Resolver Stator Terminal Block Isolation and Cover Flexibility
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Solution Overview
Problem
In stator structures for resolvers, manufacturing variations in coil covers can lead to positional errors and distortions, resulting in unintended gaps that allow foreign matter to intrude and cause electrical short-circuits, reducing the reliability of the resolver.
Innovation Solution
A stator structure with a terminal block section and a terminal-block cover section featuring isolating members, such as ribs, that separate terminals and prevent foreign matter from reaching the coils, including concave sections and ribs designed to ensure secure engagement and prevent short-circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or locking is performed to couple coil covers, then the coil covers are securely coupled, but manufacturing variations cause positional errors and distortions that create gaps allowing foreign matter intrusion
Solution Approach 1:
The patent uses a resin material for the coil covers that provides flexibility to absorb manufacturing variations. The resin material allows the covering portions to adapt to positional deviations without creating gaps, while maintaining secure coupling through the engagement structure between first and second coil covers.
Solution Approach 2:
The engagement structure is designed with tolerance for manufacturing variations before assembly. The first and second coil covers are configured to engage in a manner that anticipates and accommodates positional errors, preventing gap formation before foreign matter can intrude.
2Strength
If protrusion bodies are used for locking, then the coil covers are coupled, but the locking process causes deformation and distortion of the protection structure
Solution Approach 1:
The resin material of the coil covers provides flexibility that allows the engagement structure to couple the covers without causing rigid deformation. The material absorbs stress during locking, preventing distortion of the protection structure while maintaining coupling strength.
3Ease of manufacture
If gaps are formed due to manufacturing errors, then assembly is easier, but foreign matter can intrude and cause electrical short-circuits
Solution Approach 1:
The resin material creates a flexible sealing effect that closes gaps formed by manufacturing variations. The material conforms to the engagement surfaces, maintaining continuous coverage over the slots and terminals even when positional deviations occur, thus preventing foreign matter intrusion while accommodating assembly tolerances.
Solution Approach 2:
The resin material provides a cost-effective solution that accepts some degree of manufacturing variation without compromising reliability. The material's inherent flexibility serves as a built-in compensation mechanism that eliminates the need for ultra-precise manufacturing, reducing overall production costs while maintaining electrical reliability.
Data Source
AI summary
A stator structure includes a stator section, coil cover, terminal block section, plurality of terminals and terminal-block cover section. Stator section includes stator core including first main body section and plurality of teeth sections extending on inner circumference side of first main body section and coils configured by winding wires wound around teeth sections via an insulator. Coil cover covers coils from axial direction of stator core. Terminal block section extends from insulator outward in radial direction of stator core. Plurality of terminals are provided in terminal block section, ends of winding wires configuring coils are bound to terminals. Terminal-block cover section is provided in coil cover, terminal-block cover section covers terminal block section. Terminal-block cover section includes a plurality of isolating members provided on interior, respective plurality of terminals are housed to be separated from one another in respective plurality of spaces formed by plurality of isolating members.