Stator structure for a resolver

Details Stator structure for a resolver Stator structure for a resolver

2003-11-19

2004-11-09

Le, Dang (Department: 2834)

Electrical generator or motor structure

Dynamoelectric

Rotary

C310S254100

Reexamination Certificate

active

06815853

ABSTRACT:

CROSS REFERENCE TO RELATED APPLICATION
This application is based on and incorporates by reference Japanese Patent Application No. 2002-336407 which was filed on 20 Nov. 2002.
BACKGROUND OF THE INVENTION
The present invention relates to stator structures of resolvers, and more particularly, to a stator structure of a resolver that includes a modular connector that resists breakage and inadvertent removal.
In conventional resolver stator structures, lead lines with connectors have been manually connected to the terminal lines of stator coils, and it has been difficult to automate the assembly of stator structures. The lead line connector parts have been stacked on top of the stator coil lines, which has had a negative impact on the characteristics of the resolver. A resolver stator structure such as that of
FIGS. 11 and 12
has been proposed for solving this problem.
FIGS. 11 and 12
are from published Japanese patent application H10-309067.
The inside of a multilayer iron core
100
is fabricated with multiple alternating tooth parts
200
and slots
300
as shown. Stator coil wires
500
are wound onto each of the tooth parts
200
on top of a well-known insulating member
400
, which is known as an insulating cap. The insulating member
400
is annular and which has parts that protrude in correspondence with each of the tooth parts
200
. The stator coil wires
500
are electrically insulated from each of the tooth parts
200
of the iron core
100
.
An insulating extension
109
, which extends radially with respect to the iron core
100
as shown, is integral with the insulating member
400
. Multiple pins
110
are embedded in the insulating extension
109
. A lead line
700
, which is fixed to a connector
600
, is connected to a terminal part
118
of the pins
110
. The terminal ends of the stator coil wires
500
are connected to the pins
110
. The connection of the pins and the stator coil wires is performed by an automated machine, not shown. A cover
129
, for covering the pins
110
, is provided on the insulating extension
109
such that the cover
129
can easily be attached and removed.
An annular coil cover
139
is located on the stator coil wire
500
, and the coil cover
139
includes a notched part
138
, which corresponds to the insulating extension part
109
. When the resolver stator structure according to
FIGS. 11 and 12
is assembled automatically, the coil wires
500
are applied to each of the tooth parts
200
after the insulating member
400
, which includes the insulating extension part
109
, is attached to the iron core
100
. Then, the terminal ends of the coil wires
500
are connected to the various pins
110
, and the coil wire cover
139
is installed. The stator structure can be assembled automatically by having the various processes described above performed by automated equipment.
In this resolver stator structure, pins are embedded in the insulating extension
109
. The insulating extension
109
is fabricated to be integral with the insulating member
400
, which is located between the iron core
100
and the coil wires
500
. The coil wires
500
are connected to the pins
110
, making it possible to automate the assembly of the stator structure. However, the conventional stator structure has been a structure in which pins are embedded in the insulating extension
109
, which is integral with the insulating member
400
. In order to make the resolver smaller and thinner, the parts that connect with the insulation extension
109
, have been made thin.
Because of this, the insulating extension
109
is susceptible to fracture at the junction between the insulation extension and the insulating member
400
when an external force is applied to the stator. Furthermore, the fact that the insulating member and the insulating extension parts have been fabricated as an integral member has required that the insulating member
400
and the insulating extension
109
be of the same material. Therefore, a different material cannot be used for the insulating extension
109
even if such material is more appropriate for a connector. In addition the material limits the shape of the parts, which is a factor in the cost of the resolver.
SUMMARY OF THE INVENTION
An object of the invention is to provide a resolver stator structure that lowers the cost of manufacture and in which the insulating extension parts are strongly resistant to removal, which improves reliability.
Basically, the invention is a stator structure for a resolver including stator core. The stator core includes protrusions that extend outwardly from a center of the stator core, and the protrusions are shaped such that a keyway is formed between the protrusions. The stator core structure includes a connector module, and the connector module includes pins for conducting electricity to the resolver. The connector module includes a key part, the shape of which conforms to the shape of the keyway, and the key part is fitted into the keyway for attaching the connector module to the stator core.
In another aspect of the invention, the resolver includes a first insulating member, which is located on a first side of the stator core, and a second insulating member, which is located on a second side of the stator core. The first side of the stator core is opposite to the second side of the stator core, and the first and second insulating members surround the stator core.
In another aspect, the connector module is mated with a socket to electrically connect a lead line to the resolver.
In another aspect, the connector module includes a fastener for fastening the connector module to one of the insulating members.
In another aspect, the fastener, when fastened, prevents the connector module from moving within the keyway.
In another aspect, distal ends of the protrusions are angled toward one another to form the keyway.
In another aspect, the connector module includes a stop member that abuts against the protrusions when the connector module is attached to the stator core. The stop member prevents movement of the key part within the keyway.
In another aspect, the stator core includes a plurality of plates that are stacked, and more than one of the plates includes protruding members that form the protrusions.
In another aspect, the resolver core is generally circular and has a central axis. The connector module has a longitudinal axis that is perpendicular the central axis of the stator core.


REFERENCES:
patent: 4132460 (1979-01-01), Porta
patent: 5389846 (1995-02-01), Okazaki et al.
patent: 5920135 (1999-07-01), Ohshita
patent: 6028383 (2000-02-01), Ohshita
patent: 6724109 (2004-04-01), Mimura
patent: 56088638 (1981-07-01), None
patent: 61121737 (1986-06-01), None
patent: 61218339 (1986-09-01), None
patent: 04049826 (1992-02-01), None
patent: 05146106 (1993-06-01), None
patent: 06022495 (1994-01-01), None
patent: H10-309067 (1998-11-01), None

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