JP2010252578A - Resolver and method of manufacturing resolver - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resolver that further improves accuracy of detecting a rotation angle, and to provide a manufacturing method of the resolver. <P>SOLUTION: A resolver 100 includes: a stator 200 that is made of a magnetic material and is provided with a plurality of stator teeth 210a-210h provided in such a manner as to cross at right angles with an annular flat surface; a plurality of stator windings provided to be wound outside the stator teeth 210a-210h as winding magnetic cores; a wiring board 400 with wires for electrically connecting at least two stator windings out of the plurality of stator windings; and a rotor 300 that is made of a magnetic material and is rotatably provided with respect to the stator 200 so that a gap permeance with each stator tooth may change due to a predetermined rotation around the axis of rotation. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a resolver and a method for manufacturing the resolver.

  Conventionally, this type of resolver has a stator and a rotor, and utilizes the fact that the mutual inductance between the stator and the rotor changes depending on the rotational position of the rotor with respect to the stator, thereby detecting according to the rotation angle of the rotor with respect to the stator. Output a signal.

  FIG. 17 shows a configuration example of a conventional resolver. FIG. 17 shows only the stator structure of the resolver.

  A conventional resolver stator 900 has a large number of teeth 904 and slots 906 inside a multilayer iron core 902, and the teeth 904 and slots 906 are alternately formed in the circumferential direction. A stator winding 910 is wound around each tooth portion 904 via an insulating cap 908, and the stator winding 910, the iron core 902, and each tooth portion 904 are electrically insulated. An insulating extension 912 extending along the end surface of the iron core 902 is integrally formed at one end of the insulating cap 908, and a plurality of terminal pins 914 are implanted in the insulating extension 912. A lead wire 918 having a connector 916 is connected to the terminal pin 914, and an end line of the stator winding 910 is connected to each terminal pin 914.

  The stator winding is composed of, for example, an excitation winding for excitation and a two-phase detection winding. When a rotor (not shown) rotates while being excited by the excitation winding, the stator winding is interposed between the rotor and the stator. The gap permeance changes sinusoidally with respect to the rotation angle θ. Since the voltage of the two-phase detection winding changes corresponding to the rotation angle θ, the rotation angle is detected based on this voltage change.

  The detection signal from the resolver is converted into a digital signal by an R / D converter, and the converted digital signal is output for use in subsequent control processing.

Japanese Patent Laid-Open No. 10-309067

  By the way, in a resolver, in order to improve the detection accuracy of a rotation angle, it is necessary to wind the excitation winding and the detection winding with high accuracy. However, in the resolver disclosed in Patent Document 1, since the tooth portion is provided inward, the excitation winding and the detection winding cannot be wound with high accuracy, which is a major obstacle to improving the detection accuracy. It was.

  In addition, in the conventional resolver, the wiring connecting the excitation windings and the detection windings wound around the tooth portion is not uniform, and even the excitation windings and the detection windings can be wound with high accuracy. Even so, there was a limit in improving the detection accuracy of the rotation angle.

  The present invention has been made in view of the technical problems as described above, and one of its purposes is to provide a resolver and a resolver manufacturing method capable of further improving the detection accuracy of the rotation angle. There is to do.

  (1) In one aspect of the present invention, a resolver is made of a magnetic material, and a stator provided so that a plurality of stator teeth intersect with an annular flat plate surface, and each stator tooth of the plurality of stator teeth is provided. A plurality of stator windings provided so as to be wound around the outside of each stator tooth as a winding magnetic core, and wiring for electrically connecting at least two stator windings constituting the plurality of stator windings A wiring board to be formed, and a rotor made of a magnetic material and provided so as to be rotatable with respect to the stator so that a gap permeance between the stator teeth is changed by rotation around a given rotation axis. Including.

  According to this aspect, since the stator windings are electrically connected to each other by the wiring board on which the wiring is formed in advance, the wiring is made uniform and the detection accuracy of the rotation angle can be improved. Become. In addition, the stator teeth can be provided with stator windings that can be aligned, so that the windings of the stator windings are uniformized, and the stator windings are connected to each other and between the stator windings. Wiring to be performed is made uniform, and the detection accuracy of the rotation angle can be further improved. Further, the stator winding is free from spillage, and the impedance of the stator winding can be determined by the geometric condition and the number of turns. Furthermore, since it is not necessary to wind the stator winding around each stator tooth in a narrow space inside the stator, the manufacturing process of the resolver can be simplified and the detection accuracy can be further improved. Become.

  (2) In the resolver according to another aspect of the present invention, the wiring board has a plurality of insertion holes into which the stator teeth of the plurality of stator teeth are inserted.

  According to this aspect, it is possible to mount the wiring board for connecting the stator windings simply and reliably from above the stator, and the resolver capable of further improving the detection accuracy of the rotation angle. Will be able to provide.

  (3) In the resolver according to another aspect of the present invention, the cross-sectional shape of each of the plurality of states in the rotation direction of the rotor has a width at the flat plate surface longer than a width at the tip portion.

  According to this aspect, in addition to the above effects, the width of the stator teeth can be widened to some extent, so that the level of the detection signal can be increased and the transformation ratio can be improved. In addition, since the harmonic component can be removed from the detection signal as the width of the stator teeth is narrow, according to this aspect, the harmonic component can be removed from the detection signal while maintaining a certain transformation ratio, and only the outer diameter shape of the rotor Harmonic components that cannot be removed by (1) can be removed by the shape of the stator. As a result, the detection accuracy can be further improved.

  (4) The resolver which concerns on the other aspect of this invention is an inner rotor type | mold from which the gap permeance between the outer-diameter side of the said rotor and each said stator teeth changes with rotation of the said rotor.

  According to this aspect, it is possible to provide an inner rotor type resolver capable of further improving detection accuracy.

  (5) The resolver according to another aspect of the present invention is an outer rotor type in which a gap permeance between the inner diameter side of the rotor and the stator teeth is changed by the rotation of the rotor.

  According to this aspect, it is possible to provide an outer rotor type resolver capable of further improving detection accuracy.

  (6) In the resolver according to another aspect of the present invention, the stator is made of one electromagnetic steel plate, SPCC which is ordinary steel, and S45C or S10C which is carbon steel for mechanical structure.

  According to this aspect, by adopting one electromagnetic steel plate, SPCC, S45C or S10C, which is easy to maintain processing accuracy and reliability by bending, as a stator material, the stator can be made of an inexpensive material in addition to the above effects. And a low-cost and highly reliable resolver can be provided.

  (7) A resolver according to another aspect of the present invention includes a converter that outputs a digital signal corresponding to a detection signal from the stator winding in accordance with a rotation angle of the rotor with respect to the stator.

  According to this aspect, by incorporating the converter, it is possible to provide a resolver in which detection of noise from the stator winding is minimized and detection accuracy is improved.

  (8) According to another aspect of the present invention, there is provided a bending step in which a method for manufacturing a resolver performs bending so as to raise a plurality of stator teeth of a stator formed on an edge of an annular flat plate made of a magnetic material, A wiring board mounting step for mounting a wiring board on which the wiring for electrically connecting a plurality of stator windings with each stator tooth as a winding magnetic core is formed on the stator, and each of the plurality of stator teeth. A winding member attaching step for attaching the plurality of stator windings for excitation and detection using the stator teeth as a winding core, and a gap permeance between the stator teeth made of a magnetic material and rotated around a rotation axis And a rotor attachment step of attaching the rotor to be rotatable with respect to the stator so as to change.

  According to this aspect, since the stator windings are electrically connected to each other by the wiring board on which the wiring is formed in advance, it is possible to manufacture a resolver that makes the wiring uniform and improves the detection accuracy of the rotation angle. become. In addition, the stator teeth can be provided with stator windings that can be aligned, so that the windings of the stator windings are uniformized, and the stator windings are connected to each other and between the stator windings. Accordingly, it is possible to manufacture a resolver in which the wiring to be made is uniform and the detection accuracy of the rotation angle can be further improved. Further, the stator winding is free from spillage, and the impedance of the stator winding can be determined by the geometric condition and the number of turns. Furthermore, since it is not necessary to wind the stator winding around each stator tooth in a narrow space inside the stator, the resolver manufacturing process can be simplified and a resolver that can further improve detection accuracy can be manufactured. become.

  (9) In the resolver manufacturing method according to another aspect of the present invention, the wiring board has a plurality of insertion holes into which the stator teeth of the plurality of stator teeth are inserted, and the wiring board mounting step includes: Each stator tooth is inserted into each insertion hole of the plurality of insertion holes, and the wiring board is attached to the stator.

  According to this aspect, it is possible to mount the wiring board for connecting the stator windings simply and reliably from above the stator, and the resolver capable of further improving the detection accuracy of the rotation angle. Can be manufactured.

  (10) In the method for manufacturing a resolver according to another aspect of the present invention, the stator of the stator may be configured such that the cross-sectional shape of the rotor in the rotational direction of each of the stators is longer in the flat plate than in the tip. A stator shape processing step for processing the shape is included.

  According to this aspect, in addition to the above effects, harmonic components can be removed from the detection signal while maintaining a certain degree of transformation ratio, and harmonic components that cannot be removed only by the outer diameter shape of the rotor are removed by the shape of the stator. It becomes possible to manufacture a resolver that can be used.

The perspective view of the structural example of the resolver in Embodiment 1 which concerns on this invention. The disassembled perspective view of the stator of FIG. The figure which shows an example of the top view of the wiring board of FIG. 1 or FIG. Explanatory drawing of the stator teeth inserted in the insertion hole provided in the wiring board. FIGS. 5A and 5B are explanatory diagrams of coils formed on a wiring board. The top view of the resolver of FIG. FIG. 3 is a flowchart of an example of a resolver manufacturing method according to the first embodiment. The perspective view of the flat plate which comprises the stator in Embodiment 1 before bending press processing. The perspective view of the structural example of the resolver in Embodiment 2 which concerns on this invention. The figure which shows an example of the perspective view of the flat plate which comprises the stator after the bending press work process in Embodiment 2. FIG. Explanatory drawing of the shape of the stator teeth in Embodiment 2. FIG. The perspective view of the structural example of the resolver in Embodiment 3 which concerns on this invention. The figure which shows an example of the perspective view of the flat plate which comprises the stator after the bending press work process in Embodiment 3. FIG. Explanatory drawing of the shape of the stator teeth in Embodiment 3. FIG. The functional block diagram of the structural example of the angle detection system to which the resolver in any embodiment was applied. FIG. 16A and FIG. 16B are diagrams illustrating a specific configuration example of a system to which the resolver in any of the embodiments is applied. The figure which shows the structural example of the conventional resolver.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The embodiments described below do not unduly limit the contents of the present invention described in the claims. In addition, all of the configurations described below are not necessarily indispensable configuration requirements for solving the problems of the present invention.

[Embodiment 1]
FIG. 1 shows a perspective view of a configuration example of a resolver according to the first embodiment of the present invention. In FIG. 1, the stator winding is schematically shown, and the wiring for connecting the stator winding is omitted. 1 illustrates an example in which the resolver 100 is a one-phase excitation two-phase output type resolver having eight stator teeth, but the present invention is not limited to this.
FIG. 2 is an exploded perspective view of the stator of FIG. 2, the same parts as those in FIG. 1 are denoted by the same reference numerals, and description thereof will be omitted as appropriate.

  The resolver 100 includes a stator (stator) 200 and a rotor (rotor) 300. The resolver 100 is a so-called inner rotor type angle detection device. That is, the rotor 300 is provided inside the stator 200, and the rotation angle of the rotor 300 is set in a state where the stator 200 (more specifically, the stator teeth) faces the outer peripheral side (outer diameter side) side surface of the rotor 300. Accordingly, the signal from the detection winding constituting the stator winding provided in the stator 200 is changed.

  The stator 200 is configured using a ring-shaped flat plate 250 made of a magnetic material, and a plurality of stator teeth are provided on the flat plate 250. These stator teeth are provided so as to intersect the flat plate surface of the flat plate 250. In FIG. 1, the stator 200 has eight stator teeth (saliency pole portions) 210a, 210b, 210c, 210d, 210e, 210f, 210g raised substantially perpendicularly to the same surface with respect to the flat plate surface by bending or the like. 210h. The stator teeth 210a to 210h are formed on the flat plate 250 in advance by press working, and then raised so as to be substantially perpendicular to the surface of the flat plate 250 by bending press processing (bending processing in a broad sense). These stator teeth are formed at the inner (inner diameter side) edge of the annular flat plate 250, and at least the surface facing the rotor 300 among the surfaces of each stator tooth is not a flat surface but in the direction of the rotation axis of the rotor 300. When viewed along, it is formed to be a part of an arc centered on a point located on the inner diameter side of the annular flat plate 250.

  Each of the stator teeth 210a to 210h is provided with coils 410a to 410h as stator windings. Each coil constituting coils 410a to 410h is provided to be wound around each stator tooth using each stator tooth constituting stator teeth 210a to 210h as a winding magnetic core. For example, each coil has a configuration in which a wire rod is wound on the outside of a bobbin having a hollow portion, and each stator tooth is inserted into the hollow portion of the bobbin by inserting the stator teeth serving as a winding core. A coil is provided. The coils 410a to 410h are an excitation winding (excitation coil) and a detection winding (detection coil) that constitute the stator winding.

  The rotor 300 is made of a magnetic material and is provided so as to be rotatable with respect to the stator 200. More specifically, the rotor 300 is provided to be rotatable with respect to the stator 200 such that gap permeance between the stator teeth of the stator 200 is changed by rotation around the rotation axis of the rotor 300. For example, the axial multiplication angle of the rotor 300 is “3”, and the outer contour line on the outer diameter side changes in three cycles in a plan view with respect to the circumference of the given radius. It has a shape to Then, the gap permeance of the outer peripheral surface of the rotor 300 facing the inner (inner diameter side, inner peripheral side) surface of the stator teeth raised with respect to the flat plate 250 changes in three cycles per rotation of the rotor 300. It is like that.

  By the way, the wiring board 400 is mounted on the stator 200, and wiring that electrically connects at least two coils among the coils 410a to 410h is formed on the wiring board 400. Then, the coils are electrically connected by the wiring board 400, and a detection signal corresponding to the rotation angle of the rotor 300 is acquired in a state where excitation signals are given to the coils 410a to 410h. Therefore, as shown in FIG. 2, the wiring board 400 has insertion holes 420a to 420h corresponding to the positions of the stator teeth 210a to 210h, and the corresponding stator teeth are inserted into the respective insertion holes. Mounted on the stator 200. The direction of the insertion holes 420 a to 420 h formed in the wiring board 400 is the direction of the rotation axis of the rotor 300.

  FIG. 2 schematically shows the mounting order of each member on the flat plate 250 constituting the stator 200 after the coils are provided on the stator teeth.

  FIG. 3 shows an example of a top view of the wiring substrate 400 of FIG. 1 or FIG. In FIG. 3, the same parts as those in FIG. 1 or FIG.

  Wiring board 400 is an annular printed board, and stator teeth insertion holes 420 a to 420 h are provided in accordance with the positions of stator teeth 210 a to 210 h of stator 200. In the wiring board 400, lands made of a conductive material are formed in the vicinity of each insertion hole. The wiring board 400 is formed with a wiring made of a conductive material that electrically connects lands, and the coils provided in different stator teeth are electrically connected to each other by this wiring. In the first embodiment, lands and wirings formed on the wiring board 400 are arranged on a given circumference around the rotation axis of the rotor 300.

  Of the coils provided so as to be wound around the stator teeth inserted into the insertion holes in the vicinity of the land LD1, a wire for an exciting coil is electrically connected to the land LD1. For example, in the land LD1 in the vicinity of the insertion hole 420a, both ends of the exciting coil wire constituting the coil 410a provided in the stator tooth 210a inserted into the insertion hole 420a are electrically connected by soldering or resistance welding, respectively. Connected.

  In the wiring board 400, wirings HS11 to HS17 made of a conductive material are formed in the same layer or a plurality of layers. The wiring HS11 electrically connects the exciting coil constituting the coil 410a and the exciting coil constituting the coil 410b. The wiring HS12 electrically connects the exciting coil constituting the coil 410b and the exciting coil constituting the coil 410c. The wiring HS13 electrically connects the exciting coil constituting the coil 410c and the exciting coil constituting the coil 410d. The wiring HS14 electrically connects the exciting coil constituting the coil 410d and the exciting coil constituting the coil 410e. The wiring HS15 electrically connects the exciting coil constituting the coil 410e and the exciting coil constituting the coil 410f. The wiring HS16 electrically connects the exciting coil constituting the coil 410f and the exciting coil constituting the coil 410g. The wiring HS17 electrically connects the exciting coil constituting the coil 410g and the exciting coil constituting the coil 410h.

  Of the coils provided in the stator teeth inserted into the insertion holes in the vicinity of the land LD2, the land LD2 is electrically connected to a wire for a detection coil that transmits a first phase detection signal. For example, one end of a wire of a detection coil constituting the coil 410a provided in the stator tooth 210a inserted into the insertion hole 420a is electrically connected to the land LD2 in the vicinity of the insertion hole 420a by soldering or resistance welding. Is done.

  In the wiring board 400, wirings HS21 to HS23 made of a conductive material are formed in the same layer or a plurality of layers. The wirings HS21 to HS23 may be formed in the same layer as any of the wirings HS11 to HS17. When the wiring board 400 is formed of a multilayer substrate, the wirings HS21 to HS23 are different from the wirings HS11 to HS17. It may be formed in a layer. The wiring HS21 electrically connects the detection coil constituting the coil 410a and the detection coil constituting the coil 410c. The wiring HS22 electrically connects the detection coil constituting the coil 410c and the detection coil constituting the coil 410e. The wiring HS23 electrically connects the detection coil constituting the coil 410e and the detection coil constituting the coil 410g.

  Of the coils provided in the stator teeth inserted into the insertion holes in the vicinity of the land LD3, the land LD3 is electrically connected to a wire for a detection coil that transmits a second-phase detection signal. For example, one end of a wire of a detection coil constituting the coil 410b provided in the stator tooth 210b inserted into the insertion hole 420b is electrically connected to the land LD3 in the vicinity of the insertion hole 420b by soldering or resistance welding. Is done.

  In the wiring substrate 400, wirings HS31 to HS33 made of a conductive material are formed in the same layer or a plurality of layers. The wirings HS31 to HS33 may be formed in the same layer as the wirings HS11 to HS17 and HS21 to HS23. When the wiring board 400 is formed of a multilayer substrate, the wirings HS31 to HS33 are replaced with the wirings HS11 to HS17 or The wirings HS21 to HS23 may be formed in a different layer. The wiring HS31 electrically connects the detection coil constituting the coil 410b and the detection coil constituting the coil 410d. The wiring HS32 electrically connects the detection coil constituting the coil 410d and the detection coil constituting the coil 410f. The wiring HS33 electrically connects the detection coil constituting the coil 410f and the detection coil constituting the coil 410h.

  In FIG. 3, the wiring board 400 shows wirings HS11 to HS17 through which excitation signals are transmitted with wavy lines, and wirings HS21 through HS23 and HS31 through HS33 through which first phase and second phase detection signals are transmitted. It is shown with a solid line.

  FIG. 4 is an explanatory view of the stator teeth 210a inserted into the insertion holes 420a provided in the wiring board 400. FIG. In FIG. 4, the same parts as those in FIG. 1 or FIG. FIG. 4 schematically shows a cross-sectional structure of the stator teeth 210a in a given circumferential direction around the rotation axis of the rotor 300 through the insertion hole 420a. FIG. 4 shows a cross-sectional view of the stator teeth 210a, but the stator teeth 210b to 210h have the same structure.

  Stator teeth 210 a raised with respect to flat plate 250 are inserted into insertion holes 420 a provided in wiring board 400. As a result, the coil 410a provided with the stator teeth 210a as a winding magnetic core functions as a stator winding (excitation winding and detection winding).

  Here, the shape of the surface of the stator teeth 210a facing the rotor 300 (the outer peripheral side surface thereof) (the shape of the outer contour line) is parallel to the flat plate surface from the flat plate surface to the tip of the stator teeth 210a, and The rotor 300 has a rectangular shape with a constant width in the circumferential direction D1 around the rotation axis. Here, the direction D1 can be referred to as the rotation direction of the rotor 300. That is, in FIG. 4, the width d1 in the direction D1 of the stator teeth 210a on the flat plate surface and the width d2 in the direction D1 of the front end portion of the stator teeth 210a coincide with each other. By having such a shape, a lot of magnetic flux passes through the stator teeth 210a, the output level of the detection signal is increased, and the transformation ratio of the resolver 100 can be increased.

  Here, the coil for taking out the detection signal output from the detection winding by the rotation of the rotor 300 will be described. The coil is composed of an excitation coil (excitation winding) and a detection coil (detection winding) as stator windings. In the resolver 100, the signal of the detection coil changes due to the rotation of the rotor 300 with respect to the stator 200 while being excited by the excitation coil.

  5A and 5B are explanatory diagrams of coils formed on the wiring board 400. FIG. FIG. 5A shows an explanatory diagram of the exciting coil. FIG. 5B shows an explanatory diagram of the detection coil. FIGS. 5A and 5B are plan views of the resolver 100 viewed in the direction of the rotation axis of the rotor 300 of FIG. 1. The same parts as those in FIG. To do. 5A schematically shows the winding direction of the excitation coil, and FIG. 5B schematically shows the winding direction of the detection coil. Actually, each coil is provided with a stator tooth as a winding magnetic core.

  As shown in FIG. 5A, the exciting coil is provided so that the winding directions of adjacent stator teeth are opposite to each other, as shown in FIG. An excitation signal is given between terminals R1 and R2 that are electrically connected to such an excitation coil. The terminals R1 and R2 are provided inside or outside the resolver 100.

  In addition, as shown in FIG. 5B, in order to obtain a two-phase detection signal, the detection coil includes two sets of detection coils as detection windings. The detection coils for obtaining the detection signal of the first phase (for example, SIN phase) of the two-phase detection signals are provided in every other stator tooth, for example, from the stator tooth 210a to the stator teeth 210g counterclockwise. . On the other hand, a detection coil for obtaining a detection signal of the second phase (for example, COS phase) of the two-phase detection signal is provided for every other stator tooth from, for example, the stator teeth 210b to the stator teeth 210h counterclockwise. Provided. The first phase detection signal is detected as a signal between the terminals S1 and S3, and the second phase detection signal is detected as a signal between the terminals S2 and S4. The terminal pins S1 to S4 are provided inside or outside the resolver 100.

  In this manner, the stator teeth 210a, 210c, 210e, and 210g are provided with the coils 410a, 410c, 410e, and 410g as the excitation coil and the first phase (SIN phase) detection coil. The stator teeth 210b, 210d, 210f, and 210h are provided with coils 420b, 420d, 420f, and 420h as an excitation coil and a second phase (COS phase) detection coil. And the exciting coil provided in each stator tooth is electrically connected by the wiring HS11 to HS17 of the wiring board 400 of FIG. 3, and the first phase detection coil is the wiring HS21 of the wiring board 400 of FIG. Are electrically connected by HS23, and the second-phase detection coils are electrically connected by wirings HS31 to HS33 of the wiring board 400 of FIG.

  In the first embodiment, the winding direction of the exciting coil is not limited to the direction shown in FIG. In the first embodiment, the winding direction of the detection coil is not limited to the direction shown in FIG.

  In the resolver 100 having the above configuration, the following magnetic circuit is formed by the rotation of the rotor 300 with respect to the stator 200.

  FIG. 6 shows a top view of the resolver 100 of FIG. 6 is a plan view of the resolver 100 viewed in the direction of the rotation axis of the rotor 300 of FIG. 1. The same parts as those in FIG. 1 or FIG. In FIG. 6, for convenience of explanation, illustration of the wiring board 400 is omitted, and the direction of the magnetic flux at a certain time when the rotor 300 is rotated with respect to the stator 200 is schematically shown. FIG. 6 schematically shows the direction of the magnetic flux passing through each stator tooth as a winding magnetic core.

  As shown in FIGS. 5A and 5B, when the rotor 300 rotates by providing coils in each of the stator teeth 210 a to 210 h of the stator 200 and electrically connecting the coils by the wiring board 400. A magnetic circuit is formed between adjacent stator teeth via the rotor 300. In the first embodiment, as shown in FIG. 6, since the coil is provided so that the direction of the magnetic flux passing through the adjacent stator teeth is the opposite direction, the gap between the stator teeth due to the rotation of the rotor 300 is provided. In response to the change in permeance, the current generated in the coil as the stator winding provided in each stator tooth also changes. For example, the current waveform generated in the detection coil can be made sinusoidal.

  At this time, when the coil is composed of a bobbin around which the wire is wound, it is possible to perform aligned winding in which the wire is neatly wound around the bobbin in advance without disturbing the winding position of the wire, and the detection accuracy can be improved. In addition, the winding state of the coils and the wiring connecting the coils are made uniform, and the detection accuracy can be further improved. Then, the coil winding does not spill, and the impedance of the coil can be determined by the geometric condition and the number of turns.

  In the resolver 100 according to the first embodiment, the flat plate 250 of the stator 200 made of a magnetic material and the material of the rotor 300 are one electromagnetic steel plate, SPCC (one steel plate), which is ordinary steel, rather than laminated electromagnetic steel plates. Or it is desirable that they are S45C and S10C (one steel plate) which are carbon steel for machine structures. SPCC (Steel Plate Cold Commercial) is a cold-rolled steel sheet and steel strip specified in JIS G3141. S45C is a carbon steel material for machine structure defined in JIS G 4051 and contains about 0.45% carbon. S10C is a carbon steel material for machine structure defined in JIS G 4051 and contains about 0.10% carbon.

  As a result, a single electromagnetic steel sheet, SPCC, S45C is used as compared with the case of adopting a laminated electrical steel sheet that is expensive as a material cost, is weak to bending by bending press processing, and is difficult to maintain processing accuracy and reliability by bending. Or by adopting S10C, it becomes possible to maintain the processing accuracy and reliability by bending at low cost.

  Next, the manufacturing method of the resolver 100 in Embodiment 1 is demonstrated.

FIG. 7 shows a flowchart of an example of a method for manufacturing the resolver 100 according to the first embodiment.
FIG. 8 is a perspective view of a flat plate 250 constituting the stator 200 in the first embodiment before bending press processing. In FIG. 8, the same parts as those in FIG. 1 or FIG.

  In order to manufacture the resolver 100 according to the first embodiment, first, after the shape of the stator 200 is processed in the stator shape processing step (step S10), the stator teeth of the plate-shaped stator 200 in the bending press processing step (bending step). Are bent, and a plurality of stator teeth are raised with respect to the flat plate surface (step S12). As a result, the stator teeth 210a to 210h are raised with respect to the flat plate 250 as shown in FIG.

  That is, in the stator shape processing step of step S10, in order to perform the bending press processing of step S12, as shown in FIG. 8, one electromagnetic steel plate, SPCC which is ordinary steel, carbon steel for machine structure is used by press processing. Stator teeth are formed on the inner diameter side edge of a flat plate made of an annular magnetic material made of S45C or S10C, and the shape of the stator 200 is formed. At this time, as described with reference to FIG. 4, the shape of the surface of the stator teeth 210 a to 210 h that faces the rotor 300 (side surface on the outer periphery side) after bending is from the edge on the inner diameter side of the flat plate 250. The width in the circumferential direction around the rotation axis of the rotor 300 is formed to be constant until reaching the tip.

  And in step S12, as shown in FIG. 2, it processes so that the several stator teeth formed in step S10 may be raised by bending press processing. As a result, the stator teeth 210 a to 210 h are raised so as to be substantially perpendicular to the flat plate surface of the stator 200.

  Next, as a wiring board attaching step, wiring board 400 on which wiring between coils is formed in advance as shown in FIG. 3 is attached to stator 200 by inserting the stator teeth raised in step S12 into its insertion hole. (Step S14).

  Subsequently, as another process, for example, a coil obtained by winding a wire around the bobbin having a hollow portion is manufactured, and as a winding member attaching process, this coil is attached to a corresponding stator tooth (step S16). In this case, the coils 410a to 410h can be provided on the stator 200 by inserting corresponding stator teeth into the hollow portions of the coils. Thus, the stator windings are provided outside the stator teeth with the stator teeth of the stator teeth 210a to 210h raised in step S12 as winding magnetic cores.

  Next, in a separate process, the rotor 300 is formed by press working. In the first embodiment, the rotor 300 is an annular flat plate, but has a shape in which the outer contour line on the outer diameter side changes in three cycles in plan view. And as a rotor attachment process, the rotor 300 is provided in the internal diameter side of the stator 200 so that it can rotate with respect to the stator 200 (step S18). More specifically, in the rotor attachment process, the rotor 300 is configured so that the gap permeance between the outer side surface of the rotor 300 and each stator tooth of the stator 200 is changed by rotation around the rotation axis of the rotor 300. Is provided to be rotatable. As described above, the resolver 100 according to the first embodiment is manufactured.

  As described above, according to the first embodiment, since the coils provided in the stator teeth are electrically connected by the wiring board 400, the wiring is made uniform and the detection accuracy of the rotation angle is improved. Will be able to. In addition, since the coils that can be aligned and wound can be provided on the stator teeth, the windings of the coils themselves are made uniform, and the detection accuracy of the rotation angle can be further improved.

  Furthermore, since the stator winding can be provided on the stator teeth after the wiring board 400 on which the wiring is formed is mounted from above the flat plate 250, the stator winding is wound around each stator tooth in a narrow space inside the stator 200. The winding process to be performed and the wiring process to electrically connect the stator windings become unnecessary. Therefore, the manufacturing process of the resolver 100 can be simplified to reduce the cost of the resolver, and the detection accuracy can be further improved.

[Embodiment 2]
In the first embodiment, the shape of the surface of the stator teeth facing the rotor 300 has been described as a rectangular shape having a constant width in the rotation direction of the rotor 300, but the present invention is not limited to this. .

In FIG. 9, the perspective view of the structural example of the resolver in Embodiment 2 which concerns on this invention is shown. In FIG. 9, the stator winding is schematically shown, and the wiring for connecting the stator winding is omitted. 9, parts that are the same as the parts shown in FIG. 1 are given the same reference numerals, and explanation thereof will be omitted as appropriate. FIG. 9 illustrates an example in which the resolver 500 is a one-phase excitation two-phase output type resolver having eight stator teeth, but the present invention is not limited to this.
In FIG. 10, an example of the perspective view of the flat plate which comprises the stator after the bending press process in Embodiment 2 is shown.
In FIG. 11, explanatory drawing of the shape of the stator teeth in Embodiment 2 is shown. FIG. 11 schematically shows a cross-sectional structure of the stator teeth in the second embodiment. 11, the same parts as those in FIG. 4 are denoted by the same reference numerals, and the description thereof will be omitted as appropriate.

  The difference between the resolver 500 in the second embodiment and the resolver 100 in the first embodiment is the shape of the surface of the stator teeth facing the rotor 300. That is, the resolver 500 includes a stator 600 and a rotor 300, and the wiring substrate 400 is mounted on the stator 600. The stator 600 is configured using a ring-shaped flat plate 650 made of a magnetic material, and is provided with stator teeth 610a to 610h so as to intersect with the flat plate surface of the flat plate 650. And the shape of the surface of stator teeth 610a-610h facing the rotor 300 has a trapezoidal shape. Except for the shape of the surfaces of the stator teeth 610a to 610h, the stator windings 610a to 610h having the same configuration as in the first embodiment are electrically connected to each other via the wiring board 400. Connected.

  That is, in the second embodiment, as shown in FIG. 10 or FIG. 11, the shape of the surface of the stator teeth 610a facing the rotor 300 (the outer peripheral side surface) (the shape of the outer contour line) is closer to the flat plate surface. The shape is parallel to the flat plate surface and the width in the circumferential direction D1 with the rotation axis of the rotor 300 as the center is widened. For example, in FIG. 11, the width f1 in the direction D1 of the stator teeth 610a on the flat plate surface and the width f2 in the direction D1 of the tip of the stator teeth 610a have a relationship of f1> f2.

  In FIG. 11, the shape of the stator teeth 610a is desirably a so-called symmetrical trapezoid, and if f1 = f2 + e1 + e2, it is desirable that e1 = e2.

  As shown in FIG. 9, stator teeth 610a to 610h of flat plate 650 shown in FIGS. 10 and 11 are inserted into insertion holes 420a to 420h formed in wiring board 400 shown in FIG.

  By having such a shape, the width of the stator teeth can be widened to some extent, so that the level of the detection signal is increased and the transformation ratio can be improved. In addition, focusing on the fact that the harmonic component can be removed from the detection signal as the width of the stator teeth is narrow, the harmonic component can be removed from the detection signal while maintaining a certain transformation ratio, and the harmonics that cannot be removed only by the outer diameter shape of the rotor. Wave components can be removed by the shape of the stator. As a result, the detection accuracy can be further improved.

[Embodiment 3]
In the second embodiment, as shown in FIG. 11, the shape of the surface of the stator teeth 610a facing the rotor 300 (the shape of the outer contour line) is such that the width in the rotational direction D1 of the rotor 300 becomes wider as the plate surface is closer. However, the present invention is not limited to this.

FIG. 12 shows a perspective view of a configuration example of the resolver according to the third embodiment of the present invention. In FIG. 12, the stator winding is schematically shown, and the wiring for connecting the stator winding is omitted. In FIG. 12, the same parts as those of FIG. FIG. 12 illustrates an example in which the resolver 700 is a one-phase excitation two-phase output type resolver having eight stator teeth, but the present invention is not limited to this.
In FIG. 13, an example of the perspective view of the flat plate which comprises the stator after the bending press-work process in Embodiment 3 is shown.
FIG. 14 is an explanatory diagram of the shape of the stator teeth in the third embodiment. FIG. 14 schematically shows a cross-sectional structure of the stator teeth in the third embodiment. In FIG. 14, the same parts as those in FIG. 4 or FIG.

  The difference between the resolver 700 in the third embodiment and the resolver 500 in the second embodiment is the shape of the surface of the stator teeth facing the rotor 300. That is, the resolver 700 has a stator 800 and a rotor 300, and the wiring substrate 400 is mounted on the stator 800. The stator 800 is configured by using a ring-shaped flat plate 850 made of a magnetic material, and is provided with stator teeth 810a to 810h so as to intersect with the flat plate surface of the flat plate 850. Except for the shape of the surfaces of the stator teeth 810a to 810h, it has the same configuration as that of the second embodiment, and the stator windings provided on the stator teeth 810a to 810h of the stator 800 are electrically connected via the wiring board 400. Connected.

  In the third embodiment, as shown in FIG. 13 or FIG. 14, the shape of the surface of the stator teeth 810a facing the rotor 300 (the side surface on the outer periphery side) (the shape of the outer contour line) is from the flat plate surface to a predetermined height. The width of the rotation direction D1 of the rotor 300 is constant, and when the height is equal to or greater than a predetermined height, the width of the direction D1 becomes narrower toward the tip. For example, in FIG. 14, the width g1 in the direction D1 of the stator teeth 810a on the flat plate surface, the width g2 in the direction D1 from the flat plate surface to a predetermined height, and the width g3 in the direction D1 of the tip portion of the stator teeth 810a > G3.

  In FIG. 14, the shape of the stator teeth 810a is preferably h1 = h2, where g1 = g2 = g3 + h1 + h2.

  As shown in FIG. 12, the stator teeth 810a to 810h of the flat plate 850 shown in FIGS. 13 and 14 are inserted into the insertion holes 420a to 420h formed in the wiring board 400 shown in FIG.

  By having such a shape, the width of the stator teeth can be made wider than that in the second embodiment, so that the magnetic flux passing as the winding core can be increased, so that the transformation ratio is improved as compared with the second embodiment. Will be able to. On the other hand, harmonic components can be reduced, and the effect of reducing cogging can be obtained.

[Angle detection system]
By the way, in the angle detection system to which the resolver in any of the above embodiments is applied, digital data corresponding to the rotation angle can be output based on the two-phase detection signal from the resolver.

  FIG. 15 shows a functional block diagram of a configuration example of an angle detection system to which the resolver in any of the above embodiments is applied. 15 illustrates an example in which the angle detection system includes the resolver 100 according to the first embodiment, but the angle detection system may include the resolver according to the second or third embodiment. In FIG. 15, the R / D converter is provided outside the resolver 100, but the resolver 100 may incorporate the R / D converter.

  The angle detection system 1000 includes a resolver 100 and an R / D converter (converter or conversion device in a broad sense) 1100. The resolver 100 includes a stator and a rotor provided to be rotatable with respect to the stator, and is a terminal corresponding to a rotation angle of the rotor with respect to the stator in a state excited by a one-phase excitation signal between the terminals R1 and R2. Two-phase detection signals are output between S1 and S3 and between terminals S2 and S4. The serial clock SCK is input to the R / D converter 1100, and the R / D converter 1100 generates an excitation signal for the resolver 100 and also generates a digital signal corresponding to the two-phase detection signal from the resolver 100. Then, it is output as serial data or parallel data in synchronization with the serial clock SCK.

  Therefore, in the subsequent processing, by performing given processing based on the serial data or parallel data from the R / D converter 1100, control processing corresponding to the rotation angle detected by the resolver 100 can be realized. .

  The resolver in any of the above-described embodiments is mounted as, for example, an in-vehicle motor or generator angle detector, or as an industrial motor or generator angle detector. Hereinafter, a specific configuration example of an angle detection system to which the resolver according to any one of the above embodiments is applied as such an angle detector will be described.

  FIGS. 16A and 16B show a specific configuration example of a system to which the resolver according to any of the above embodiments is applied. FIG. 16A shows a configuration example of a hybrid engine system that detects rotational positions of a motor and a generator of a hybrid vehicle. FIG. 16B illustrates a configuration example of an electric power steering system that assists the steering operation in the vehicle steering apparatus.

  A hybrid engine system 1200 shown in FIG. 16A includes an engine 1210, a motor 1220, a generator 1230, a battery 1240, an inverter device 1250, a power distribution device 1260, a differential gear 1270, and driving wheels 1280 and 1290, which are not shown. Controlled by control system. The engine 1210 is a gasoline engine and drives the crankshaft 1212 to rotate. A battery 1240 is connected to the motor 1220 and the generator 1230 via an inverter device 1250, and the drive shaft 1222 is rotated by receiving power supply from the battery 1240. On the other hand, the generator 1230 can charge the battery 1240 with the electromotive force generated by the rotation of the rotating shaft 1232 via the inverter device 1250. A crankshaft 1212, a drive shaft 1222, and a rotating shaft 1232 are mechanically coupled to the power distribution device 1260. The power distribution device 1260 has a characteristic that the rotational speed and torque of the remaining one axis are determined according to the power of two of these three axes. For example, the power of the crankshaft 1212 is output to the rotating shaft 1232. To the power to be exchanged with the motor 1220.

  The power transmission gear 1272 to which the power from the power distribution device 1260 is transmitted and coupled to the drive shaft 1222 is coupled to the differential gear 1270, and the power from the power transmission gear 1272 is driven to the drive wheel via the drive shaft 1282. 1280, 1290.

  In such a hybrid engine system 1200, a resolver 1202 whose rotor is attached to the drive shaft 1222 of the motor 1220 and a resolver 1204 whose rotor is attached to the rotating shaft 1232 of the generator 1230 are provided. The resolver 1202 detects the rotation position (rotation angle) of the drive shaft 1222 of the motor 1220 and outputs the detection result to a control system (not shown). The resolver 1204 detects the rotation position (rotation angle) of the rotating shaft 1232 of the generator 1230 and outputs the detection result to a control system (not shown). A control system (not shown) controls the engine 1210 by determining, for example, the rotational angular acceleration of the engine 1210 based on the detection results from the resolvers 1202 and 1204.

  The resolver in any one of the above embodiments is employed as at least one of the resolvers 1202 and 1204.

  Thus, for example, when the hybrid vehicle is at a low speed and when it is stopped, the engine 1210 is stopped, and power is transmitted to the drive wheels 1280 and 1290 by the battery 1240, the inverter device 1250 and the motor 1220, and otherwise, both the engine 1210 and the motor 1220 Thus, power can be transmitted to the drive wheels 1280 and 1290. At the time of deceleration or control, the driving wheels rotate the rotating shaft of the generator 1230 by driving 1280 and 1290 to convert braking energy into electric power, and the battery 1240 is charged via the inverter device 1250.

  The configuration of hybrid engine system 1200 is not limited to the configuration shown in FIG. 16A, and the resolver in any of the above embodiments can be applied to hybrid engine systems having various configurations.

  An electric power steering system 1300 illustrated in FIG. 16B includes a steering wheel 1310, a steering shaft 1320, a joint 1330, a pinion shaft 1340, a steering shaft 1350, and a motor 1360. When the steering wheel 1310 fixed to the tip of the steering shaft 1320 is rotated, the pinion shaft 1340 is rotated via the joint 1330. The rotational force of the pinion shaft 1340 is converted into the reciprocating motion of the steering shaft 1350 in the axial direction, and the snake angle of the steering wheel (not shown) is changed. A motor 1360 is coaxially coupled to the steering shaft 1350, and the motor 1360 applies a driving force so as to assist the reciprocating movement of the steering shaft 1350 due to the rotation of the steering wheel 1310.

  In such an electric power steering system 1300, a resolver 1370 to which a rotor is attached to the drive shaft of the motor 1360 is provided. The resolver 1370 detects the rotational position (rotational angle) of the drive shaft of the motor 1360 and outputs the detection result to a control system (not shown). A control system (not shown) detects, for example, the rotational direction of the steering wheel 1310 based on the detection result from the resolver 1370 and controls the motor 1360 to assist the rotational force in that direction.

  As the resolver 1370, the resolver in any one of the above embodiments is employed.

  The configuration of the electric power steering system 1300 is not limited to the configuration shown in FIG. 16B, and the resolver in any of the above embodiments can be applied to electric power steering systems having various configurations. .

  In addition, the resolver in any of the above embodiments is not limited to those applied to the above-described system, and needless to say, can be applied to industrial equipment and other various systems.

  As mentioned above, although the resolver and the manufacturing method of a resolver concerning the present invention were explained based on this embodiment, the present invention is not limited to this, and can be implemented in the range which does not deviate from the gist. For example, the following modifications are possible.

  (1) In any of the above-described embodiments, the resolver according to the present invention has been described as being a one-phase excitation two-phase output type, but the present invention is not limited to this. The resolver in any of the above embodiments may be a signal having an excitation signal having a phase other than one phase, or a detection signal having a phase other than two phases.

  (2) In any of the above-described embodiments, the stator material made of a magnetic material has been described as one electromagnetic steel plate, ordinary steel, or carbon steel material for mechanical structure, but the present invention is limited to this. Is not to be done.

  (3) In any of the above embodiments, the stator has been described as having eight stator teeth, but the present invention is not limited to this. For example, the stator teeth of the stator may be 10, 12, or 14.

  (4) In any of the embodiments described above, the resolver as the so-called inner rotor type angle detection device has been described as an example, but the present invention is not limited to this. For example, the resolver according to the present invention may be a so-called outer rotor type. In this case, the gap permeance changes in a given cycle per rotation of the rotor on the inner peripheral surface of the rotor that faces the outer (outer diameter side, outer peripheral side) surface of the stator teeth.

  (5) In any of the above embodiments, the rotor having a shaft angle multiplier of “3” has been described as an example. However, the present invention is not limited to this, and for example, a rotor having a shaft angle multiplier of “5” may be used. Good. In this case, the shape of the rotor, which is an annular flat plate, changes the outer contour line on the outer diameter side in five cycles in plan view with respect to the circumference of the given radius. You may make it be a shape.

100, 500, 700 ... resolver, 200, 600, 800 ... stator,
210a to 210h, 610a to 610h, 810a to 810h ... stator teeth,
250, 650, 850 ... flat plate, 300 ... rotor, 400 ... wiring board,
410a-410h ... coil, 420a-420h ... insertion hole,
1000 ... Angle detection system, 1100 ... R / D converter,
1200 ... hybrid engine system, 1210 ... engine,
1212 ... crankshaft, 1220, 1360 ... motor,
1222, 1282 ... Drive shaft, 1230 ... Generator, 1232 ... Rotating shaft,
1240 ... Battery, 1250 ... Inverter device, 1260 ... Power distribution device,
1270: Differential gear, 1272: Power transmission gear,
1280, 1290 ... drive wheels, 1300 ... electric power steering system,
1310 ... Steering wheel, 1320 ... Steering shaft,
1330 ... Joint, 1340 ... Pinion shaft, 1350 ... Steering shaft,
LD1-LD3 ... Land,
HS11-HS17, HS21-HS23, HS31-HS33 ... wiring

Claims (10)

A stator made of a magnetic material and provided so that a plurality of stator teeth intersect with an annular flat plate surface;
A plurality of stator windings provided so as to be wound around the outside of each stator tooth with each stator tooth of the plurality of stator teeth as a winding core;
A wiring board on which wiring for electrically connecting at least two stator windings constituting the plurality of stator windings is formed;
A resolver comprising a rotor made of a magnetic material and provided rotatably with respect to the stator so that a gap permeance between the stator teeth is changed by rotation around a given rotation axis. . In claim 1,
The wiring board is
A resolver having a plurality of insertion holes into which the stator teeth of the plurality of stator teeth are inserted. In claim 1 or 2,
The resolver characterized in that the cross-sectional shape of each of the plurality of states in the rotational direction of the rotor is such that a width of the flat plate surface is longer than a width of a tip portion thereof. In any one of Claims 1 thru | or 3,
The resolver is an inner rotor type in which a gap permeance between the outer diameter side of the rotor and the stator teeth is changed by the rotation of the rotor. In any one of Claims 1 thru | or 3,
The resolver is an outer rotor type in which a gap permeance between the inner diameter side of the rotor and the stator teeth is changed by the rotation of the rotor. In any one of Claims 1 thru | or 5,
The resolver is characterized in that the stator is made of one electromagnetic steel plate, SPCC which is ordinary steel, and S45C or S10C which is carbon steel for mechanical structure. In any one of Claims 1 thru | or 6.
A resolver comprising a converter that outputs a digital signal corresponding to a detection signal from the stator winding in accordance with a rotation angle of the rotor with respect to the stator. A bending step of bending so as to cause a plurality of stator teeth of the stator formed at the edge of an annular flat plate made of a magnetic material;
A wiring board attaching step for attaching to the stator a wiring board on which a wiring for electrically connecting a plurality of stator windings each having a stator core as a winding magnetic core is formed;
A winding member attaching step for attaching the plurality of stator windings for excitation and detection using each stator tooth of the plurality of stator teeth as a winding core;
And a rotor mounting step of attaching a rotor rotatably to the stator so that a gap permeance between the stator teeth is changed by rotation around a rotation axis. Production method. In claim 8,
The wiring board has a plurality of insertion holes into which the stator teeth of the plurality of stator teeth are inserted,
The wiring board attaching step includes
A method for manufacturing a resolver, wherein each stator tooth is inserted into each insertion hole of the plurality of insertion holes, and the wiring board is attached to the stator. In claim 8 or 9,
A resolver comprising: a stator shape processing step for processing the shape of the stator such that a cross-sectional shape of the rotor in the rotation direction of each of the teeth is longer than a width at a tip portion of the flat plate surface. Production method.

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