Plastic-Welded Resolver Stator Cover to Cut Weight and Eddy Currents
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Solution Overview
Problem
The use of metal covers and fasteners for resolvers increases weight, material cost, eddy current interference, assembly time, and thermal expansion issues, leading to decreased accuracy and increased cost.
Innovation Solution
A resolver design featuring a stator and cover made of plastic materials, attached via a plastic weld, eliminating the need for metal fasteners and addressing thermal expansion differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal fasteners are used to attach the stator to the cover, then mechanical strength is improved, but weight increases and eddy current interference worsens
Solution Approach 1:
The patent removes metal fasteners from the assembly and replaces them with an integrated plastic attachment structure. The stator and cover are made of non-conductive plastic materials that are molded to fit together without separate fastening components, extracting the harmful metal elements while maintaining structural integrity through design integration.
Solution Approach 2:
The patent merges the attachment function into the plastic material itself. The stator and cover are designed with complementary features that allow them to be securely attached through the plastic material properties, combining the fastening function with the structural material rather than using separate metal fastener components.
2Strength
If metal fasteners are used to attach the stator to the cover, then mechanical strength is improved, but assembly time increases
Solution Approach 1:
The patent merges the attachment function into the plastic material itself. The stator and cover are designed with complementary features that allow them to be securely attached through the plastic material properties, combining the fastening function with the structural material rather than using separate metal fastener components.
3Strength
If metal cover is used, then mechanical protection is improved, but eddy current interference worsens
Solution Approach 1:
The patent changes the material parameter from conductive metal to non-conductive plastic. This fundamental material parameter change eliminates eddy current interference while the plastic material is designed with sufficient mechanical strength and structural features to provide the necessary protection for the stator and rotor components.
4Adaptability or versatility
If different materials are used at the interface between stator and cover, then functional requirements are met, but thermal expansion damage occurs
Solution Approach 1:
The patent uses the same plastic material for both the stator and cover, creating a homogeneous material interface. This eliminates thermal expansion mismatches between different materials, as both components expand and contract at the same rate when exposed to temperature changes, preventing interface damage while still meeting functional requirements through design features.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The plastic weld securely attaches the stator to the cover, maintaining high accuracy and reducing weight and cost while minimizing eddy current interference.
Implementation Method 1
The first plastic material of the stator body is attached to the second plastic material of the cover body by a plastic weld
Data Source
AI summary
A resolver includes a stator having a stator body formed of a first plastic material and a cover covering a side of the stator. The cover has a cover body formed of a second plastic material. The first plastic material of the stator body is attached to the second plastic material of the cover body by a plastic weld.