VR Resolver Stator Aluminum Winding Corrosion Resistance
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Solution Overview
Problem
The existing technologies for resolvers, such as those used in electric vehicles, face corrosion issues due to sulfide contamination in ATF oil, leading to conduction deterioration, and existing solutions like insulating oil or waterproof resin coatings increase production costs and reliability concerns.
Innovation Solution
The use of aluminum conductive portions or polytetrafluoroethylene (PTFE) coated wires for the coils in a VR type resolver, particularly for the outermost winding, enhances corrosion resistance without increasing production costs, and ensures consistent characteristics for sine and cosine phase detection coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper wire with polyurethane or polyester coating is used for winding, then good electrical conduction is achieved, but corrosion occurs due to sulfide penetration through the coating
Solution Approach 1:
The patent changes the material parameter of the outermost winding wire from copper-based to aluminum-based, which fundamentally alters the chemical interaction with sulfide in ATF oil. Aluminum forms a protective oxide layer that prevents further corrosion, whereas copper continues to corrode when sulfide penetrates the coating. This material substitution resolves the corrosion issue without requiring additional protective structures.
2Reliability
If insulating oil is used to enclose the winding, then corrosion protection is improved, but production cost increases and reliability decreases due to leakage risk
Solution Approach 1:
The patent extracts and eliminates the insulating oil enclosure system from the resolver structure. Instead of adding a separate protective medium, the solution integrates corrosion resistance directly into the winding wire material itself. This removes the need for enclosing structures, eliminates production cost increases, and avoids reliability issues associated with oil leakage in vibrating environments.
3Reliability
If waterproof resin coating is applied to the winding, then corrosion resistance is improved, but production processes increase and production cost increases
Solution Approach 1:
The patent changes the fundamental material parameter of the winding wire to aluminum, which inherently resists corrosion from ATF oil. This eliminates the need for additional waterproof resin coating processes, thereby simplifying manufacturing and reducing production costs while maintaining reliable corrosion protection.
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 solution effectively prevents corrosion of the resolver winding and terminals while maintaining cost-effectiveness, ensuring reliable operation without the need for additional protective measures like insulating oil or resin coatings.
Implementation Method 1
at least the coils wound at the outermost side are formed by wires in which conductive portions are made of aluminum or wires in which coat portions are made of polytetrafluoroethylene (PTFE)
Data Source
AI summary
A stator structure and a VR type resolver, in which the winding of the resolver can be prevented from corroding without increasing the production cost, are provided. The stator structure has stator protruding portions and coils wound around the stator protruding portions, the coils consisting of exciting coils, sine phase detection coils, and cosine phase detection coils, and at least the coils wound at the outermost side are formed by wires in which conductive portions are made of aluminum.