Resolver Winding Bracket Lead Wire Management
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Solution Overview
Problem
Current resolvers for brushless motors primarily function to insulate windings and have limited functionality, lacking multi-functionality in detecting rotor position and managing lead wires effectively.
Innovation Solution
A resolver design featuring a winding bracket with an annular portion, connector, and cover that secures lead wires, includes conductive terminals and guide slots to manage lead wires, reducing connection risks and facilitating assembly by reducing the strength of the bracket at recesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a winding bracket is mounted on the resolver stator to insulate windings, then insulation function is achieved, but the bracket has only single function and lacks multi-functionality
Solution Approach 1:
The winding bracket is designed to perform multiple functions: it provides insulation between windings and the stator core, supports the windings mechanically, and incorporates a lead wire management structure with guide slots and pressing members to secure lead wires. This multi-functional design eliminates the need for separate components, achieving versatility without proportionally increasing structural complexity.
2Reliability
If lead wires are left unsecured, then assembly is simple, but connection damage risk increases
Solution Approach 1:
The lead wire securing function is merged into the winding bracket by integrating guide slots and pressing members directly into the bracket structure. This combination allows the bracket to simultaneously perform insulation, support, and lead wire securing functions, improving connection reliability while minimizing additional structural complexity through functional integration.
3Strength
If the winding bracket has high strength, then structural integrity is maintained, but assembly difficulty increases
Solution Approach 1:
The winding bracket incorporates recesses that segment the structural continuity, creating localized flexibility zones. These recesses allow the bracket to be assembled more easily by enabling slight deformations during installation, while the overall structure maintains sufficient strength through the distributed reinforcement patterns and material selection.
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
Enhances the functionality of the resolver by securely managing lead wires, reducing the risk of connection damage and simplifying assembly, while maintaining effective rotor position detection in brushless motors.
Implementation Method 1
When the resolver rotor rotates, the width of the gap formed between the rotor and the tooth of the resolver stator changes, resulting in a change of the induced potential produced on the output winding.
Data Source
AI summary
A resolver which includes a resolver rotor and a resolver stator. The resolver stator includes a resolver stator core, a winding bracket mounted on the resolver stator core, and a plurality of resolver windings wound on the winding bracket. The winding bracket includes an annular portion surrounding the resolver rotor, a connector extending outwardly from the annular portion, and a cover mounted on the connector. The connector includes a plurality of conductive terminals connecting both the resolver winding and lead wires, and a body receiving the conductive terminals. The cover abuts against the lead wires to secure the lead wires to connector.