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KR-20260062219-A - Resolver cover welding structure

KR20260062219AKR 20260062219 AKR20260062219 AKR 20260062219AKR-20260062219-A

Abstract

The resolver welding structure of the present invention can be formed by forming a plurality of welding grooves in an insulator on which a stator coil is wound, forming upper welding protrusions on an upper cover covering the upper surface of the insulator that are joined by ultrasonical or thermal welding to each welding groove, and forming lower welding protrusions on a lower cover covering the lower surface of the insulator that are joined by ultrasonical welding to each welding groove, so that the insulator and the upper cover, and the insulator and the lower cover, are each welded together.

Inventors

  • 김도균
  • 최윤재
  • 심완보
  • 최원석

Assignees

  • (주)동보

Dates

Publication Date
20260507
Application Date
20241028

Claims (8)

  1. A resolver fusion structure, wherein the fusion structure comprises forming a plurality of fusion grooves in an insulator on which a stator coil is wound, forming an upper fusion projection on an upper cover covering the upper surface of the insulator that is joined by ultrasonically fusing to each fusion groove, and forming a lower fusion projection on a lower cover covering the lower surface of the insulator that is joined by ultrasonically fusing to each fusion groove, so that the insulator and the upper cover, and the insulator and the lower cover, are each fused.
  2. In Article 1, A resolver fusion structure having a terminal block formed on the upper surface of the insulator to which the windings of a stator coil are gathered and drawn out, an additional fusion block formed on at least one side of the upper terminal block, and a fusion projection formed on the upper cover corresponding to the additional fusion block that is ultrasonically or thermally fused.
  3. In Article 1, A resolver fusion structure in which fusion grooves are formed at equal intervals on the outside of the circular rim of the insulator, behind the bobbin on which the coil is wound.
  4. In Paragraph 3, A resolver fusion structure, wherein the rim of the insulator comprises a first rim located at the outermost edge and a second rim formed behind the backup plate of the bobbin and spaced inward from the first rim with a fine gap, and the fusion groove is formed as an empty space between the inner surface of the first rim and the outer surface of the second rim located behind the bobbin.
  5. In Paragraph 4, A resolver fusion structure in which the fusion protrusions of the upper cover and lower cover are column-shaped.
  6. In Paragraph 5, A resolver fusion structure in which the size of the above-mentioned fusion protrusion is in the range of width 3 to 5 mm, length 0.5 to 2 mm, and height 1 to 3 mm.
  7. In Paragraph 2, A resolver welding structure in which the welding portion formed on the terminal block portion is composed of a welding surface with a flat upper surface, and the welding projection of the upper cover that is ultrasonically welded to the welding portion is in the shape of a welding peak with a pointed lower end facing the welding surface.
  8. In Article 1, The above-mentioned fusion groove is a resolver fusion structure having a narrow channel shape that connects the upper and lower surfaces of the insulator.

Description

Resolver cover welding structure The present invention relates to a resolver cover fusion structure. A resolver is used as an angle sensor to control the rotation of a driving motor of an automobile. The resolver is equipped with a resolver stator, which is a stator, and a resolver rotor, which is a rotor, and detects the rotation angle by utilizing the change in the gap between the two. Conventional resolver assembly structures require connection to upper and lower covers to protect internal coils and terminal pins, and are equipped with welding pillars for this purpose. Specifically, existing technology inserts a welding pillar passing between two adjacent slots and joins the upper and lower covers through the welding grooves of the opposing covers. However, in this case, a gap occurs between the core and the cover combined with the insulator, and vibration and noise are generated during the operation of the drive motor, affecting the durability and reliability of the product. For example, Japanese Patent No. 4792577 discloses a resolver fixing structure as illustrated in FIG. 7, wherein a column (support; 11') of a ring-shaped coil cover (lower cover; 10') is inserted into all slots (3') between each pole (2') of a ring-shaped stator (1'), and the protruding upper end of the column (11') is fused to a corresponding groove of an upper cover not illustrated. The size of the column (11') is 2 mm in width, 4 mm in length, and 10 mm in height, with a volume of 80 m³ , and there is a problem of increased cost due to the large size. In addition, since there is no separate cover coupling structure in the terminal section (terminal part) of the insulator assembly, the terminal section must be coupled separately from the upper cover, the upper cover must be fastened to the insulator assembly from the top downwards, the lower cover must be fastened to the insulator assembly from the bottom upwards, and the upper end of the protruding column must be fused, which has the disadvantage of making the assembly process complex in three steps and increasing the process time. Furthermore, as mentioned above, there is a fundamental problem in that vibration and noise occur due to the gap between the insulator assembly and the upper and lower covers. Korean Patent No. 10-1605630 discloses a structure in which a slit portion is formed in a body portion to correspond to a terminal pin when winding a coil onto a terminal pin of a terminal portion formed on one side of an insulating cover, i.e., an insulator assembly, and a winding guide portion is formed protruding from a winding machine to correspond to the slit portion so as to be inserted into or withdrawn from the slit portion. However, this patent does not disclose the fastening of the insulator assembly with the upper and lower covers. Furthermore, it does not disclose the fastening structure with the upper and lower covers specific to the terminal portion, i.e., the terminal block portion. The present invention has been devised to resolve the problems of the above prior art at once. FIG. 1 is a drawing showing the upper surface of an insulator assembly forming the resolver of the present invention and the inner surface of an upper cover covering the upper surface of the insulator assembly; FIG. 2 is a drawing showing the lower surface of an insulator assembly forming the resolver of the present invention and the inner surface of a lower cover covering the lower surface of the insulator assembly; FIG. 3 is an enlarged perspective view illustrating the joining portion of the insulator assembly and the upper cover of the present invention, centering on the fusion groove and the fusion projection; FIG. 4 is a drawing illustrating the structure of a terminal block portion of the prior art; FIG. 5 is a cross-sectional view showing the welded portion of the insulator and the welded protrusion of the upper cover before and after welding in FIG. 1; FIG. 6 is a schematic diagram illustrating the process steps when using the structure of the present invention; and Figure 7 is a drawing illustrating the resolver fixing structure of a prior patent. A resolver is largely composed of a stator assembly and a rotor assembly. The components of the former include an insulating injection molded part consisting of a stator core, an upper insulator, and a lower insulator, a coil (e.g., an enamel coil), an upper cover, a lower cover, and lead wires. The stator core is rigidly bonded to the insulating injection molded part, and an enamel coil is wound on the tooth portion above it. The enamel coil consists of an input winding and an output winding; when power is applied to the input winding, a voltage is induced in the output winding, and sine and cosine waveforms are output. At this time, the resolver precisely calculates the rotation angle by comparing the values of the output waveforms. Since the enamel coil is very thin, if it is subjected to external impact or foreign matter, its electrical