Resolver Stator Coil Cover Ultrasonic Welding Inspection
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Solution Overview
Problem
The existing stator structure in resolvers makes it difficult to visually check the welded state of coil covers, leading to potential insufficient coupling and foreign matter intrusion, which deteriorates the reliability of the resolver.
Innovation Solution
A stator structure with a first and second coil cover coupled via an insulator, where the coil covers are molded from resin and feature protrusion sections and ribs for enhanced protection and coupling, allowing for firm attachment and easy visual inspection of the caulking process, thereby preventing foreign matter intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultrasonic vibration is applied to weld the first coil cover and second coil cover, then the coil covers are coupled together, but the welded state cannot be visually checked
Solution Approach 1:
The patent applies paint to the surface of the first coil cover at the welding position before ultrasonic welding. During the welding process, the paint is removed by the welding pressure, creating a visible mark that indicates the welding location. This allows operators to visually confirm that welding has occurred at the correct positions, resolving the inability to inspect the welded state.
Solution Approach 2:
The patent introduces paint as an intermediary substance between the first coil cover and the welding process. The paint serves as a visual indicator that mediates between the invisible ultrasonic welding process and the human inspection process, making the welding state detectable without interfering with the actual welding operation.
2Object-affected harmful factors
If the coil covers are coupled using the existing method, then the coils are protected, but foreign matter may intrude due to insufficient coupling
Solution Approach 1:
The patent implements a visual feedback mechanism through the paint removal method. The exposed areas where paint has been removed provide immediate visual feedback to operators about the welding status, allowing them to confirm proper coupling before assembling the resolver. This ensures that the coil covers are adequately coupled to prevent foreign matter intrusion, thereby maintaining resolver reliability.
Solution Approach 2:
The patent applies paint to the coil cover surfaces before the welding operation. This preliminary action creates a visual reference that will be modified during welding, allowing for subsequent verification of proper coupling. The preliminary painting ensures that the welding process can be monitored and verified before the resolver is finalized.
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 improved stator structure enhances the reliability of the resolver by ensuring a firm and visually inspectable coupling of the coil covers, reducing the risk of foreign matter intrusion and maintaining the integrity of the stator windings.
Implementation Method 1
After the first coil cover and the second coil cover are attached to the stator core, ultrasonic vibration is applied to positions where the second receiving sections of the second coil cover are provided. The first column sections of the first coil cover and the second receiving sections of the second coil cover are welded to each other.
Data Source
AI summary
A stator structure includes a stator core including a plurality of tooth sections, coils wound around the respective plurality of tooth sections via an insulator, and a first coil cover and a second coil cover that cover the coils from both sides in an axial direction of the stator core. The first coil cover and the second coil cover being coupled via the insulator.