Resolver Stator Guide Hook Strength and Compactness
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Solution Overview
Problem
The connecting pin in resolver stators lacks sufficient strength, which can lead to deformation or damage during the winding process and may result in connecting wires coming off or being cut off due to vibration.
Innovation Solution
The design incorporates a guide hook with a hook beam part and hook body that is reinforced to improve strength, allowing the connecting wire to be caught with appropriate tension and reducing the likelihood of coming off or damage, while also enabling a thinner profile and compact stator design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a connecting pin is used to guide the connecting wire, then the wire can be secured, but the pin lacks sufficient strength and may deform or break under vibration and tension
Solution Approach 1:
The guide hook is merged with the insulating cover as an integrated structure, eliminating the need for separate supporting components. The insulating cover itself is designed with the guide hook protrusion, combining structural support and wire guidance functions into one element, thereby improving strength without proportionally increasing complexity.
Solution Approach 2:
The guide hook utilizes the thickness dimension of the insulating cover by extending protrusions in the radial direction. This dimensional approach allows the guide hook to achieve sufficient structural strength by leveraging the cover's thickness, rather than requiring additional lateral support structures.
2Reliability
If the guide hook is made stronger to prevent deformation, then reliability improves, but the stator becomes larger and less compact
Solution Approach 1:
The insulating cover is designed with localized guide hook protrusions at specific positions where wire guidance is needed, rather than uniformly thickening the entire cover. This local reinforcement approach provides necessary strength at critical points while maintaining overall compactness and minimizing stator volume.
Solution Approach 2:
The guide hook structure is pre-formed as an integral part of the insulating cover during the molding process, ensuring proper wire guidance geometry is established beforehand. This preliminary structuring provides reliable wire guidance without requiring additional reinforcement that would increase volume.
3Strength
If the insulating cover is made thicker to strengthen the guide hook, then strength improves, but manufacturing complexity and cost increase
Solution Approach 1:
The guide hook is combined with the insulating cover as a single molded part, eliminating the need for separate manufacturing steps for the supporting structure. This integration simplifies manufacturing by producing everything in one operation, avoiding assembly complexity and associated costs.
Solution Approach 2:
The insulating cover serves multiple functions: electrical insulation, mechanical support, and wire guidance through the integrated guide hook. This multi-functionality reduces the need for additional components and simplifies the overall manufacturing process while maintaining guide hook strength.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An insulator (5) has a yoke upper surface cover part (15) that covers a yoke upper surface (8A), a yoke inner peripheral surface cover part (17) that covers a yoke inner peripheral surface (8C), an outer peripheral wall that projects upward from the yoke upper surface cover part (15), and a guide hook (18) located radially inward of an outer peripheral wall (20) and guiding a connecting wire (7). A first outer peripheral wall (20P) and a second outer peripheral wall (20Q) are joined to each other in a seamless manner. A guide hook (18) includes a hook beam part (44) fixed to a cover upper surface (15B) facing upward of the yoke upper surface cover part (15) and extends radially inward, and a hook body (42) projecting downward from the hook beam part (44) and is opposite the yoke inner peripheral surface cover part (17) in a radial direction.