Resolver Production Process And Matters Needing Attention

The production process of resolvers, also known as synchronous resolvers, involves a series of meticulous steps to ensure precision and reliability, especially for their application in electric vehicles and industrial motors. Below is a comprehensive overview of the production process along with essential considerations in English, condensed to meet the 800-word limit.

Production Process of Resolvers

1. Material Preparation

The production starts with the selection of high-quality materials for both the stator and rotor. Typically, non-magnetic materials like aluminum or steel are used for the stator housing, while copper windings are preferred for electrical conductivity. Magnetic materials, such as neodymium or ferrite, are used for the rotor. Material specifications are strictly adhered to ensure resistance to vibration, temperature fluctuations, and electromagnetic interference.

2. Stator Fabrication

The stator, the stationary part of the resolver, is fabricated by winding copper wires around a non-magnetic bobbin. This primary winding receives the high-frequency sine signal, which generates the magnetic field. Precise winding techniques are employed to maintain consistent impedance and minimize inductance variation. After winding, the stator is insulated and encapsulated to protect the windings from the environment.

3. Rotor Assembly

The rotor, attached to the motor shaft, undergoes a similar but more intricate process. Its windings, acting as the secondary side of the transformer, are precisely wound and positioned. These windings are usually at 90° angular displacement to provide sine and cosine outputs. The rotor assembly is balanced to minimize vibrations during rotation.

4. Assembly and Alignment

The stator and rotor are then assembled into the resolver housing, ensuring precise alignment. The gap between the stator and rotor (air gap) is critical for performance, and its tolerance is tightly controlled. Techniques like laser alignment are used to ensure that the rotor rotates smoothly and accurately reflects angular changes.

5. Testing and Calibration

After assembly, the resolver undergoes rigorous testing to verify its functionality and accuracy. This includes testing the output voltage at various rotor positions, validating the sine and cosine relationship, and assessing the response to high-frequency signals. Calibration is performed to adjust any deviations from the ideal characteristics, ensuring consistency across all units.

6. Environmental Testing

The resolver is exposed to various environmental conditions, including temperature extremes, humidity, and vibration, to assess its durability and reliability. This ensures that the resolver can perform consistently in harsh automotive and industrial environments.

7. Quality Control

A strict quality control process ensures that every resolver meets the specified standards. Defective units are identified and reworked or discarded. Serial numbers and traceability information are recorded for each unit to facilitate traceability and warranty management.

Key Considerations

• Precision: The alignment and assembly processes must be highly precise to ensure accurate angular measurements.

• Materials: The selection of materials is crucial for withstanding the operating environment and maintaining performance over time.

• Testing: Comprehensive testing is essential to identify and correct any defects before the resolver reaches the end-user.

• Environmental Resistance: Resolvers must be designed to withstand temperature fluctuations, humidity, and vibrations encountered in real-world applications.

• Quality Control: Strict quality control measures ensure consistent performance and reliability across all produced units.

In conclusion, the production process of resolvers involves multiple stages, each requiring precision and attention to detail. By adhering to strict material specifications, employing advanced manufacturing techniques, and conducting rigorous testing, manufacturers can produce high-quality resolvers that meet the demanding requirements of the automotive and industrial sectors.