Resolver Integration Sleeve for Compact Motor Control
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Solution Overview
Problem
Variable reluctance resolvers require significant space for installation due to the need for high resolution, which is a challenge in compact motor control systems, especially in hybrid and electric vehicles where space efficiency is crucial.
Innovation Solution
An integration kit that includes a resolver integration sleeve with anti-rotation slots, tabs, and flanges to securely position and mount the rotor, trigger wheel, and bearing assembly, allowing for a compact and lightweight assembly without additional fixing elements, formed via deep-drawing or stamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional separate mounting of resolver components is used, then each component can be independently installed and maintained, but the overall space requirement increases and assembly complexity increases
Solution Approach 1:
The patent combines multiple resolver components (trigger wheel, bearing assembly, and rotor mounting) into a single integrated sleeve structure. This integration reduces the overall volume occupied by these components and simplifies assembly by providing a unified mounting solution that eliminates the need for separate installation procedures.
Solution Approach 2:
The integration sleeve serves multiple functions simultaneously: it acts as a mounting structure for the trigger wheel, houses the bearing assembly, provides rotor attachment, and ensures proper alignment. This multi-functionality reduces the number of separate components needed, thereby reducing overall space requirements and assembly complexity.
2Manufacturing precision
If additional fixing elements are used to secure resolver components, then component positioning accuracy improves, but the assembly becomes heavier and more complex
Solution Approach 1:
The fixing elements are integrated into the sleeve structure itself rather than being separate components. The sleeve includes built-in features such as mounting protrusions, bearing races, and alignment features that are formed as part of the single sleeve piece, eliminating the need for additional separate fixing elements.
Solution Approach 2:
The sleeve design incorporates specific geometric parameters and features (such as radial thickness variations, axial lengths, and integrated mounting features) that provide precise positioning and secure mounting of components without requiring additional fixing elements, thereby maintaining positioning accuracy while reducing complexity.
Data Source
AI summary
An integration kit is disclosed herein that allows for mounting of a resolver trigger wheel relative to a bearing assembly, resolver, and rotor. The integration kit simplifies assembly and saves space. The integration kit includes a resolver integration sleeve that includes a first axial section including a radially inner surface defining a bearing support and radially inwardly extending flange defining an axial abutment surface. The resolver integration sleeve also includes a second axial section including at least one anti-rotation slot dimensioned to receive a portion of a trigger wheel, at least one anti-rotation tab extending axially towards the first axial section and dimensioned to be received by a rotor, at least one securing tab extending radially outward and configured to engage a trigger wheel, and a radially outwardly extending flange.