Stator Terminal Block Potting Structure for Faster Resolver Assembly
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Solution Overview
Problem
The assembly efficiency of stator assemblies in resolvers is hindered by the need to move the terminal pin base unit up and down during potting, which complicates the electrical connection process.
Innovation Solution
A stator assembly design featuring a terminal block with recessed parts and through-holes, where electrical connections are covered with a filler, allowing for improved assembly efficiency by eliminating the need to move the assembly vertically during potting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal pin base unit is moved up and down during potting, then the electrical connection can be established, but the assembly work efficiency is reduced
Solution Approach 1:
The terminal block is designed with through-holes and recessed parts in advance, allowing the filler to be applied directly without requiring subsequent vertical movement of the assembly. The electrical connection structure is prepared beforehand to enable direct filling operation.
Solution Approach 2:
Instead of moving the assembly vertically to achieve electrical connection, the invention inverts the approach by designing the terminal block structure to allow the filler to flow through pre-formed through-holes, eliminating the need for vertical movement during potting.
2Ease of manufacture
If the terminal block structure is designed with through-holes and recessed parts, then the filler application is simplified, but the device complexity increases
Solution Approach 1:
The terminal block serves multiple functions: it provides electrical connection, structural support, and guides the filler application through its integrated through-holes and recessed parts. This multi-functionality reduces the need for separate components.
Solution Approach 2:
The terminal block merges the electrical connection function with the filler application guide function into a single integrated structure, combining what could be separate components into one unified element that simplifies the overall assembly process.
Data Source
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AI summary
A stator assembly 1 includes a stator core 22, a plurality of coils 23 including a winding 25 wound around the stator core 22, a terminal 35 electrically connected to the winding 25, and a terminal block 33 provided on the stator core 22 and supporting the terminal 35. The terminal block 33 includes a recessed part 39 and a plurality of through-holes 40 formed in the recessed part 39. The terminal 35 electrically connected to the lead 36 in the through-hole 40 is covered with a filler 43.