Segmented Stator Cover for Resolver Flatness Control
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Solution Overview
Problem
Large resolvers with covers of significant diameter face challenges in manufacturing thin, flat covers with high precision and yield, leading to issues with internal stress, performance, strength, and lifetime due to warping and irregularities.
Innovation Solution
The stator cover is divided into sections, with each section having protrusion parts that correspond to island parts on the insulator, allowing for precise positioning and welding, preventing instability and stress during attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-piece thin cover of large diameter is manufactured, then the cover provides complete protection for the stator winding, but manufacturing precision and yield deteriorate due to warping and irregularities
Solution Approach 1:
The cover is divided into multiple cover sections (first cover section and second cover section) that can be manufactured separately and then assembled. This segmentation allows each section to be produced with controlled dimensions and flatness, avoiding the warping and irregularities that occur when manufacturing a single large-diameter cover. The segmented approach maintains complete protection while improving manufacturing precision and yield.
2Reliability
If a single-piece thin cover of large diameter is manufactured, then the cover provides complete protection for the stator winding, but productivity deteriorates due to difficult manufacturing processes
Solution Approach 1:
The cover is divided into multiple cover sections that can be manufactured separately using standardized processes, then assembled together. This segmentation enables parallel production of multiple sections simultaneously, improving overall productivity. Each section can be manufactured with optimized processes for smaller components, resulting in higher yield and reduced manufacturing difficulty compared to producing a single large cover.
Solution Approach 2:
Multiple cover sections are joined together through welding to form the complete cover structure. This merging process allows the individual sections to be manufactured with high precision and then combined to provide the same protection as a single large cover, while improving productivity through modular manufacturing and assembly.
3Reliability
If a cover with warping and irregularities is attached to the stator, then the cover provides protection, but internal stress increases causing adverse effects on performance, strength and lifetime
Solution Approach 1:
The cover is segmented into multiple sections that are each manufactured with controlled flatness and minimal warping. By assembling these precision sections together rather than attaching a single warped cover, the overall structure maintains uniform stress distribution. This prevents the internal stress concentration that occurs with warped covers, thereby preserving stator strength and structural integrity.
Solution Approach 2:
Each cover section is manufactured with specific local quality requirements for flatness and dimensional accuracy. The welding joints between sections are designed to minimize stress concentration. This localized quality control ensures that the entire cover structure, when assembled, provides uniform protection without introducing harmful internal stresses that would compromise stator strength.
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 enables the production of high-yield, flat covers with improved precision and performance, reducing internal stress and enhancing the productivity and strength of large resolver stators.
Implementation Method 1
the protrusion part is welded and fixed to the one of the island parts
Data Source
AI summary
A stator of a resolver has an annular core having teeth, an insulator that covers a part of the core, windings wound around the teeth with the insulator interposed therebetween, and a cover that covers the windings and connecting wires that are extensions of the windings. The insulator has winding parts, a connecting wire part, a barrier wall and a plurality of island parts, and a positioning projection part is formed on the island parts. The cover is formed by cover sections arranged along the circumference thereof, each of the cover sections has a protrusion part that is to be welded and fixed to one of the island parts. Each of the cover sections is positioned with a positioning recess of the protrusion part being fitted onto the positioning projection part and a side wall thereof being interposed between the barrier wall and the positioning projection part.