Resolver Stator Alignment Adapter for Electric Machine Positioning
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Solution Overview
Problem
Existing electric machines face challenges in accurately aligning resolvers with stators to enhance rotor position determination and overall performance.
Innovation Solution
An alignment adaptor system is introduced, featuring alignment members and elements on both the stator and resolver, which are registered within a slot system to establish a precise alignment, ensuring accurate rotor position sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment methods are used to position the resolver relative to the stator, then the alignment process is simple, but the alignment precision and rotor position determination accuracy are insufficient
Solution Approach 1:
The patent introduces an alignment adaptor as an intermediary device between the stator and resolver. The adaptor includes alignment features (such as alignment pins and slots) that mechanically guide and constrain the relative positioning of the stator and resolver, ensuring precise alignment without requiring complex manual adjustment procedures. This mediator device translates the simple act of insertion into precise alignment.
Solution Approach 2:
The alignment adaptor is pre-configured with alignment features during manufacturing. The alignment pins, slots, and other alignment mechanisms are built into the adaptor structure beforehand, so that when the stator and resolver are assembled, the alignment is automatically established without requiring complex real-time adjustments or measurements.
2Manufacturing precision
If precision alignment features are added to the stator and resolver, then the alignment accuracy is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent divides the alignment function into separate components: the stator, the resolver, and the alignment adaptor. Each component has its own alignment features (such as pins, slots, or keyed structures), allowing each part to be manufactured independently with standard tolerances. The alignment adaptor acts as a buffer that accommodates minor variations in manufacturing tolerances of the stator and resolver, achieving precise overall alignment without requiring ultra-precise manufacturing of each individual component.
3Reliability
If the resolver is directly mounted to the stator, then the device structure is simple, but the alignment consistency and reliability are insufficient
Solution Approach 1:
The alignment adaptor serves as a reliable intermediary that ensures consistent alignment between the stator and resolver across multiple assemblies. The adaptor includes mechanical constraints (such as pinned connections or keyed interfaces) that prevent relative movement and ensure the resolver maintains its precise angular relationship with the stator during operation, enhancing reliability.
Solution Approach 2:
The patent applies alignment features at specific critical locations on the stator, resolver, and adaptor. Rather than requiring precision across the entire surfaces, alignment pins, slots, or keyed features are placed at strategic locations where they most effectively constrain the relative positioning. This localized approach to precision ensures reliable alignment while minimizing overall manufacturing complexity.
Data Source
AI summary
An electric machine including a stator having a body provided with at least one alignment member, and a resolver positioned relative to the stator. The resolver includes at least one alignment element. An alignment adaptor is configured to receive each of the stator and the resolver. The alignment adaptor includes an alignment system that positions the alignment member and the alignment element to establish a desired alignment between the stator and the resolver.