Resolver Winding Segmentation for Angle Detection Accuracy
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Solution Overview
Problem
The existing resolver designs are prone to accidental unwinding and increased angle detection errors due to overlapping windings and thin insulating partition walls, which can lead to misalignment and deformation issues.
Innovation Solution
A resolver design where the excitation windings and detection windings are wound around different teeth, with each winding group having distinct radial positions and winding widths, preventing overlap and allowing for independent adjustment to minimize misalignment and enhance insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sine-phase output winding and cosine-phase output winding are wound with overlapping outer rims, then the winding space is efficiently utilized, but the windings are prone to accidental unwinding and angle detection errors
Solution Approach 1:
The patent divides the windings into distinct segments with clear separation. Each winding (sine-phase and cosine-phase) is assigned to specific teeth without overlap, creating discrete segments that are easier to manufacture and less prone to unwinding. The excitation winding is placed on teeth 1-12, sine-phase on teeth 13-24, and cosine-phase on teeth 25-36, establishing clear segmentation boundaries.
Solution Approach 2:
The patent transitions from a one-dimensional overlapping arrangement to a two-dimensional distributed arrangement across multiple teeth. By spreading the windings across different teeth in the circumferential direction and utilizing the radial dimension for separation, the design achieves both efficient space utilization and enhanced reliability through dimensional distribution.
2Reliability
If the sine-phase output winding and cosine-phase output winding are separated in the direction in which the tooth protrudes, then accidental unwinding is reduced, but the partition walls become thin and deformation-prone
Solution Approach 1:
Instead of separating windings on the same tooth (which would require thin partition walls), the patent segments the windings across different teeth. This eliminates the need for thin partition walls between windings, as each tooth carries only one type of winding, thereby avoiding the manufacturing precision issues associated with thin walls.
Solution Approach 2:
The patent introduces teeth as intermediary structures between different winding types. Rather than placing multiple windings on the same tooth requiring thin insulating partitions, the tooth itself acts as a natural separator and support structure, providing robust mechanical separation without requiring thin partition walls.
3Manufacturing precision
If the width of each winding in the direction in which the tooth protrudes is reduced to ensure thick partition walls, then partition wall deformation is minimized, but the windings become thicker in the circumferential direction and still prone to unwinding
Solution Approach 1:
The patent eliminates the need for partition walls by segmenting windings across different teeth. Each winding maintains its full width in the radial direction without being constrained by partition wall thickness requirements, while the tooth structure itself provides the necessary separation and support to prevent unwinding.
Solution Approach 2:
The patent resolves the conflict by moving the separation function to the circumferential dimension (across different teeth) rather than relying on radial dimension partition walls. This dimensional shift allows windings to maintain adequate width while achieving separation through the tooth structure in the circumferential direction.
4Device complexity
If all winding types are wound around the same tooth, then the stator core structure is simplified, but the windings are prone to misalignment and angle detection errors
Solution Approach 1:
The patent segments the winding assignments across different teeth to prevent misalignment. By assigning excitation windings to teeth 1-12, sine-phase to teeth 13-24, and cosine-phase to teeth 25-36, the design ensures that each winding type has dedicated space, eliminating overlap and misalignment issues that would compromise angle detection accuracy.
Solution Approach 2:
The patent utilizes the circumferential dimension across multiple teeth to separate winding types, rather than relying solely on radial positioning on the same tooth. This dimensional distribution prevents misalignment and ensures accurate angle detection while maintaining a relatively simple stator core structure.
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
This configuration reduces the likelihood of winding misalignment, prevents accidental unwinding, and minimizes angle detection errors by ensuring proper insulation and alignment of windings, thereby improving the accuracy and reliability of angle detection.
Implementation Method 1
each of the plurality of excitation windings being wound around each one of the plurality of teeth... the first detection winding group including a plurality of first windings as detection windings, the second detection winding group including, as detection windings, a plurality of second windings different from the plurality of first windings in a phase of a detection voltage
Data Source
AI summary
In a resolver, a detecting stator core includes a first detection winding group, a second detection winding group, and a plurality of excitation windings. The first detection winding group includes a plurality of first windings as detection windings. The second detection winding group includes, as detection windings, a plurality of second windings different from the first windings in the phase of the detection voltage. The excitation windings are each wound around one of teeth of the detecting stator core. Each first winding and each second winding are wound around different teeth from each other without being wound around the same tooth. The detection winding and the excitation winding that are wound around the same tooth are arranged so as to be separated from each other in a radial direction.