Resolver Terminal Holding Part for Lead Wire Slack Management
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Solution Overview
Problem
In VR type resolvers, lead wires often break due to temperature changes because they are under tension, and existing solutions require a special jig to maintain slackness, which is impractical in cases where space is limited or the distance between the wound wire end and terminal pin cannot be maintained.
Innovation Solution
A movable terminal holding part that can be positioned to maintain tension or slackness in the lead wire, eliminating the need for a special jig, and includes a fixing mechanism such as pins or adhesives to secure the terminal holding part at the desired position, allowing for reduced size and increased design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead wire is kept under tension to maintain connection stability, then the connection reliability is improved, but the lead wire may break due to temperature changes
Solution Approach 1:
The terminal holding part is designed to be movable relative to the insulator, allowing the system to dynamically adjust between tensioned and slack states. During assembly, the terminal holding part is positioned to tension the lead wire for reliable connection, then moved to create slack to prevent breakage from thermal expansion and contraction.
2Strength
If a jig is used to maintain lead wire slackness, then the lead wire breakage is prevented, but the device complexity increases
Solution Approach 1:
The terminal holding part itself serves the dual function of both holding the terminal and creating slack in the lead wire. By making the terminal holding part movable, it automatically provides the slack-making function that previously required a separate jig, thereby eliminating additional components and simplifying the overall device.
3Strength
If the terminal holding part is fixed at a position that maintains lead wire slackness, then the lead wire breakage is prevented, but the design flexibility is reduced
Solution Approach 1:
The movable terminal holding part enables the design to adapt to different configurations. It can be positioned at different locations on the insulator depending on the specific application requirements, allowing designers to optimize for various space constraints and wiring arrangements while still maintaining lead wire slackness.
4Adaptability or versatility
If the terminal holding part is made movable to enable slack positioning, then the design flexibility is increased, but the manufacturing complexity increases
Solution Approach 1:
The resolver is divided into distinct components: the insulator with its through-hole, the terminal holding part that can move independently, and the lead wire. This segmentation allows each component to be manufactured separately using standard processes, with the movable terminal holding part being a simple independent piece that doesn't require complex manufacturing.
Data Source
AI summary
A resolver has a lead wire that can be slack even in a structure in which it is impossible to maintain the distance between an end of wound wire and a terminal pin without using a special jig. A lead wire of a stator coil 500 is entwined on a plurality of terminal pins 603 in a slack condition, and the entwined parts are fixed by soldering or welding. Terminal base 600 is then moved to a stator core 200 side, and the lead wire is made slack by contacting the lower surface of a terminal base body 601 to the upper surface of the stator core 200. Next, end part of the pins 306 of a primary insulator 300 are melted so as to fix the terminal base 600.