Insulated Resolver Bearing Support to Prevent Motor Bearing Arcing
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Solution Overview
Problem
Arcing and degradation of bearings in electric motors due to excessive voltage, which is conducted through metallic bearings, leading to undesirable pitting and degradation.
Innovation Solution
Integration of a housing made of electrically insulating material to support both the resolver stator and rotor bearing, ensuring concentric positioning and electrical isolation, reducing the possibility of arcing and allowing unencumbered rotor shaft rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic bearings are used to support the rotor shaft, then mechanical support and rotation are enabled, but electrical noise is conducted through the bearings to the housing and arcing occurs when voltage exceeds threshold
Solution Approach 1:
The patent introduces an intermediary bearing support structure made of electrically insulating material between the metallic bearing and the conductive housing. This intermediary component blocks the conduction path for electrical noise and prevents arcing while still providing mechanical support for the rotor shaft rotation.
Solution Approach 2:
The patent changes the electrical conductivity parameter of the bearing support structure by using electrically insulating materials instead of metallic materials. This parameter change transforms the housing from being electrically conductive to electrically insulating, thereby preventing arcing and electrical noise conduction.
2Ease of manufacture
If separate components are used for housing and bearing support, then manufacturing flexibility is maintained, but device complexity and number of fasteners increase
Solution Approach 1:
The patent merges the housing and bearing support into a single integrated bearing support structure. This combination eliminates the need for separate fasteners and assembly steps while maintaining the electrical insulation function and mechanical support capability, thereby reducing device complexity.
Solution Approach 2:
The integrated bearing support structure serves multiple functions simultaneously: it provides mechanical support for the bearing, electrical insulation to prevent arcing, and structural integration to reduce complexity. This multi-functionality reduces the need for separate components and fasteners.
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
Reduces arcing in bearings, facilitates concentric positioning of rotor and resolver stator, decreases the number of fasteners and stress points, and lowers system complexity and financial expense.
Implementation Method 1
a housing comprised of an electric insulating material, the housing configured to support a resolver stator and a rotor bearing support cup
Data Source
AI summary
Systems and methods for integrating a resolver stator and a bearing support for a rotor bearing are described. The system may electrically isolate the rotor bearing from electrically conductive materials so that arcing of electric power at rotor bearings may be addressed. In one example, the resolver stator and the bearing support may be over molded with plastic.