Resolver Stator Terminal Pin Double-Layer Fold Design
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Solution Overview
Problem
The existing stator terminal pin structure lacks sufficient strength, particularly in the projection area, which affects the reliability and durability of the resolver's connections.
Innovation Solution
The stator of a resolver is enhanced by forming the stator winding connecting portion in a double layer with a single fold along the longitudinal direction, having a U-shaped cross-section, and a tapered distal end, with external cable connecting portions arranged in a staggered manner, and a method for manufacturing the stator assembly that involves connecting and bending the terminal pins to secure the external cables effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the terminal pin projection is formed by simple winding connection, then the manufacturing process is simple, but the strength of the connection is insufficient
Solution Approach 1:
The terminal pin projection is formed by folding a metal piece in the longitudinal direction to create a double-layer structure. This dimensional change from a single layer to a double layer significantly enhances the connection strength while maintaining a relatively simple overall structure. The fold creates overlapping layers that provide better mechanical interlocking with the coil winding.
Solution Approach 2:
The metal piece undergoes parameter changes through folding, transforming from a flat single-layer configuration to a folded double-layer configuration. This parameter change in structural arrangement increases the contact area and mechanical interlocking capability, thereby improving the connection strength without adding complex multi-component assemblies.
2Area of stationary object
If multiple external cable connecting portions are arranged closely, then the space utilization is improved, but the manufacturing and cable connection process becomes more difficult
Solution Approach 1:
The external cable connecting portions are segmented into two distinct rows: front-side connecting portions and back-side connecting portions. This segmentation allows for a systematic manufacturing process where cables are first connected to front-side portions, then terminal pins are bent to displace front-side portions, creating clearance for back-side cable connections. This staged approach simplifies the overall manufacturing complexity despite achieving compact space utilization.
3Strength
If the stator winding connecting portion is formed with a fold along the longitudinal direction, then the connection strength is improved, but the manufacturing precision requirement increases
Solution Approach 1:
The fold is formed along the longitudinal direction of the metal piece, creating a double-layer structure in the longitudinal dimension. This approach distributes the strength enhancement along the length of the connecting portion rather than concentrating it in a single point, which helps mitigate the impact of manufacturing variations and reduces the overall precision requirement compared to transverse folding.
Data Source
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AI summary
A stator (3) of a resolver (1) includes: a stator body (5) including multiple magnetic pole portions (10); multiple stator windings (6) respectively wound around the magnetic pole portions (10); multiple terminal pins (7) each including: a stator winding connecting portion (11) around which the corresponding stator winding (6) is wound; and an external cable connecting portion (12) to be connected with an external cable (4); and a terminal pin holding portion (8) that holds the terminal pins (7). The stator winding connecting portion (11) of each terminal pin (7) is formed in a double layer by folding a metal piece (M) and has a fold (11a) formed when the metal piece (M) is folded. The fold (11a) of the stator winding connecting portion (11) of each terminal pin (7) is formed along a longitudinal direction of the stator winding connecting portion (11).