Integrated coated rotary transformer

Abstract

The utility model discloses an integrated cladding resolver, including stator subassembly and resolver rotor, the resolver rotor is located in the stator subassembly to generate alternating magnetic field, the stator subassembly includes: stator core, gullet and winding, the stator core is fixedly connected with the wiring shell, the gullet is opened on the inner wall of stator core, the winding is connected with the wiring shell, the gullet is opened on the inner wall of stator core. The stator assembly comprises a stator iron core and a winding, the stator iron core is provided with a tooth groove, the tooth groove is coated with an insulator, the winding is wound on the insulator, the winding is connected with a wire, the wire is communicated with the wiring shell, the wire is used for transmitting signals on the winding, and the stator assembly is coated with a protective layer so that the stator iron core, the insulator and the winding can be coated into a whole. The integrally-coated rotary transformer can work in a high-strength vibration environment, the flexibility of a power assembly mechanism cannot be limited, the structural space of a power motor is effectively saved, and development of a whole vehicle is facilitated.

Description

Technical Field

[0001] The utility model belongs to the technical field of resolver, and particularly relates to an integrated coated resolver. Background Art

[0002] A resolver is a type of signal motor and is mainly used as a sensor for measuring speed, angle, and position. Due to its simple structure, good stability, high reliability, and significant energy-saving effect, the resolver has a good application in new energy vehicles.

[0003] With the continuous development of new energy vehicles, the requirements for products are getting higher and higher, and they need to be able to adapt to more complex and harsh environments. For example, in trunk logistics vehicles with dual-motor power, power devices are installed on the front axle and the rear axle respectively. The vibration intensity at the front axle position is generally 10g, and at the vehicle-mounted rear axle position, the vibration intensity is as high as 20 - 30g. The resolver needs to operate normally for a long time in this environment. Therefore, high requirements are put forward for the structural strength of the resolver.

[0004] In order to meet the high anti-vibration intensity of the resolver, the current treatment method is to increase the structural size of the resolver and the wire diameter of the resolver. Although the structural size of the resolver and the wire diameter of the resolver can improve the vibration resistance of the resolver to a certain extent, the accompanying result is an increase in volume and structure, which limits the flexibility of the powertrain mechanism and is not conducive to vehicle development.

[0005] Therefore, in view of the above technical problems, it is necessary to provide an integrated coated resolver.

[0006] The information disclosed in this background art section is only intended to enhance the overall understanding of the present utility model and should not be regarded as an admission or any form of suggestion that this information constitutes prior art already known to those of ordinary skill in the art. Summary of the Utility Model

[0007] The purpose of the present utility model is to provide an integrated coated resolver, which can be used to solve the above problems.

[0008] To achieve the above purpose, a specific embodiment of the present utility model provides an integrated coated resolver, which includes a stator assembly and a resolver rotor. The resolver rotor is located inside the stator assembly to generate an alternating magnetic field. The stator assembly includes:

[0009] A stator core, on which a wiring shell is fixedly connected;

[0010] Tooth grooves are formed on the inner wall of the stator core, and an insulator is coated on the tooth grooves;

[0011] A winding is wound around the insulator, and a wire is connected to the winding. The wire is in communication with the connection housing, and the wire is used to transmit signals on the winding.

[0012] Wherein, a protective layer is coated on the stator assembly to enclose the stator core, insulator and winding into a whole.

[0013] In one or more embodiments of the present utility model, the protective layer is a BMC resin layer.

[0014] In one or more embodiments of the present utility model, a cavity is formed in the groove wall of the tooth groove, and a support rod is arranged in the cavity. The length of the support rod is 1.2 times the height of the stator core.

[0015] In one or more embodiments of the present utility model, the rotating rotor is provided with a mounting hole and a convex block protruding radially towards the mounting hole. The mounting hole is used for the rotating shaft of the object to be measured to pass through, and the convex block is used for clamping in the groove of the rotating shaft.

[0016] In one or more embodiments of the present utility model, the resolver rotor is further provided with a through hole for identifying the mounting direction.

[0017] In one or more embodiments of the present utility model, the connection housing and the stator core are integrally formed. A connection terminal is clamped on the connection housing, and a limiting block is fixedly connected to the connection terminal.

[0018] In one or more embodiments of the present utility model, a limiting groove matching with the limiting block is formed in the connection housing, and the connection terminal is clamped in the limiting groove through the limiting block.

[0019] In one or more embodiments of the present utility model, the limiting groove is T-shaped.

[0020] In one or more embodiments of the present utility model, a connection hole is formed on the upper end surface of the connection terminal. The wire on the winding is inserted into the connection hole on the connection terminal. A connection wire is further connected to the connection housing, and the connection wire is in communication with the wire on the winding.

[0021] In one or more embodiments of the present utility model, the winding is an electromagnetic copper wire.

[0022] Compared with the prior art, the integrated wrapped resolver of the present utility model can work in an environment with high-intensity vibration, does not limit the flexibility of the powertrain mechanism, effectively saves the structural space of the power motor, and is beneficial to the development of the whole vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the attached drawings required in the description of the embodiments or the prior art. Obviously, the attached drawings in the following description are only some embodiments recorded in the present invention. For those of ordinary skill in the art, without creative efforts, other attached drawings can also be obtained based on these attached drawings.

[0024] Figure 1 It is the top view of the integrated coated resolver without the coated protective layer in an embodiment of the present invention;

[0025] Figure 2 It is the front view of the integrated coated resolver without the coated protective layer in an embodiment of the present invention;

[0026] Figure 3 For Figure 2 It is the structural schematic diagram of the position A in

[0027] Figure 4 It is the top view of the integrated coated resolver after the coated protective layer is applied in an embodiment of the present invention;

[0028] Figure 5 It is the front view of the integrated coated resolver after the coated protective layer is applied in an embodiment of the present invention.

[0029] Main reference numeral description:

[0030] 1, stator core; 101, tooth slot; 102, cavity; 1021, support rod; 2, insulator; 3, winding; 4, connecting wire; 5, protective layer; 6, resolver rotor; 61, bump; 62, through hole; 7, wiring shell; 701, limiting slot; 71, wiring post; 711, limiting block. Detailed implementation manners

[0031] In order to enable those skilled in the art to better understand the technical solutions in the present invention, the following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the attached drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0032] [[ID=�6]]Such as Figure 1 And Figure 4As shown in the figure, the integrated encapsulated resolver in an embodiment of the present utility model includes a stator assembly and a resolver rotor 6. The stator assembly includes a stator core 1, and a wiring shell 7 is integrally formed on the stator core 1. A connecting wire 4 is installed in the wiring shell 7, and the connecting wire 4 is used to transmit electrical signals. One end of the connecting wire 4 away from the wiring shell 7 is connected to a signal processor. Tooth grooves 101 are formed on the inner wall of the stator core 1, a winding 3 is wound on the tooth grooves 101, and an insulator 2 is coated on the tooth grooves 101. When the resolver rotor 6 rotates in the stator core 1, it converts the angular displacement into an electrical signal and transmits the electrical signal to the connecting wire 4. After receiving the electrical signal transmitted on the connecting wire 4, the signal processor collects and processes the electrical signal.

[0033] As Figures 1 to 5 shown, in order to reduce the vibration received by the resolver, a protective layer 5 is coated on the stator assembly to fix the stator core 1, the insulator 2 and the winding 3 into a whole. When the resolver is vibrated, the protective layer 5 can absorb a certain amount of vibration to reduce vibration.

[0034] Specifically, the protective layer 5 is BMC resin. The protective layer 5 is formed by injection molding, which can meet different regular structures and has high structural strength. Each part of the formed resolver is coated in the dense protective layer 5 and forms an integral structure with the protective layer 5. Under high-intensity vibration conditions, each component of the resolver is within the protective layer 5 and can meet the use of various resolver structures.

[0035] The BMC resin completely fills the gaps between the resolver stator core, the resolver insulator, and the resolver winding, making them an integral whole. When the resolver receives a vibration source, since each component of the resolver is an integral whole, the vibration source does not change due to the materials and gaps between the components of the resolver. It is ensured that the parts operate at the same frequency when receiving the vibration source.

[0036] Furthermore, the number of tooth grooves 101 is even. The even number of tooth grooves 101 can enable the stator assembly to maintain the same frequency and have the same amplitude in a vibration environment, so that the resolver operates at the same frequency and the same amplitude, and this will not cause damage to the resolver.

[0037] The winding 3 is wound on the insulator 2, and the winding 3 is made of electromagnetic copper wire. Specifically, the insulator 2 is integrally formed with the tooth grooves 101 and the stator core 1. The insulator 2 makes the stator core 1 and the tooth grooves 101 have insulation properties, which can prevent electromagnetic interference phenomena from occurring when the resolver works.

[0038] As Figure 1 、 Figure 2 and Figure 5As shown, a cavity 102 is formed in the groove wall of the tooth groove 101. A support rod 1021 is inserted into the cavity 102, and the length of the support rod 1021 is 1.2 times the height of the stator core 1. Specifically, when injecting the BMC resin, the support rod 1021 is injected together, which can enhance the seismic performance of the formed protective layer 5. The size of the cast protective layer 5 can also be controlled by the length of the support rod 1021 to prevent the protective layer 5 from being too thin to lose seismic resistance or too thick to be installed.

[0039] As Figure 4 shown, the resolver rotor 6 has 4 salient poles. When the resolver rotor 6 rotates within the stator core 1, the salient poles on the resolver rotor 6 induce a periodic current change to complete the resolver operation. The 4 salient poles can make the monitoring data more accurate.

[0040] An installation hole and a convex block 61 protruding radially towards the installation hole are formed on the resolver rotor 6. The installation hole is used for the rotation axis of the object to be measured to pass through, and a groove matching the convex block 61 is formed on the rotation axis of the object to be measured. The convex block 61 is used for being clamped in the groove of the rotation axis. When installing the resolver rotor 6, the convex block 61 is clamped in the groove of the rotation axis. When the rotation axis rotates, it can prevent the resolver rotor 6 from slipping on the rotation axis, effectively ensuring the monitoring accuracy.

[0041] Furthermore, a through hole 62 is also formed on the resolver rotor 6. The through hole 62 facilitates the identification of the installation direction, can distinguish whether the integrally coated resolver is in the front or back, and has an anti-fooling function.

[0042] As Figures 1 to 5 shown, the wiring shell 7 and the stator core 1 are integrally formed. A wiring post 71 is clamped on the wiring shell 7, and a limit block 711 is integrally formed on the wiring post 71. Specifically, a limit groove 701 matching the limit block 711 is formed on the wiring shell 7, and the limit groove 701 is T-shaped. The wiring post 71 is clamped in the limit groove 701 through the limit block 711. A wiring hole is provided on the upper end surface of the wiring post 71, and the wire on the winding 3 is inserted into the wiring hole on the wiring post 71.

[0043] Specifically, first, one end of the connecting wire 4 is extended into the wiring shell 7, pulled out from the limit groove 701, and then inserted into the wiring post 71 to be connected to the wire on the winding 3. After the connecting wire 4 is connected to the wire on the winding 3, the wiring post 71 is clamped in the limit groove 701 to seal the limit groove 701. The connection point between the connecting wire 4 and the wire is in the middle of 77. The wiring post 71 wraps the connection point between the connecting wire 4 and the wire, and the wiring post 71 is perpendicular to the ground. When the new energy vehicle is driving in a waterlogged section, the wiring post 71 can protect the connection point between the connecting wire 4 and the wire, and it is not easy to have a short circuit phenomenon.

[0044] For those skilled in the art, it is obvious that the present utility model is not limited to the details of the above-mentioned exemplary embodiments, and without departing from the spirit or basic characteristics of the present utility model, the present utility model can be implemented in other specific forms. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present utility model is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be embraced within the present utility model. Any reference signs in the claims should not be construed as limiting the claims involved.

[0045] In addition, it should be understood that although this specification is described according to embodiments, not every embodiment only contains an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. One-piece encapsulated resolver, characterized in that, Comprising a stator assembly and a resolver rotor, the resolver rotor is located within the stator assembly to generate an alternating magnetic field, and the stator assembly includes: A stator core, on which a wiring case is fixedly connected; Tooth grooves, which are opened on the inner wall of the stator core, and an insulator is coated on the tooth grooves; Windings, wound on the insulator, a wire is connected to the windings, the wire is communicated with the wiring case, and the wire is used to transmit the signals on the windings; Wherein a protective layer is coated on the stator assembly to coat the stator core, the insulator and the windings into a whole.

2. The integrated covered rotary transformer according to claim 1, characterized in that: The protective layer is a BMC resin layer.

3. The integral-cladding rotary transformer according to claim 2, wherein A cavity is opened on the groove wall of the tooth groove, and a support rod is arranged in the cavity, and the length of the support rod is 1.2 times the height of the stator core.

4. The one-piece encapsulated resolver according to claim 2, wherein The resolver rotor is provided with a mounting hole and a convex block radially protruding towards the mounting hole, the mounting hole is used for the rotation axis of the object to be measured to pass through, and the convex block is used for being clamped in the groove of the rotation axis.

5. The one-piece encapsulated resolver according to claim 4, wherein The resolver rotor is also provided with a through hole for identifying the mounting direction.

6. The integrated encapsulated resolver according to claim 2, wherein The wiring case and the stator core are integrally formed, a terminal post is clamped on the wiring case, and a limiting block is fixedly connected to the terminal post.

7. The integrated wrapped resolver according to claim 6, characterized in that, A limiting groove matching the limiting block is opened on the wiring case, and the terminal post is clamped in the limiting groove through the limiting block.

8. The integrated encapsulated resolver according to claim 7, wherein The limiting groove is T-shaped.

9. The integrated encapsulated resolver according to claim 6, wherein A wiring hole is arranged on the upper end surface of the terminal post, the wire on the windings is inserted into the wiring hole on the terminal post, and a connecting wire is also connected to the wiring case, and the connecting wire is communicated with the wire on the windings.

10. The integral-clad resolver according to claim 1, wherein The windings are electromagnetic copper wires.

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