Resolver Cover Member Sealing Wire Harness Gap
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Solution Overview
Problem
Existing resolvers face mechanical installation errors and foreign object intrusion due to the gap between the wire harnessing member and the opening in the flange cover, which affects the accuracy of rotational angle detection and allows dust or dirt to enter.
Innovation Solution
A cover member with a curved base portion and abutting portion is used to cover the gap between the wire harnessing member and the opening, ensuring the cover member abuts on three sides of the wire harnessing member, preventing foreign object intrusion regardless of the member's position during adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the circumferential dimension of the opening is set larger than the wire harnessing member to allow swinging, then the ease of operation is improved, but the reliability deteriorates due to foreign object intrusion through the gap
Solution Approach 1:
A cover member is introduced as an intermediary element between the opening and the wire harnessing member. The cover member has a curved base portion that fits into the opening and an abutting portion that contacts the wire harnessing member, thereby preventing foreign objects from entering through the gap while allowing the wire harnessing member to swing freely for adjustment.
2Reliability
If the gap between the wire harnessing member and the opening is reduced to prevent foreign object intrusion, then the reliability is improved, but the ease of operation deteriorates due to restricted swinging movement
Solution Approach 1:
The sealing function is segmented from the opening structure itself and assigned to a separate cover member. This segmentation allows the opening to maintain its larger dimension for swinging operation while the cover member provides the sealing function, thus resolving the contradiction between reliability and ease of operation.
3Adaptability or versatility
If the opening dimension is increased to accommodate wire harnessing member adjustment, then the adaptability is improved, but the manufacturing precision deteriorates due to larger gap and potential foreign object contamination
Solution Approach 1:
The cover member acts as a mediator that decouples the opening dimension from the sealing requirement. The opening can be designed with larger dimensions to accommodate adjustment movements, while the cover member maintains precise sealing against the wire harnessing member, thus preserving manufacturing precision despite increased adaptability.
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 solution effectively prevents the intrusion of foreign objects like dust and dirt, enhancing the accuracy of rotational angle detection by ensuring the cover member reliably seals the gap between the wire harnessing member and the opening, regardless of the member's position during assembly adjustments.
Implementation Method 1
a cover member with a curved base portion and abutting portion is used to cover the gap between the wire harnessing member and the opening
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A resolver includes a resolver rotor that is provided in an outer circumference of the motor shaft and rotates integrally with the motor shaft, a resolver stator that has a plurality of coils and surrounds an outer circumference of the resolver rotor such that a rotational angle detection gap is provided between the outer circumference of the resolver rotor and the resolver stator, a housing that houses the resolver rotor and the resolver stator and has an opening for extracting wires of the coils in an outer circumference side of the resolver stator, a wire harnessing member provided to extend from the resolver stator to an outer side of the housing through the opening and consolidates wires of a plurality of the coils, and a cover member that covers a gap between the opening and the wire harnessing member.