EPS Motor Resolver Insulator Labyrinth Sealing

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Solution Overview

Problem

In electric power steering motors, foreign substances can pass through the partition between the resolver and controller, entering the controller's interior due to the design of the terminals passing through a separation partition.

Innovation Solution

A labyrinth structure is implemented between the housing and the insulator surrounding the terminal fixing portion to prevent foreign substances from entering the controller, using a sealing mechanism that fits convex and concave portions on the housing and insulator to create a sealing barrier without additional sealing members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If terminals pass through the partition portion to electrically connect the resolver and controller, then electrical connection is achieved, but foreign substances can enter the controller interior

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidforeign substance contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A sealing member (O-ring or gasket) is introduced as an intermediary element between the partition portion and the insulator to block the passage of foreign substances. The sealing member fits into a groove on the partition portion and contacts the insulator, creating a seal that prevents contamination while allowing terminals to pass through for electrical connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The sealing member is made of a flexible material (such as rubber or elastomer) that can deform to accommodate the groove structure and maintain contact with the insulator. This flexibility allows the sealing member to effectively block foreign substances while accommodating manufacturing tolerances and assembly variations.

Inventive Principle:

Principle #30Flexible shells and thin films

2Object-affected harmful factors

If additional sealing members are added to prevent foreign substance entry, then sealing performance improves, but device complexity increases

Engineering Contradiction:

Improveforeign substance preventionVSAvoidassembly complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The sealing function is merged with the existing partition portion structure by incorporating a groove directly into the partition portion. This integration eliminates the need for separate sealing structures and reduces assembly steps, as the sealing member is simply placed into the pre-formed groove during assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The groove structure on the partition portion serves a dual purpose: it provides structural support for the partition and simultaneously acts as a retention feature for the sealing member. This self-service design allows the partition portion to contribute to both structural and sealing functions without requiring additional components.

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP2639947B1Motor for electric power steering

Publication Date: 2019.12.25 MITSUBISHI ELECTRIC CORP

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AI summary

Provided is a motor for electric power steering, which prevents a foreign substance from entering the interior of a controller. The motor for electric power steering includes a resolver structure provided between a housing for separating the controller and a resolver from each other and an insulator opposed to the housing so as to surround a fixing portion for fixing base end portions of terminals electrically connected to distal end portions of conductors of coils, the resolver structure preventing a foreign substance from passing between the housing and the insulator to enter the interior of the controller.