The Production Process of Resolver Is Introduced

The production process of a resolver, an electromagnetic sensor widely used in motion control systems, involves a series of meticulous steps to ensure precision, reliability, and performance. From laser marking to final testing, each stage plays a vital role in the manufacturing of this crucial component. Here is an in-depth look at the production process of a resolver, highlighting key stages such as laser marking, winding, welding, varnishing, encapsulating, curing, and testing.

Laser Marking

The production of a resolver begins with laser marking, a process that involves etching identifying information onto the resolver's components, such as the stator, rotor, and housing. This information typically includes part numbers, serial numbers, and manufacturer details. Laser marking provides a durable and clear mark that resists wear and tear, ensuring that the resolver can be easily traced and identified throughout its lifecycle.

Winding

Next, the winding process begins. This involves carefully winding insulated copper or aluminum wires onto the stator or rotor cores. The winding pattern is precisely calculated to ensure optimal electromagnetic performance. The number of turns, wire gauge, and winding layout are all critical factors that affect the resolver's output signal and accuracy. Precision winding machines are used to ensure consistency and repeatability in this critical step.

Welding

Once the winding is complete, the wire ends are connected to the resolver's terminals through a welding process. This ensures a reliable electrical connection that can withstand the mechanical stresses and environmental conditions that the resolver will encounter in use. High-precision welding equipment is used to ensure clean, strong welds that do not compromise the resolver's performance.

Varnishing and Encapsulating

After welding, the windings are coated with varnish or encapsulated in a protective resin to provide insulation and moisture protection. This step is crucial for ensuring the resolver's long-term reliability and performance. The varnish or resin is applied using specialized equipment to ensure a uniform and consistent coating.

Curing

The varnished or encapsulated resolver is then subjected to a curing process, which involves heating the component to a specific temperature for a specified period. This step ensures that the varnish or resin is fully hardened and forms a durable protective layer. Proper curing also helps to reduce stress and improve the overall mechanical strength of the resolver.

Testing

Finally, the resolver undergoes a rigorous testing process to verify its performance and reliability. This includes electrical tests to check for insulation resistance, winding resistance, and inductance, as well as functional tests to ensure that the resolver produces an accurate output signal. In some cases, the resolver may also be subjected to environmental testing, such as temperature cycling and vibration testing, to ensure that it can perform reliably in a wide range of conditions.

In conclusion, the production process of a resolver is a complex and precise endeavor that requires careful attention to detail at each stage. From laser marking to final testing, each step is critical in ensuring that the resolver meets the rigorous standards required for motion control applications.