Sheet Metal Resolver Housing Interlock Design

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Solution Overview

Problem

Brushless resolvers have limitations in measuring precision and production costs due to inefficient transformer designs and expensive turned housing components.

Innovation Solution

A resolver design featuring two rotatable subassemblies with housing shells made from sheet metal, produced by stamping and bending, which interlock with axial overlap to enhance measuring accuracy and reduce production expenses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If turned housing components are used, then structural strength is improved, but production cost increases and measuring precision is limited

Engineering Contradiction:

Improvestructural strengthVSAvoidmeasuring precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent changes the manufacturing parameters and material form from turned components to deep-drawn sheet metal housings. This parameter change enables automated production while achieving sufficient structural strength through proper sheet metal thickness and forming processes, thereby improving measuring precision without significantly increasing production cost

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs deep-drawn housing components made from sheet metal that can be produced economically through automated stamping processes. These components replace expensive turned parts while maintaining adequate structural integrity for the application, reducing production cost without sacrificing necessary strength

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Strength

If turned housing components are used, then structural strength is improved, but production expense increases

Engineering Contradiction:

Improvestructural strengthVSAvoidproduction expense

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical turning process with a deep-drawing and stamping process for housing production. This substitution enables automated manufacturing of housing components from sheet metal, significantly reducing production expense while maintaining structural strength through proper design of the deep-drawn components

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the manufacturing method parameter from turning to deep-drawing/stamping, and the material form from bar stock to sheet metal. These parameter changes enable cost-effective automated production while achieving sufficient structural strength through appropriate thickness and geometric design of the deep-drawn housing

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If deep-drawn housing components are used, then production cost is reduced, but measuring accuracy decreases

Engineering Contradiction:

Improveproduction costVSAvoidmeasuring accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies local quality by ensuring that the deep-drawn housing components have sufficient precision in the specific areas critical for measuring accuracy (such as mounting surfaces for windings and bearings), while allowing less critical areas to have standard deep-drawing tolerances. This localized precision approach maintains measuring accuracy while benefiting from cost-effective deep-drawn construction

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent optimizes parameters of the deep-drawn housing components, including thickness, geometric precision in critical areas, and surface quality, to achieve the necessary measuring accuracy. By carefully controlling these parameters in the deep-drawing process, the patent attains both cost-effectiveness and adequate measuring precision

Inventive Principle:

Principle #35Parameter changes

4Loss of energy

If transformer efficiency is improved, then current consumption is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvecurrent consumptionVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent employs composite construction with laminated cores made from multiple thin sheets, which reduces eddy current losses and improves transformer efficiency. The deep-drawn housing components are also used, creating a composite structure that achieves better electromagnetic performance without excessively increasing manufacturing complexity through standardized production processes

Inventive Principle:

Principle #40Composite materials

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 design achieves high measuring accuracy and cost-effectiveness by generating homogeneous stray fields and reducing tangential eddy currents, leading to improved transformer efficiency and economical production.

Implementation Method 1

The design achieves high measuring accuracy and cost-effectiveness by generating homogeneous stray fields and reducing tangential eddy currents

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Data Source

PatentUS9013178B2Resolver

Publication Date: 2015.04.21 DR JOHANNES HEIDENHAIN GMBH

AI summary

In a resolver for determining the relative angular position between two subassemblies, each subassembly includes a winding, the winding being situated inside a housing made up of two housing shells. The housing shells have tabs which are oriented with an axial directional component and joined in interlocking manner with axial overlap at a mutual offset in the circumferential direction.