Resolver Terminal Pin Sealing Against Corrosion
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Solution Overview
Problem
Resolvers face corrosion issues with winding terminals and lead wires due to exposure in corrosive environments, leading to poor conduction and potential conduction failures.
Innovation Solution
A resolver design featuring a terminal pin base with integral terminal pins, where each pin has a first and second connecting portion, sealed within a filler, with a first space between the terminal pin cover and base and a second space between the slide cover and base, filled with varnish to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal pin cover is filled with filler to seal the winding terminal, then corrosion of the winding terminal is prevented, but the lead wire connected to the terminal remains exposed and susceptible to corrosion
Solution Approach 1:
The terminal pin cover is divided into two distinct spaces: a first space for sealing the winding terminal connection and a second space for sealing the lead wire connection. This segmentation allows each space to be independently filled with filler, ensuring both connection points are protected from corrosion while maintaining proper sealing for each function.
2Ease of operation
If the terminal pin base extends outward in radial direction to accommodate terminal pins, then electrical connection is facilitated, but the terminal pins and connected wires become exposed to corrosive components
Solution Approach 1:
The terminal pins are nested within the terminal pin base structure, which itself is integrated into the insulator. The terminal pin cover then encloses both the terminal pins and the base, creating a nested protective structure that maintains electrical connection accessibility while shielding the components from corrosive environments.
Solution Approach 2:
The first space and second space within the terminal pin cover are filled with filler material that creates a protective, inert environment around the terminal pins and lead wire connections. This filler atmosphere prevents corrosive components from reaching the electrical connections, ensuring long-term reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively prevents corrosion of terminal pins and lead wires, ensuring reliable conduction even in environments with corrosive components like moisture or sulfur-containing oils, thereby preventing rust and short circuits.
Implementation Method 1
a first space and a second space are filled with a filler, the first space being formed between the first cover and the terminal pin base, and the second space being formed between the second cover and the terminal pin base, and wherein the first connecting portion and the second connecting portion of terminal pin are sealed in the filler
Data Source
AI summary
A resolver includes: a stator core; and an insulator that is mounted on the annular stator core, wherein a terminal pin base that extends outward in a radial direction is integrally formed in the insulator, wherein a plurality of terminal pins are disposed on the terminal pin base, wherein each of the terminal pins has a first connecting portion at one end and a second connecting portion at the other end, wherein first and second covers are provided on the terminal pin base at each sides in an axial direction, wherein the first connecting portion and the second connecting portion of the terminal pin are sealed in a filler which fills a first space and a second space, the first space being formed between the first cover and the terminal pin base, and the second space being formed between the second cover and the terminal pin base.