial expense of an electric motor. The electric motor may be a traction motor that provides propulsion for a vehicle. The vehicle may be an electric vehicle or a hybrid vehicle. The electric motor may include: a rotary transformer including a rotary transformer stator and a rotary transformer lobe; a rotor; and a housing that supports the rotary transformer and rotor bearings. In one example, the vehicle may be a Figure 1 The electric vehicle shown. The vehicle may include an integrated housing configured to support Figure 2 The resolver stator and rotor bearings shown, rather than the resolver stator support, are shown as Figure 2 shown. Figure 4 and Figure 5 A cross-sectional view of the integrated housing is shown. Figure 6 A method for constructing a housing to support resolver stator and rotor bearings is shown.

[0017] Figure 1 1 is a block diagram of a vehicle 121 including a powertrain or driveline 100. The front of the vehicle 121 is indicated at 110, and the rear of the vehicle 121 is indicated at 111. The driveline 100 includes an electric machine 126. The electric machine 126 can consume or generate electricity depending on its operating mode. Figure 1 , mechanical connections between various components are shown as solid lines, while electrical connections between various components are shown as dashed lines.

[0018] The drivetrain 100 includes a rear axle 122 . In some examples, the rear axle 122 may include two half-shafts, such as a first half-shaft 122 a and a second half-shaft 122 b . The drivetrain 100 also includes front wheels 130 and rear wheels 131 . The rear wheels 131 may be driven by the motor 126 .

[0019] The rear axle 122 is coupled to a motor 126. The rear drive unit 136 can transfer power from the motor 126 to the axle 122, thereby rotating the rear wheels 131. The rear drive unit 136 can include a low range 175 and a high range 177 coupled to the motor 126 via an output shaft 126o of the motor 126. The low range 175 can be engaged via a fully closed low range clutch 176. The high range 177 can be engaged via a fully closed high range clutch 178. The high range clutch 178 and the low range clutch 176 can be opened and closed via commands received by the rear drive unit 136 via a network 199. Alternatively, the high range clutch 178 and the low range clutch 176 can be opened and closed via a digital output or pulse width provided by the control system 114. The rear drive unit 136 can include a differential 128, so that torque can be provided to the first half-shaft 122a and the second half-shaft 122b. In some examples, an electronically controlled differential clutch (not shown) may be included in rear drive unit 136 .

[0020] The motor 126 can receive power from an onboard electrical energy storage device 132. In addition, the motor 126 can provide a generator function to convert the vehicle's kinetic energy into electrical energy, where the electrical energy can be stored at the electrical energy storage device 132 for later use by the motor 126. The inverter 134 can convert the alternating current generated by the motor 126 into direct current for storage at the electrical energy storage device 132, and vice versa. The electric drive system 135 includes the motor 126 and the inverter 134. The electrical energy storage device 132 can be a traction battery (e.g., a battery that supplies power to propel the vehicle), a capacitor, an inductor, or other electrical energy storage device. The power flowing into the electric drive system 135 can be monitored via a current sensor 145 and a voltage sensor 146. The position and speed of the motor 126 can be monitored via a position sensor 147. The torque generated by the motor 126 can be monitored via a torque sensor 148.

[0021] In some examples, electrical energy storage device 132 can be configured to store electrical energy that can be provided to other electrical loads resident on the vehicle (in addition to the motor), including cabin heating and air conditioning systems, engine starting systems, headlight systems, cabin audio and video systems, etc.

[0022] The control system 114 may communicate with the electric motor 126, the electrical energy storage device 132, and the like. The control system 114 may receive sensory feedback information from the electric drive system 135, the electrical energy storage device 132, and the like. Furthermore, the control system 114 may send control signals to the electric drive system 135, the electrical energy storage device 132, and the like in response to this sensory feedback. The control system 114 may receive an indication of an operator-requested output of the vehicle propulsion system from the human operator 102 or the autonomous controller. For example, the control system 114 may receive sensory feedback from a pedal position sensor 194 in communication with a pedal 192. Pedal 192 may schematically represent a driver demand pedal. Similarly, the control system 114 may receive an indication of an operator-requested vehicle deceleration via the human operator 102 or the autonomous controller. For example, the control system 114 may receive sensory feedback from a pedal position sensor 157 in communication with a caliper control pedal 156.

[0023] The electrical energy storage device 132 may periodically receive electrical energy from a power source residing external to the vehicle (e.g., not part of the vehicle), such as a stationary power grid (not shown). As a non-limiting example, the powertrain 100 may be configured as a plug-in electric vehicle (EV), whereby electrical energy may be supplied to the electrical energy storage device 132 via a power grid (not shown).

[0024] The electrical energy storage device 132 includes an electrical energy storage device controller 139. The electrical energy storage device controller 139 may provide charge balancing between energy storage elements (eg, battery cells) and communication with other vehicle controllers (eg, controller 112).

[0025] One or more wheel speed sensors (WSS) 195 may be coupled to one or more wheels of the drivetrain 100. The wheel speed sensors may detect the rotational speed of each wheel. Such examples of WSSs may include permanent magnet type sensors.

[0026] Controller 112 may include part of a control system 114. In some examples, controller 112 may be the single controller for the vehicle. Control system 114 is shown receiving information from a plurality of sensors 116 (various examples of which are described herein) and sending control signals to a plurality of actuators 181 (various examples of which are described herein). As one example, sensors 116 may include tire pressure sensors (not shown), wheel speed sensors 195, and the like. In some examples, sensors associated with motor 126, wheel speed sensors 195, and the like may transmit information regarding various states of motor operation to controller 112. Controller 112 includes non-transitory (e.g., read-only memory) 165, random access memory 166, digital input / output 168, and a microcontroller 167. Infotainment system 140 (e.g., a human / machine interface) may receive input data from person 102 and may display messages and data to person 102. Infotainment system 140 may communicate with controller 112 and power distribution module 138 via a network 199 (e.g., a controller area network (CAN) or Ethernet network). The infotainment system 140 may operate as a human / machine interface in several modes.

[0027] Now refer to Figure 2 , shows a schematic diagram of an exemplary prior art rotary transformer 200. Rotary transformer 200 includes a stator 202 that can be fastened to the housing of an electric machine via a mounting flange 206. Rotary transformer 200 includes an electrical connector 204 so that it can transmit the position of the rotor shaft to a controller (not shown). Stator 202 may include a steel stamping and a winding (not shown) wound around the steel stamping.

[0028] Now refer to Figure 3, shows a perspective view of an exemplary integrated resolver stator and rotor bearing support 300 according to the present specification. Integrated resolver stator and rotor bearing support 300 includes a resolver stator 308 comprising a steel stamping 310 and copper windings 312 wound around the steel stamping 310. Furthermore, integrated resolver stator and rotor bearing support includes an electrical connector interface 304 (e.g., a socket or plug) within an integrated resolver stator and rotor bearing support housing 302, a mounting flange 306, and a rotor bearing support 320. Electrical connector interface 304 and integrated resolver stator and rotor bearing support housing 302 can be of unitary and / or seamless construction. Mounting flange 306 can include a metal sleeve 307. Integrated resolver stator and rotor bearing support 300 includes resolver stator 308, which is shown docked with an electrical connector 330. Resolver stator 308 and rotor bearing support 320 are concentric with respect to centerline 350 .

[0029] The integrated rotary transformer stator and rotor bearing support 300 can be molded from an electrically insulating material, such as plastic, such that a rotor bearing (not shown) can be mounted into the integrated rotary transformer stator and rotor bearing support 300 and electrically isolated from a motor housing to which the integrated rotary transformer stator and rotor bearing support can be coupled. The insulating material is substantially non-conductive relative to the current carrying components. The integrated rotary transformer stator and rotor bearing support 300 can be manufactured via injection molding or other known processes. The integrated rotary transformer stator and rotor bearing support 300 can be molded over the rotary transformer stator 308 (e.g., with the molding medium (e.g., plastic) at least partially covering the device being molded thereon), such as Figure 4 Additionally, the integrated resolver stator and rotor bearing support 300 may be molded over the rotor bearing support cup.

[0030] Move to Figure 4 , shows a cross-sectional view of 300. This cross-sectional view shows a rotor bearing support cup 406 inserted (e.g., press-fitted) into and occupying a portion of the rotor bearing support 320, which is located within the integrated rotary transformer stator and rotor bearing support housing 302. The centerline 451 of the rotor bearing support cup 406 is aligned with the centerline 450 of the rotary transformer stator 308. In addition, the centerline 451 and the centerline 450 are aligned with each other. Figure 3The centerline 350 of the rotor bearing support 320 is shown aligned. The steel stamping 310 and copper windings 312 of the resolver stator 308 are annular in shape to allow the rotor shaft to rotate within the resolver stator 308. The resolver stator 308 can be held in place via a press-fit retainer 410 or alternatively molded over the resolver stator 308. Conductors 402 extend from the resolver stator 308 to the electrical connector interface 304. The electrical connector interface 304 is shown mated to the electrical connector 330.

[0031] Now refer to Figure 5 , a cutaway perspective view of an integrated rotary transformer stator and rotor bearing support 300. In this view, the integrated rotary transformer stator and rotor bearing support 300 is shown mechanically coupled to Figure 1 Motor housing 502 of motor 126 is shown. Furthermore, rotor bearing 504 is inserted into rotor bearing support cup 406. Rotor bearing 504 supports rotor shaft 506 and rotor sleeve 508. Rotor shaft 506 supports a rotor core (not shown). Rotary transformer lobes 510 are coupled to rotor shaft 506. Rotor shaft 506 and rotor sleeve 508 are supported via motor housing 502, integrated rotary transformer stator and rotor bearing support, integrated rotary transformer stator and rotor bearing support housing 302, rotor bearing 504, and rotor bearing support cup 406. Fasteners 510 couple integrated rotary transformer stator and rotor bearing support housing 302 to motor housing 502.

[0032] Figures 2 to 5 Drawn to scale, however other relative dimensions may be used. Figures 1 to 5An exemplary configuration with relative positioning of various components is shown. Unless otherwise stated, in at least one example, if shown as being in direct contact with each other or directly coupled, such elements may be referred to as being in direct contact or directly coupled, respectively. Similarly, in at least one example, elements that are shown as being adjacent or adjacent to each other may be adjacent or adjacent to each other, respectively. As an example, components that are in coplanar contact with each other may be referred to as being in coplanar contact. As another example, in at least one example, components that are positioned apart from each other with only space between them and no other components may be referred to as being so. As another example, elements that are shown as being above / below each other, on opposite sides, or on the left / right side of each other may be referred to as being so relative to each other. In addition, as shown in the accompanying drawings, in at least one example, the topmost element or the vertex of an element may be referred to as the "top" of a component, and the bottommost element or the lowest point of an element may be referred to as the "bottom" of a component. As used herein, top / bottom, upper / lower, above / below may be relative to the vertical axis of the accompanying drawings and are used to describe the positioning of the elements of the accompanying drawings relative to each other. Thus, in one example, an element shown as being above another element is directly above the other element. As another example, the shapes of elements depicted in the drawings may be referred to as having these shapes (e.g., such as being circular, linear, planar, curved, rounded, chamfered, angled, etc.). Additionally, in at least one example, elements shown as intersecting each other may be referred to as intersecting elements or intersecting each other. Furthermore, in one example, an element shown as being within another element or being shown as being outside another element may be referred to as such.

[0033] Figures 1 to 5A support system is provided, the support system comprising: a housing constructed of an electrically insulating material, the housing configured to support a resolver stator and a bearing support cup, wherein when the resolver stator and the bearing support cup are integrated with the housing, the resolver stator and the bearing support cup are concentric. In a first example, the support system comprises: wherein the housing is molded over at least a portion of the resolver stator. In a second example, which may include the first example, the support system comprises: wherein the resolver stator is retained within the housing via a retainer. In a third example, which may include one or both of the first and second examples, the support system comprises: wherein the bearing support cup comprises steel or aluminum. In a fourth example, which may include one or more of the first to third examples, the support system comprises: wherein the housing is molded over the bearing support cup. In a fifth example, which may include one or more of the first to fourth examples, the support system further comprises an interface for an electrical connector seamlessly integrated into the housing. In a sixth example, which may include one or more of the first to fifth examples, the support system further comprises an electrical conductor extending from the resolver stator to the interface.

[0034] Figures 1 to 5 The system also provides a support system, the support system comprising: a motor housing; a motor rotor shaft; a housing made of an electrically insulating material, the housing comprising a rotary transformer stator and a bearing support cup, the rotary transformer stator being concentric with the rotor bearing support cup, the housing being coupled to the motor housing. In a first example, the support system further comprises a bearing, the bearing being pressed into the rotor bearing support cup. In a second example, which may include the first example, the support system comprises: the motor rotor shaft being inserted into the rotor bearing support cup. In a second example, which may include the first example, the support system further comprises a rotary transformer lobe coupled to the motor rotor shaft. In a third example, which may include one or both of the first and second examples, the support system further comprises an electrical connector receiver formed in the housing, an electrical connector coupled to the motor housing, the electrical connector mating to the electrical connector receiver.

[0035] Now refer to Figure 6 , a method for constructing an integrated rotary transformer stator and rotor bearing support housing is shown. Method 600 can be performed by humans and / or automated machines in the physical world.

[0036] At 602, method 600 molds or machines an integrated resolver stator and rotor bearing support housing. The integrated resolver stator and rotor bearing support housing can be molded or alternatively machined from plastic or another electrically insulating material. In some examples, the integrated resolver stator and rotor bearing support housing can be molded over the resolver stator and / or bearing support cup, such as Figure 4 Additionally, the integrated resolver stator and rotor bearing support housing can be molded over the conductors extending from the resolver stator to the electrical connector interface, as shown. Figure 4 As shown. The integrated resolver stator and rotor bearing support housing includes and / or forms a resolver stator support and a rotor bearing support. The resolver stator support and the rotor bearing support are formed or molded such that, when the rotor bearing and resolver are supported by the integrated resolver stator and rotor bearing support, the rotor bearing centerline and the rotor bearing support cup centerline are concentric with the resolver stator centerline. Additionally, the resolver stator and bearing support cup are mounted to the integrated resolver stator and rotor bearing support without being molded above the resolver stator and bearing support cup. Method 600 proceeds to 604.

[0037] At 604 , the rotor bearing is pressed into the rotor bearing support cup. Method 600 proceeds to 606 .

[0038] At 606 , the resolver stator is pressed into the integrated resolver stator support and rotor bearing support without being molded over the resolver stator. Method 600 proceeds to 608 .

[0039] At 608 , method 600 inserts the electric machine rotor shaft into the rotor bearing that has been pressed into the integrated resolver stator support and rotor bearing support. Method 600 proceeds to 610 .

[0040] At 610 , a resolver lobe is coupled to the motor rotor shaft. The lobe allows the rotor shaft position to be determined via the resolver stator. Method 600 proceeds to 612 .

[0041] At 612 , the integrated rotary transformer stator and rotor bearing supports, along with the rotor bearings, are coupled to the motor housing. The motor housing supports the integrated rotary transformer stator and rotor bearing supports, the rotor bearings, and the motor rotor shaft. Method 600 proceeds to exit.

[0042] Thus, method 600 manages the operation of the DC / DC converter so that sufficient power is available to the DC electrical loads on the DC bus while compensating for DC / DC converter efficiency and output capacity. Additionally, method 400 provides for user input to override automatic power management in situations where the user may not want to reduce the distance the vehicle can travel based on the current energy level stored in the traction battery.

[0043] therefore, Figure 6 A method for constructing a support member for a rotary transformer stator and rotor bearing support cup is provided, the method comprising: molding the support member from an electrically insulating material such that the rotary transformer stator and rotor bearing support cup are concentric about the rotary transformer stator centerline and the rotor bearing support cup centerline when assembled with the support member. In a first example, the method comprises: wherein the electrically insulating material is plastic. In a second example, which may include the first example, the method further comprises: molding an electrical conductor into the support member. In a third example, which may include one or both of the first and second examples, the method further comprises: molding an electrical connector interface into the support member. In a fourth example, which may include one or more of the first to third examples, the method comprises: wherein the electrical conductor extends from the electrical connector interface to the rotary transformer. In a fifth example, which may include one or more of the first to fourth examples, the method further comprises: molding the support member over the rotary transformer stator. In a sixth example, which may include one or more of the first to fifth examples, the method further comprises: molding the support member over the bearing support cup. In a seventh example, which may include one or more of the first to sixth examples, the method further includes pressing a bearing into the rotor bearing support cup.

[0044] It should be noted that the exemplary configuration processes included herein can be used with various motor system configurations. The configuration processes disclosed herein can be performed by humans or by machine automation. The configuration processes described herein can be performed in a different order than that described herein. One or more of the illustrated actions, operations, and / or functions can be repeatedly performed depending on the specific process used.

[0045] This specification ends here. Without departing from the spirit and scope of this specification, those skilled in the art will think of many variations and modifications after reading this specification. For example, electric and hybrid vehicle configurations may benefit from using this specification.

[0046] According to the present invention, a support system is provided having: a housing constructed of an electrically insulating material, the housing being configured to support a resolver stator and a rotor bearing support cup, the resolver stator being concentric with the rotor bearing support cup when the resolver stator and the rotor bearing support cup are integrated with the housing.

[0047] According to one embodiment, the housing is molded over at least a portion of the resolver stator.

[0048] According to one embodiment, the resolver stator is held in the housing via a holder.

[0049] According to one embodiment, the rotor bearing support cup comprises steel or aluminum.

[0050] According to one embodiment, the housing is molded over the rotor bearing support cup.

[0051] According to one embodiment, the invention also features an interface for an electrical connector that is seamlessly integrated into the housing.

[0052] According to one embodiment, the invention also features an electrical conductor extending from the resolver stator to the interface.

[0053] According to the present invention, a method for constructing a support for a resolver stator and rotor bearing support cup includes molding the support from an electrically insulating material so that the resolver stator and rotor bearing support cup are concentric about a resolver stator centerline and a rotor bearing support cup centerline when assembled with the support.

[0054] In one aspect of the invention, the electrically insulating material is plastic.

[0055] In one aspect of the invention, the method comprises moulding an electrical conductor into the support.

[0056] In one aspect of the invention, the method further comprises molding an electrical connector interface into the support member.

[0057] In one aspect of the invention, the electrical conductors extend from the electrical connector interface to a rotary transformer.

[0058] In one aspect of the invention, the method further comprises molding the support over the resolver stator.

[0059] In one aspect of the invention, the method further comprises molding the support member over the bearing support cup.

[0060] In one aspect of the invention, the method further comprises pressing a bearing into the rotor bearing support cup.

[0061] According to the present invention, a support system is provided, comprising: a motor housing; a motor rotor shaft; a housing constructed of electrically insulating material, the housing including a rotary transformer stator and a rotor bearing support cup, the rotary transformer stator being concentric with the rotor bearing support cup, the housing being coupled to the motor housing.

[0062] According to one embodiment, the invention also features a bearing that is pressed into the rotor bearing support cup.

[0063] According to one embodiment, the motor rotor shaft is inserted into the rotor bearing support cup.

[0064] According to one embodiment, the invention also features a resolver lobe coupled to the motor rotor shaft.

[0065] According to one embodiment, the invention further features an electrical connector receptacle formed in the housing, an electrical connector coupled to the motor housing, the electrical connector mated to the electrical connector receptacle.

Claims

1. A support system comprising: A housing constructed of an electrically insulating material is configured to support a resolver stator and a rotor bearing support cup, the resolver stator being concentric with the rotor bearing support cup when the resolver stator and the rotor bearing support cup are integrated with the housing. 2 . The support system of claim 1 , wherein the housing is molded over at least a portion of the resolver stator.

3. The support system of claim 1, wherein the rotary transformer stator is retained within the housing via a retainer.

4. The support system of claim 1 , wherein the rotor bearing support cup comprises steel or aluminum.

5. The support system of claim 4, wherein the housing is molded over the rotor bearing support cup.

6. The support system of claim 1 further comprising an interface for an electrical connector seamlessly integrated into the housing.

7. The support system of claim 6, further comprising an electrical conductor extending from the rotary transformer stator to the interface.

8. A method for constructing a support for a rotary transformer stator and rotor bearing support cup, comprising: The support is molded from an electrically insulating material such that the resolver stator and the rotor bearing support cup are concentric about a resolver stator centerline and a rotor bearing support cup centerline when assembled with the support.

9. The method of claim 8, wherein the electrically insulating material is plastic.

10. The method of claim 8, further comprising molding an electrical conductor into the support.

11. The method of claim 10, further comprising molding an electrical connector interface into the support.

12. The method of claim 11, wherein the electrical conductor extends from the electrical connector interface to a rotary transformer.

13. The method of claim 12, further comprising molding the support over the resolver stator.

14. The method of claim 13, further comprising molding the support member over the bearing support cup.

15. The method of claim 14, further comprising pressing a bearing into the rotor bearing support cup.

Images