Resolver Stator Coil Cover Segmentation for Sealing Integrity
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Solution Overview
Problem
The existing stator structure in resolvers faces challenges in preventing foreign materials from entering due to deformation issues caused by the contact pressure required to ensure high dimensional accuracy of resin-based coil covers, which can compromise the reliability of the resolver.
Innovation Solution
The stator structure incorporates annular-shaped coil covers with flange parts and peripheral walls that face each other with a space, using resin pins for connection and caulking to enhance the sealing and prevent foreign material entry without deforming the flange parts or inner peripheral walls, thereby improving the reliability of the resolver.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If resin-based coil covers are used to prevent foreign material entry, then sealing performance is improved, but deformation occurs due to contact pressure required for dimensional accuracy
Solution Approach 1:
The coil cover is divided into a cover body and a separate sealing ring, allowing each component to be optimized independently. The sealing ring specifically contacts the coil to prevent foreign material entry, while the cover body maintains structural integrity without deformation.
Solution Approach 2:
The sealing ring acts as an intermediary element between the coil cover and the coil. It transfers the sealing function from the entire coil cover to this dedicated component, preventing foreign material entry without requiring the main cover body to deform under pressure.
2Manufacturing precision
If contact pressure is applied to ensure high dimensional accuracy of coil covers, then sealing performance is improved, but the flange parts or inner peripheral walls may be deformed
Solution Approach 1:
The sealing function is segmented from the main coil cover structure and assigned to a separate sealing ring. This allows the coil cover body to maintain its shape and dimensional accuracy without the need to apply contact pressure that would cause deformation of flange parts or inner peripheral walls.
Solution Approach 2:
The sealing ring provides localized sealing contact only where needed (at the coil interface), while the rest of the coil cover structure maintains its original shape and dimensions without deformation. This localizes the functional requirement without compromising overall structural integrity.
Data Source
AI summary
A stator structure according to an embodiment includes a stator core having a plurality of teeth; insulators configured to cover the teeth; a coil wound around each of the teeth with the insulators interposed therebetween; and first and second coil covers configured to cover the coil, each of the first and second coil covers being formed in an annular shape. The insulators have respective flange parts configured to cover respective distal end portions of the teeth. Each of the first and second coil covers has a first peripheral wall. The first peripheral wall of the first coil cover and the flange part located on one side of the insulator are arranged to face each other with a space therebetween. The first peripheral wall of the second coil cover and the flange part located on the other side of the insulator are arranged to face each other with a space therebetween.