Resolver Stator Terminal Bend for Thermal Wire Strain Relief
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Resolvers are prone to wire breakage due to strain from rapid temperature changes in harsh environments, and existing strain relief solutions require additional components and processes, increasing cost and risk of damage.
Innovation Solution
A stator design with a bent terminal section forming a slackened portion for the wire, allowing it to accommodate temperature changes without additional elements or complex assembly steps, maintaining electrical and mechanical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external element is added to provide strain relief to the wires, then wire breakage is prevented, but device complexity and production cost increase
Solution Approach 1:
The patent combines the strain relief function with the existing terminal structure by creating a bent section at the termination end. This integrates the protective function into the terminal itself rather than adding a separate external element, thereby preventing wire breakage while avoiding increased device complexity
Solution Approach 2:
The bent section of the terminal serves as a self-contained strain relief mechanism that automatically compensates for temperature-induced wire expansion and contraction. The terminal structure itself provides the strain relief without requiring additional components or external elements
2Reliability
If an external element is added for strain relief, then wire protection is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The bent section is formed as an integral part of the terminal during the manufacturing process itself, before assembly. This preliminary formation of the strain relief feature eliminates the need for separate assembly steps involving external elements, thereby protecting the wire while maintaining production efficiency
Solution Approach 2:
By combining the strain relief function into the terminal structure, the patent eliminates the need for separate assembly operations with external elements. The bent section is formed as part of the terminal manufacturing process, reducing overall manufacturing time and process complexity
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
The design reduces wire strain and breakage risk by allowing the wire to expand and contract without additional components, enhancing reliability and reducing production costs.
Implementation Method 1
Rapid temperature change, for example, in these harsh environments causes strain on the tensioned wire that can result in breakage of the wire
Data Source
AI summary
A stator of a resolver includes a body having a pole, a connector interface disposed in a portion of the body and including a terminal having a wire termination at a termination end, and a wire disposed around the pole and extending to the termination end of the terminal. The terminal has a bent section at the termination end that is bent to a bending angle greater than 0° and less than or equal to 90° with respect to a main section of the terminal. The wire is electrically and mechanically connected with the terminal at the wire termination. The bent section of the terminal forms a slackened portion of the wire adjacent to the wire termination.