Resolver Insulation Cover Slack Part Winding Method
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Solution Overview
Problem
Resolvers face coil breakage due to thermal deformation, vibration, or deterioration, and existing solutions increase the size and manufacturing cost of the insulation cover by requiring additional members to relieve tension.
Innovation Solution
An insulation cover with a main body, teeth insulation parts, and terminal parts featuring slit and winding guide parts allows for winding the coil at a predetermined angle to form slack parts, eliminating the need for additional tension-relief members and enhancing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate member is added to relieve tension on the coil, then coil breakage is prevented, but the size of the insulation cover increases and manufacturing cost increases
Solution Approach 1:
The patent merges the tension relief function into the existing insulation cover structure by creating a slack part that is integrated with the terminal part. The coil is wound at an angle to form a slack portion that naturally absorbs thermal deformation, eliminating the need for separate tension relief members while maintaining coil durability.
Solution Approach 2:
The patent introduces dynamic flexibility into the coil winding structure by creating a slack part that can move and deform. The coil is wound at a predetermined angle (90°-180°) to form a slack portion that dynamically absorbs thermal expansion and contraction, preventing breakage without rigid structural additions.
2Reliability
If a separate member is added to relieve tension on the coil, then coil breakage is prevented, but manufacturing cost increases
Solution Approach 1:
The patent combines the tension relief function with the existing insulation cover and terminal part structure. The slack part is formed as an integrated feature during the normal winding process, eliminating the need for additional components and reducing manufacturing complexity and cost.
Solution Approach 2:
The coil structure itself provides the tension relief mechanism through its own geometry. The slack part is formed by the winding angle and naturally absorbs thermal stress, making the system self-regulating without external intervention or additional components.
3Reliability
If a separate member is added to relieve tension on the coil, then coil breakage is prevented, but work time increases and productivity decreases
Solution Approach 1:
The patent performs the tension relief function during the initial coil winding process itself. By winding the coil at a predetermined angle to form a slack part, the tension relief mechanism is created in advance as part of the normal manufacturing process, eliminating the need for separate assembly steps.
Solution Approach 2:
The patent merges the tension relief function into the standard winding operation. The slack part is formed simultaneously with the coil winding by controlling the winding angle, combining multiple functions into a single process step and improving manufacturing efficiency.
Data Source
AI summary
The present description relates to an insulation cover of a resolver and a method for winding a coil of the insulation cover, which has a slack part formed on a coil by: a slit part formed on a body part so as to correspond to a terminal pin when winding the coil on the terminal pin of a terminal part formed at one side of the insulation cover; and a winding guide part protrudingly formed on a winder so as to correspond to the slit part such that the coil is inserted into or withdrawn from the slit part, relieves the tension, applied to the coil, by the slack part so as to minimize a break in the coil according to the thermal deformation or the deterioration of the coil, has a compact structure, is easily manufactured and reduces manufacturing costs.