Resolver Lead Wire Axial Guiding Groove Vibration
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Solution Overview
Problem
The existing connection structure between a resolver and a lead wire in brushless motors is prone to damage due to external forces, such as vibration, leading to reliability issues and increased production costs, especially when space is limited, requiring a secure and compact connection solution.
Innovation Solution
A connector portion with a guiding groove that directs the lead wire in an axial direction, allowing for a secure connection without adhesives and minimizing the radial dimension of the resolver, thereby reducing the impact of external forces on the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead wire is connected to the terminal member in a conventional manner, then the connection structure is simple, but the connection is prone to damage from external forces such as vibration
Solution Approach 1:
A resin layer is introduced as an intermediary substance between the lead wire and terminal member. The resin layer penetrates into the lead wire and固化 to form a mechanical interlock, acting as a mediator that bonds the two components together while protecting the connection from external forces like vibration.
Solution Approach 2:
The connection structure transitions from a simple planar connection to a three-dimensional interlocking structure. The resin layer penetrates vertically into the lead wire cross-section, creating bonding in the depth dimension rather than just surface-level attachment, thereby enhancing connection strength.
2Volume of moving object
If the radial size of the resolver is reduced, then the compactness is improved, but the lead wire connection becomes more vulnerable to external forces
Solution Approach 1:
The lead wire connection structure utilizes the axial dimension (depth direction) by having the resin layer penetrate into the lead wire cross-section. This vertical penetration creates a strong mechanical interlock that compensates for the reduced radial size, maintaining connection reliability while enabling compact radial dimensions.
Solution Approach 2:
The connection structure combines the lead wire, terminal member, and resin layer into a composite assembly. The resin material fills and penetrates the lead wire structure, creating a composite bond that integrates multiple materials with complementary properties to achieve both compactness and reliability.
Data Source
AI summary
A connector portion of a resolver stator includes a connecting portion to which a lead wire is connected and a guiding groove which guides the lead wire in an axial direction. The lead wire connected to the connecting portion is retained by the guiding groove and guided in the axial direction.