Slotless Resolver Cylindrical Stator Winding Design
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Solution Overview
Problem
Conventional resolvers require complex molding designs for teeth and slots, leading to high-frequency components in output waveforms and inadequate insulation due to uneven silicon coating, complicating fabrication and insulation.
Innovation Solution
A slotless resolver with a cylindrical stator core featuring distribution windings for sine and cosine output windings, alternately stacked and coated with insulating resin, eliminating the need for teeth and slots, and utilizing a specialized winding tool for manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If teeth and slots are used for coil windings in a conventional resolver, then the coils can be wound on specific locations, but the fabrication becomes complicated requiring complex molding design
Solution Approach 1:
The patent removes the teeth and slots structure from the stator core, extracting the problematic elements that caused complex molding design. The coils are now wound directly on the smooth cylindrical surface of the stator core without requiring tooth-shaped protrusions or slot structures, thereby simplifying the molding design while maintaining the winding functionality.
2Ease of manufacture
If concentration winding structure is used on teeth only, then the winding process is simplified, but high-frequency components are caused in the output waveform due to broken voltage sections between teeth
Solution Approach 1:
The patent applies different winding structures to different regions of the stator core. Distribution windings are used in radial sections to ensure continuous voltage output and eliminate high-frequency components, while concentration windings can be used in axial sections for simplicity. This local differentiation of winding quality resolves the contradiction between winding simplicity and waveform quality.
3Reliability
If a large amount of silicon is coated to insulate coils wound on teeth, then insulation coverage is attempted, but the silicon is not evenly coated on every corner resulting in insufficient insulation property
Solution Approach 1:
By removing the teeth structure, the patent eliminates the geometric complexity that prevented even silicon coating. The smooth cylindrical surface of the stator core allows uniform coating of insulating resin without dead corners or hard-to-reach areas, thereby achieving sufficient insulation property with a simpler coating process.
4Adaptability or versatility
If teeth and slots are fabricated in the stator, then coil winding locations are defined, but the overall design and fabrication complexity increases
Solution Approach 1:
The patent makes the stator core surface universally suitable for coil winding by removing specialized tooth and slot structures. The smooth cylindrical surface can accommodate various winding patterns (concentration or distribution windings) without requiring specific geometric features, thereby defining coil winding locations through winding pattern design rather than structural features.
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
Simplifies fabrication, removes high-frequency components, ensures sufficient insulation with reduced silicon coating, and achieves a more compact design by eliminating protrusions, resulting in a more efficient and reliable resolver.
Implementation Method 1
coated with insulating resin
Implementation Method 2
a plurality of sine output windings attached on an excitation winding pattern in the circumferential direction in such a way as to be stacked and each forming a distribution winding; and a plurality of cosine output windings attached on the excitation winding pattern in the circumferential direction in such a way as to be stacked
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a resolver having a stator for detecting the rotational position of a rotor rotating at the inner center thereof. The stator includes: a stator core having a cylindrical shape; a plurality of excitation windings attached to the inner surface of the stator core at a predetermined distance in the circumferential direction, each of the plurality of excitation windings being tightly wound; a plurality of sine output windings stacked and attached to the patterns of the excitation windings in the circumferential direction, each of the plurality of sine output windings being loosely wound; and a plurality of cosine output windings stacked and attached to the patterns of the excitation windings in the circumferential direction, the sine output windings and the cosine output windings being alternately attached such that the sine output windings and the cosine output windings have the same winding distribution. Therefore, it is possible to easily manufacture the resolver without designing a complicated mold necessitated by the removal of a tooth and slot structure in the stator. Also, it is possible to remove high-frequency components from an output waveform and easily apply an insulating resin for insulating a coil. In addition, the amount of applied insulating resin may be reduced, and sufficient insulation characteristics may be further achieved.