Solve

Abstract

Resolver (1), comprising: a stator core (5); an insulator (7, 8) mounted on the stator core (5), and a winding (9) which is wound on the insulator (7, 8) attached to the stator core (5); a terminal pin base (10) extending radially outwards and formed integrally with the insulator (7, 8), the terminal pin base comprising: a plurality of grooves (16) provided on the terminal pin base, each of the plurality of grooves receiving one of a plurality of external conductor wires (12), a plurality of connecting pins (11) arranged on the connecting pin base (10), each of the connecting pins having a first connecting part (11a) at one end and a second connecting part at the other end, a first cover (13) which is provided on the connecting pin base (10) at one end side in an axial direction; and a second cover (14) which is provided on the connecting pin base (10) at the other end side in the axial direction, wherein the first connecting part (11a) of each terminal pin (11) is connected to the winding (9), and the second connecting part of each terminal pin is connected to one of the external conductor wires (12), wherein the first cover (13) covers the first connecting part (11a) of the connecting pin (11) and the grooves (16) and the second cover (14) covers a rear side of the second connecting part of the connecting pin, wherein a first space (21) is formed between the first cover (13) and the connecting pin base (10) and the first connecting part (11a) is arranged in the first space; wherein a second space (22) is formed between the second cover (14) and the connecting pin base (10); wherein the second connecting part of each connecting pin (11) is arranged within a corresponding groove (16) of the plurality of grooves; wherein the first space (21), the second space (22) and the plurality of grooves (16) are filled with a filler material (20); and wherein the first connecting part (11a) and the second connecting part of each connecting pin (11) are sealed in the filler material (20) and wherein the filler material (20) filled into the first space (21) and the filler material (20) filled into the second space (22) are connected to each other by a through hole (10b).

Description

Background of the inventionField of the invention

[0001] The present invention relates to a resolver, and more particularly to a resolver having a structure for protecting a terminal pin and a terminal. Description of the state of the art

[0002] A resolver is known as a device for detecting a rotation angle. The resolver is equipped with a rotor that rotates and is mounted on a rotating shaft of a motor, and a stator that is fixed to a casing and the like and arranged to oppose the rotor in a radial direction. An excitation winding and a detection winding are wound on the stator. The detection winding has windings for outputting a sine signal and a cosine signal. When the rotor of the resolver is rotated by applying an excitation current to the excitation winding, the dimension of a distance between the rotor and the stator changes, and a voltage corresponding to the change is induced in the detection winding.The voltage generated by the detection winding is a signal that reflects the angle of rotation of the rotor, which is why it is possible to detect the angle of the rotating shaft using the signal.

[0003] The respective winding terminals of the excitation winding and the detection winding are connected to terminal pins arranged in a terminal pin socket formed integrally with an insulator. A problem may arise in that a portion where the copper wire of the winding terminal connected to the terminal pin is exposed may corrode in the resolver's operating environment, resulting in poor conductivity. Therefore, a resolver capable of preventing corrosion at the resolver's winding terminals has been proposed (for example, see JP 2015-45510 A).

[0004] Fig. 8 is a plan view of a resolver 100 described in JP 2015-45510 A, and Fig. 9 is a perspective view of its stator part. Fig. The resolver 100 shown in Fig. 8 is provided with a wiring lead-out part 111 in which a plurality of terminal pins are arranged, the terminal of a coil 114 is connected to each of the plurality of terminal pins, a terminal pin cover 115 covering the plurality of terminal pins is mounted on the wiring lead-out part 111, the terminal pin cover 115 is filled with a filler material, and the terminal of the coil 114 connected to the terminal pin is sealed in the filler material.

[0005] In the configuration disclosed in JP 2015-45510 A, the terminals 113 are formed integrally with the terminal pins, arranged radially outside the terminal pins, and a lead wire for connection to the outside is electrically connected to the terminals 113. With the configuration disclosed in JP 2015-45510 A, it is possible to prevent corrosion of the terminal of the winding because the terminal of the winding 114 connected to the terminal pin is sealed in the filler material filled in the terminal pin cover 115. However, since the terminal 113 to which the lead wire for connection to the outside is electrically connected is exposed, a problem may occur in that a part of the lead wire connected to the terminal 113 corrodes, resulting in poor conductivity.

[0006] US 2013 / 0049742 A1 describes a variable reluctance resolver having terminal pins on an insulator. A first insulator is formed together with a terminal pin base on which terminal pins are provided. The terminal pins are connected to end portions of windings of a stator coil. A cover, into which resin is filled, is mounted on the terminal pin base. The resin is also applied to the stator coil. The resin filled in the cover seals the terminal pins, and the cover protects the terminal pins.

[0007] US 2012 / 0236479 A1 describes a waterproof structure of an electronic unit comprising a housing defining a housing portion accommodating a first terminal, and a connector including an insulating body secured to the housing. The connector includes a second terminal supported by the insulating body and connecting a conductor end portion of a cable to the first terminal. The insulating body includes a wall portion partitioning a portion of the housing portion by covering an open portion of the housing. The insulating body includes a cable entry portion defining a cable entry hole for inserting the cable into the housing and connected to the wall portion. A potting resin is filled and cured into a space between the inner periphery of the cable entry hole and the outer periphery of the cable and the housing portion. Summary of the invention

[0008] One of the objects of the present invention is to provide a resolver capable of preventing corrosion of a terminal of a winding connected to a terminal pin and a lead wire connected to the terminal even when the resolver is used in an environment where there are corrosive components.

[0009] The invention is defined by the main claim. The dependent claims describe further embodiments of the invention. Short description of the drawings

[0010] The attached drawings show: Fig. 1 is a plan view illustrating a resolver according to an embodiment; Fig. 2 a cross-sectional view of the resolver along the line AA, which is shown in Fig. 1 is shown; Fig. 3 a cross-sectional view of the Fig. 1 shown resolver; Fig. 4 a representation of the Fig. 1 shown resolver from below; Fig. 5 a cross-sectional view of the Fig. 1, showing an attachment state of a terminal pin cover and a sliding cover; Fig. 6 a perspective view of the Fig. 4, showing a state in which the sliding cover is removed; Fig. 7 a view of the Fig. 6 resolvers shown from above; Fig. 8 is a plan view illustrating a resolver according to a prior art; and Fig. 9 a perspective view of the Fig. 8 shown resolvers. Detailed description

[0011] Fig. Figure 1 illustrates a resolver 1 according to an embodiment of the present invention. The resolver 1 is an inner rotor variable reluctance (VR) resolver. The resolver 1 includes a stator 2 and a rotor 3 rotatable on the inside of the stator 2. The rotor 3 has a shaft angle multiplier 2X structure with two convex portions formed on the outer peripheral surface. Fig. 2 is a cross-sectional view taken along a line AA shown in Fig. 1 is shown. Fig. 3 is a cross-sectional view of Fig. 1. Fig. 4 is a view of Fig. 1 from the bottom. Fig. 5 is a cross-sectional view illustrating a state in which a terminal pin cover and a sliding cover are mounted on a stator in Fig. 1 are attached. Fig. Fig. 6 is a view illustrating a state in which the sliding cover of Fig. 4. For ease of description, the rotor 3 is shown in the drawings with the exception of Fig. 1 not shown.

[0012] The rotor 3 is configured by stacking a plurality of layers of soft magnetic cores in the form of thin plates and is mounted on the rotating shaft 4 of a motor (not shown). The stator 2 includes an annular stator core 5 formed by stacking a plurality of layers of soft magnetic cores in the form of thin plates, an insulator 6 made of synthetic resin, including a first insulator 7 and a second insulator 8 (see Fig. 5), each mounted at both ends in the axial direction of the stator core 5, and a winding 9 wound on the insulator 6 mounted on the stator core 5. The winding 9 includes the excitation winding and the detection windings of the two phases, a sine phase and a cosine phase.

[0013] The soft magnetic core in the form of thin plates constituting the stator core 5 has a plurality of teeth (pole teeth) (10 teeth in the present embodiment) extending from an annular magnetic return portion in the radial direction inward (in the direction of the rotor 3). The stator core 5 is manufactured by rotating and stacking a plurality of layers of cores on top of each other (i.e., stacking them while rotating) and caulking them together.

[0014] As in Fig. 5, the first insulator 7 is mounted on one end in the axial direction of the stator core 5 and the second insulator 8 is mounted on the other end of the stator core 5 in the axial direction and the excitation winding is wound on all the teeth via the insulator 6 and the detection winding is wound on a predetermined tooth.

[0015] A terminal pin socket 10 extending in the radial direction is integrally molded onto the resin-made insulator 7. A plurality of (in this example, six) terminal pins 11 are arranged in the terminal pin socket 10. The terminal pin 11 is L-shaped, with one end extending axially, and a coil connecting portion 11a is provided to which the terminal coil is connected. The other end of the terminal pin 11 extends outward in the radial direction, and its distal end portion is a terminal 11b connected to a lead wire 12, which is an external wiring.

[0016] As in Fig. As shown in Fig. 6, a terminal part 17 is provided in the terminal pin socket 10. Grooves 16, in which the distal end (the distal end part of which is exposed from the stripped conductor part of the cover) of the lead wire 12 is accommodated, are provided in the terminal part 17 in a number corresponding to the number (in this case, six) of the lead wires 12. The terminal 11b of the above-described terminal pin 11 is formed into a flat shape and is arranged at the bottom part of the above-described groove 16 and is exposed before it is filled with a varnish 20. As shown in Fig. As shown in Figure 6, the distal end of the lead wire 12 is placed on the terminal 11b of the terminal pin 11 at the portion of the groove 16, and the lead wire 12 and the terminal pin 11 are brought into contact with each other. As described below, when the terminal 11b of the terminal pin 11 and the lead wire 12 are fixed by welding, the welding electrode is brought into contact with the back surface 11c of the terminal. Therefore, in the state where the lead wire 12 is connected to the terminal 11b, the back surface 11c of the terminal 11b is exposed.

[0017] The winding terminal of the excitation winding is connected to the winding connection part 11a of the terminal pin 11 at each position corresponding to the winding terminal of the detection winding, and is electrically connected. Tungsten inert gas welding (TIG welding) is used as the connection method, but the method is not limited to this; other methods such as soldering can also be used as long as an electrical connection is established. Furthermore, the winding connection is not shown in the drawings.

[0018] A terminal pin cover 13 (a first cover) covering the coil connection part 11a and the terminal part 17 is attached to the coil connection part 11a side of the terminal pin socket 10. A sliding cover 14 (a second cover) is attached to the side of the terminal pin socket opposite to the coil connection part 11a side, and the back side 11c of the terminal 11b of the terminal pin 11 is covered with the sliding cover 14.

[0019] A space 21 formed between the terminal pin cover 13 and the terminal pin base 10 is filled with the varnish 20, which is a filling material (see Fig. 5). The varnish 20 filled in the space 21 also flows through a plurality of through holes 10b formed in the terminal pin socket 10 into a space 22 formed between the sliding cover 14 and the terminal pin socket 10, filling the space 22. According to this structure, on the winding connection part 11a side, a connecting part of the terminal pin 11 and the winding 9 is sealed in the varnish 20 filling the space 21. Then, on the opposite side of the winding connection part 11a, the back surface 11c of the terminal 11b of the terminal pin 11 is sealed in the varnish 20.

[0020] When assembling the resolver 1, after connecting the winding terminal of the excitation winding and the winding terminal of the detection winding to the winding connection part 11a of the terminal pin 11 inside the groove 16 of the terminal part 17, the lead wire 12 for connection to the outside is connected to the terminal 11b (the other end of the terminal pin 11) by resistance welding or the like. Since it is necessary for welding to contact the back surface 11c of the terminal with the electrodes when welding the lead wire 12 to the terminal 11b, the back surface 11c of the terminal is located, as viewed from the perspective of Fig. 7 to see, free at this stage.

[0021] Next, the sliding part formed in the terminal pin cover 13 is fitted with the sliding part 10a (see Fig. 6) formed on the side surface of the terminal pin socket 10. The terminal pin cover 13 is mounted on the terminal pin socket 10 in such a manner as to cover the exposed part of the terminal pin 11 by engaging the engaging claw 13a formed in the distal end portion of the side surface of the terminal pin cover 13 with the side surface of the terminal pin socket 10.

[0022] Next, the sliding cover 14 is attached to the terminal pin cover 13 by inserting the sliding cover 14 into the sliding groove 13b formed inside the terminal pin cover 13 and sliding the sliding cover 14 from the outside to the inside in the radially outward direction. After the sliding cover 14 is attached, the terminal pin cover 13 covering the exposed part of the winding connection part 11a of the terminal pin 11 is attached to the terminal pin base 10, and the sliding cover 14 is attached to the terminal pin base on the opposite side of the exposed part of the terminal pin 11. Since the sliding cover 14 is attached, the back surface 11c (see Fig. 7) of connection 11b is covered.

[0023] Next, the opening 13c of the terminal pin cover 13 is filled with the varnish 20, and the space 21 formed between the terminal pin cover 13 and the terminal pin socket 10 is filled with the varnish 20. The varnish 20 that has been filled in the space 21 also flows into the space 22 formed between the sliding cover 14 and the terminal pin socket 10 through a plurality of through holes 10b formed in the terminal pin socket 10, and fills the space 22. Since the space 21 is also connected to the groove 16 of the terminal part 17, the varnish 20 also penetrates into the groove 16, and the groove 16 is filled with the varnish.

[0024] By the above-mentioned filling of the varnish 20, the connecting part of the terminal pin 11 and the winding 9 and a fixed part of the terminal pin 11 and the lead wire 12 on the side where the terminal pin 11 is exposed are sealed in the varnish 20, and the back surface 11c of the terminal 11b on the opposite side of the terminal pin 11 is sealed in the varnish 20.

[0025] Here, several through holes 14a are formed in the sliding cover 14 (in Fig. 4, three through holes 14a are formed). The through holes 14a are in Fig. 6 is not shown. Regarding the diameter of the through-hole 14a, a dimension is selected so that the varnish 20 filled into the space 22 does not flow out through the through-hole 14a. The through-hole 14a is used to check the filling state of the varnish 20 filled into the space 22 formed between the sliding cover 14 and the terminal pin socket 10. When the through-hole 14a is filled with the varnish 20, it is possible to confirm that the space 22 is filled with the varnish 20. When the varnish 20 does not reach enough to fill the through-hole 14a, it is possible to confirm that the varnish 20 is insufficient to fill the space 22.

[0026] Grooves 14b are formed over the entire length in the width direction (the direction intersecting the radial direction) on the inside of the sliding cover 14 (two grooves are formed in the Fig. 5 and Fig. 6). The inside of the sliding cover 14 is in contact with the terminal pin socket 10, except for the parts that form the space 22 between the terminal pin socket 10 and itself. Therefore, the varnish 20 filled into the space 22 penetrates into the contact surface between the sliding cover 14 and the terminal pin socket 10 by capillary force. As this phenomenon becomes more significant, there is a possibility that filling the varnish into the spaces 21 and 22 may not be sufficient due to the varnish overflow. In the structure described above, since the space formed by the groove 14b on the inside of the sliding cover 14 is filled, the penetration of the varnish 20 into the contact surface is stopped at the part of the groove 14b due to the equalization with the atmospheric pressure of this space.In other words, the groove 14b functions as a barrier for stopping the outflow of the paint 20. The shape of the groove 14b is not limited to the shown shape, but other shapes are also possible as long as the groove 14b serves as a barrier for stopping the outflow of the paint.

[0027] As described above, in a resolver in which the fixed part of the terminal pin 11 and the lead wire 12 is arranged at one end in the axial direction of the terminal pin socket 10 and the back surface 11c of the terminal 11b is arranged at the other end in the axial direction of the terminal pin socket 10, the space 21 is formed between the terminal pin cover 13 and the terminal pin socket 10 and the space 22 is formed between the sliding cover 14 and the terminal pin socket 10, and the spaces 21 and 22 are filled with the varnish 20, and in this way, the connecting part of the terminal pin 11 and the lead wire 12 and the back surface 11c of the terminal 11b are sealed in the varnish 20. According to this structure, since the space 21 corresponds to the terminal part 17 (see Fig.5) and the groove 16, the varnish from the space 21 also enters the groove 16 (a groove in which the distal end of the lead wire 12 is accommodated) of the terminal part 17, and the varnish also penetrates and fills the groove 16. Therefore, the fixed part of the terminal 11b, which is the other end of the terminal pin 11 and the lead wire 12, is also sealed in the varnish 20. According to this structure, it is possible to prevent corrosion of the terminal of the coil 9 connected to the terminal pin 11 and the lead wire 12 connected to the terminal 11b, which is the other end part of the terminal pin 11, even when the resolver 1 is used in an environment where corrosive components are present.

[0028] In the structure described above, the fixed part of the terminal pin 11 and the lead wire 12, and the back surface 11c of the terminal 11b are sealed in the varnish 20, which is filled in the space 21 formed between the terminal pin cover 13 and the terminal pin socket 10, as well as the space 22 formed between the sliding cover 14 and the terminal pin socket 10. Therefore, it is possible to prevent the occurrence of rust due to moisture and corrosion caused by sulfur components contained in oil or the like in the terminal pin and the terminal, especially even when the resolver 1 is used in an environment where there are corrosive components, an environment where, for example, moisture or sulfur components contained in oil or the like are present.

[0029] Since the coil connection part 11a of the terminal pin 11 and the groove 16 of the terminal part 17 are covered by the terminal pin cover 13, the above-described varnish sealing is reliably performed. In the above example, since the terminal 11b (the other end of the terminal pin 11) and the lead wire 12 are connected by electric welding, such as resistance welding, and must be in contact with the electrodes for welding at this time, the back surface 11c of the terminal 11b must be exposed. If this part remains exposed, corrosion will progress from the back surface 11c of the terminal 11b, and there is a possibility of contact failure.However, since the space 22 in the above example is filled with the paint and the back surface 11c of the terminal 11b, which was exposed at the time of welding, is sealed with the paint, corrosion originating from the back surface 11c of the terminal 11b is prevented.

[0030] Furthermore, since the connecting part of the terminal pin 11 and the lead wire 12 and the back surface 11c of the terminal 11b are sealed with the varnish 20, it is possible to prevent the occurrence of a short circuit between terminals even in an environment where the resolver 1 is directly in contact with water.

[0031] Insofar as a protective structure capable of performing similar functions to the above-described structure, the embodiment of the present invention is not limited to the above-described example. In addition, a configuration is possible in which the connecting part of the lead wire 12 is not disposed on the terminal pin side, but rather on the opposite side, and the back surface 11c of the terminal 11b is disposed on the terminal pin 11 side. The varnish is preferred as the filler material, but as long as the same function as the varnish is provided, another synthetic resin-based filler such as a silicone resin filler or an acrylic resin may also be used.

[0032] Although the filler material filled in the first space 21 and the filler material filled in the second space 22 are in communication with each other via the through hole 10b, a configuration may also be used in which each space is filled with a filler material without using the through hole 10b.

[0033] Although the sliding cover 14 is formed in a separate body from the terminal pin cover 13, the sliding cover 14 may of course have a configuration such that it is formed integrally with the terminal pin cover 13.

[0034] In the embodiment of the present invention, the slidable cover 14 is configured to be attached by being fitted into the sliding groove 13b formed on the inside of the terminal pin cover 13 and being slid from the outside to the inside in the radial direction, but the slidable cover 14 may be replaced by any other type of cover attached by means other than sliding.

[0035] Although resistance welding is used as the connection method between the terminal 11b and the lead wire 12, other connection methods may also be used as long as they can establish electrical connection.

[0036] As described above, the resolver of the present invention is suitable for use in an environment where there are corrosive components, for example, moisture or sulfur components contained in oil or the like, but the resolver can also be used in an environment where there are no such corrosive components.

[0037] According to the present invention, a resolver is provided which is capable of preventing corrosion of the terminal of the winding connected to the terminal pin and the lead wire connected to the terminal even when the resolver is used in an environment where there are corrosive components.

Claims

[1] Resolver (1), comprising: a stator core (5); an insulator (7, 8) mounted on the stator core (5), and a winding (9) wound on the insulator (7, 8) mounted on the stator core (5); a terminal pin base (10) extending outward in a radial direction and formed integrally with the insulator (7, 8), the terminal pin base comprising: a plurality of grooves (16) provided on the terminal pin base, each of the plurality of grooves receiving one of a plurality of external lead wires (12), a plurality of terminal pins (11) arranged on the terminal pin base (10), each of the terminal pins having a first connecting part (11a) at one end and a second connecting part at the other end, a first cover (13) provided on the terminal pin base (10) at one end side in an axial direction; and a second cover (14) provided on the terminal pin base (10) at the other end side in the axial direction, wherein the first connecting part (11a) of each terminal pin (11) is connected to the winding (9), and the second connecting part of each terminal pin is connected to one of the external lead wires (12), wherein the first cover (13) covers the first connecting part (11a) of the terminal pin (11) and the grooves (16) and the second cover (14) covers a back side of the second connecting part of the terminal pin, wherein a first space (21) is formed between the first cover (13) and the terminal pin socket (10), and the first connecting part (11a) is arranged in the first space; wherein a second space (22) is formed between the second cover (14) and the terminal pin socket (10); wherein the second connecting part of each terminal pin (11) is arranged within a corresponding groove (16) of the plurality of grooves; wherein the first space (21), the second space (22) and the plurality of grooves (16) are filled with a filling material (20); and wherein the first connecting part (11a) and the second connecting part of each terminal pin (11) are sealed in the filling material (20), and wherein the filling material (20) filled in the first space (21) and the filling material (20) filled in the second space (22) are connected to each other through a through hole (10b). [2] Resolver (1) according to claim 1, wherein the second cover (14) is engaged with the first cover (13). [3] Resolver (1) according to one of claims 1 or 2, wherein a second groove (14b) extending in a direction intersecting the radial direction is formed inside the second cover (14) in the radial direction at a position outside the second space (22). [4] Resolver (1) according to one of claims 1 to 3, wherein the first cover (13) is provided with an engagement claw (13a) which engages with a side surface of the terminal pin socket (10).

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