Resolver Stator Fixation via Rotational Insertion and Segmented Engagement
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Solution Overview
Problem
Existing resolver structures face issues with stator fixation in housings, including cracking of housings, reduced strength due to clamping deformation, and adhesive strength degradation over time, leading to potential stator loosening.
Innovation Solution
A resolver design featuring a cylindrical housing with an annular stator core and rotor core, utilizing a concavity and engaging portion structure that contacts the stator core, combined with an adhesive or filler to prevent deterioration of the fixed state, allowing for secure stator installation without requiring special jigs or equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the housing is clamped and fixed to the stator by pressing, then the stator is secured in the housing, but the housing is often cracked depending on the material or shape
Solution Approach 1:
The fixing structure is divided into multiple engagement portions distributed around the housing perimeter, rather than applying force at a single location. This segments the clamping force into multiple smaller contact points, preventing stress concentration that would cause housing cracks.
Solution Approach 2:
The engagement portions are strategically positioned at locations optimized for each specific housing material and shape characteristics. Each engagement portion provides localized fixation quality tailored to the regional properties of the housing, ensuring secure attachment without causing structural damage.
2Object-affected harmful factors
If the clamping deformation amount is decreased to prevent housing crack, then housing damage is reduced, but the fixation strength is reduced
Solution Approach 1:
Multiple engagement portions distribute the total fixation strength across several locations, so that each portion can use minimal clamping deformation to contribute to overall strength. The cumulative effect of multiple weak fixation points creates strong overall attachment without deforming the housing.
Solution Approach 2:
The fixation strength from multiple engagement portions is merged together to achieve the required total strength. By combining several weak fixation points, the system achieves strong overall fixation without requiring any single point to apply high clamping force that would damage the housing.
3Ease of manufacture
If adhesive is used to fix the stator in the housing, then installation is simplified, but the adhesive strength is decreased by aging and the stator is loosened
Solution Approach 1:
The fixation system uses a composite approach combining adhesive material with mechanical engagement structures. The adhesive provides initial bonding and fills gaps, while the engagement portions provide long-term mechanical interlocking that resists aging effects, creating a hybrid fixation system with superior durability.
Solution Approach 2:
The fixation function is segmented between the adhesive (providing initial bonding and sealing) and the engagement portions (providing long-term mechanical strength). This segmentation allows each component to perform its optimal function, with the mechanical structures preventing the aging-related strength loss that plagues pure adhesive systems.
4Strength
If ultrasonic welding is used to fix the stator, then strong fixation is achieved, but special equipment and horn are required
Solution Approach 1:
The engagement portions are designed to automatically self-align and self-lock when the stator is inserted into the housing, eliminating the need for external welding equipment or specialized tools. The structure performs its own fixation function through simple insertion, achieving strong attachment without complex equipment.
5Strength
If rivet is used to fix the stator, then strong fixation is achieved, but rivet and specific apparatus are required
Solution Approach 1:
The engagement portions are designed to automatically engage and lock the stator in place through a simple insertion motion, eliminating the need for rivets or specialized riveting apparatus. The structure performs its own mechanical fastening function without requiring external fastening components or equipment.
Data Source
AI summary
A resolver can have a stator installed in a housing simply, without requiring a special jig. In the resolver including a housing and a stator core fixed in the housing, the stator core is fixed to the inside of the housing by rotating relative to the housing.