JP5301170B2 - Resolver stator and resolver - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resolver stator wherein a winding can be prevented from becoming prone to break because of the commonality of a terminal to which windings are welded, and a resolver including this resolver stator. <P>SOLUTION: An exciting coil 31, a first coil 32, and a second coil 33 are wound on multiple annularly arranged teeth 24. The exciting coil 31, first coil 32, and second coil 33 are tied on one pin 44. A second end 35 of the exciting coil 31, a second end 36 of the first coil 32, and a second end 37 of the second coil 33 are aligned in the direction 47 of extension and wound on the pin 44. In this state, the second ends 35 to 37 of the individual coils 31 to 33 are TIG (Tungsten Inert Gas) welded to the pin 44. <P>COPYRIGHT: (C)2009,JPO&amp;INPIT

Description

  The present invention relates to a resolver stator of a resolver that detects a rotation angle of a rotor included in a motor, and a resolver.

  A conventional brushless motor is provided with a resolver that detects a rotation angle of a rotor that is rotated with respect to a stator that forms a magnetic field (see, for example, Patent Document 1). This resolver has a resolver rotor and a resolver stator. The resolver rotor is configured by laminating magnetic steel plates, and is fixed to the rotor. In the resolver stator, an excitation winding and a two-phase output winding are wound around a plurality of teeth arranged around the resolver rotor. When an excitation voltage is applied to the excitation winding, output voltages having different phases according to the rotation of the resolver rotor are output from the two-phase output winding based on the excitation of the excitation winding. The brushless motor detects the rotation angle of the resolver rotor, that is, the rotation angle of the rotor based on the output voltage, and controls the rotation of the rotor.

  The resolver described in Patent Document 2 has a huge portion at the tip of a rod-like terminal (hereinafter also referred to as “pin”) to which a winding is welded. The enormous portion is formed in a spherical shape in which the tip of the pin is enlarged compared to the pin body. For this reason, when the end portion of the winding wound around the teeth is wound from the proximal end side of the pin toward the enormous portion side, the winding position of the winding is restricted immediately below the enormous portion. Thereby, the variation in the winding state of the winding is reduced. In addition, the welding process which consists of a huge part and the edge part of a coil | winding is formed by performing a welding process with respect to the pin by which the edge part of the coil | winding was wound. As a result, the winding and the pin are physically and electrically connected. Patent Document 2 also discloses a pin having a slit formed at the tip.

JP 2007-28826 A JP 2004-135430 A

  By the way, in order to reduce the cost of the resolver, it can be considered to use a common pin to which the winding is welded. For example, it is conceivable to perform the welding process by winding an excitation winding and a two-phase output winding around one pin. FIG. 8 is an enlarged view of a main part of the pin 80 in which three windings 81 to 83 are entangled, (A) shows a state before the welding process, and (B) shows a state after the welding process. . As shown in FIGS. 8A and 8B, a welding process is performed on the pin 80 around which the windings 81 to 83 are wound, so that a welded portion including the pin 80 and the windings 81 to 83 is obtained. 85 is formed at the tip of the pin 80. When such a welding process is performed, the winding 83 wound later may be wound around the pin 80 so as to cover the windings 81 and 82 wound earlier. For this reason, the welding process is performed in a state where tension is applied to the winding 83 wound around the outer sides of the windings 81 and 82, and the winding 83 is applied with the tension acting on the outer winding 83 during the welding process. If it becomes thinner, a disconnection failure may occur. In particular, when the winding 83 is thinned, the winding 83 may be disconnected due to vibration or thermal stress on the resolver, expansion or contraction of the winding 83, etc. even if there is normal conduction initially (FIG. 8). (See (B)).

  The present invention has been made in view of such a problem, and a resolver stator capable of preventing the winding from being easily disconnected due to the common pin to which the winding is welded, and the resolver thereof. An object is to provide a resolver including a stator.

(1) A resolver stator according to the present invention is arranged in an annular shape, and a plurality of teeth around which an excitation winding, a first output winding, and a second output winding are wound, and each of the windings is entangled. And one end of the excitation winding, one end of the first output winding, and one end of the second output winding extending from one pin with respect to one pin. It is welded to the pin in a state of being wound in alignment in the direction. One end portion of the excitation winding, one end portion of the first output winding, and one end portion of the second output winding are arranged on the one pin as one bundle arranged in the extending direction. It is wound in a spiral with a gap.

  For example, a brushless motor is provided with a resolver for detecting the rotation angle of the rotor. The resolver stator of the present invention constitutes such a resolver. The resolver stator includes, for example, a plurality of teeth arranged in an annular shape around the resolver rotor. An excitation winding, a first output winding, and a second output winding are wound around each tooth. An excitation voltage is applied to the excitation winding. When the resolver rotor is rotated together with the rotor in this state, the excitation voltage is output from the first output winding and the second output winding as the SIN output voltage and the COS output voltage. Based on these output voltages, the rotation angle of the resolver rotor, that is, the rotation angle of the rotor is detected.

  One end of the excitation winding, one end of the first output winding, and one end of the second output winding are wound around one pin in alignment with the extending direction of the pin. In this state, one end of each of the excitation winding, the first output winding, and the second output winding is welded to the one pin. For this reason, one end of each winding wound around one pin interferes with each other and tension is applied to the outer winding, and this does not cause one end of the winding to become thin during the welding process. . Therefore, it is possible to prevent the winding from being easily disconnected due to the common pin to which the winding is welded.

  (2) It is preferable that one end of the excitation winding, one end of the first output winding, and one end of the second output winding are wound in parallel with the one pin.

  One end of the excitation winding, one end of the first output winding, and one end of the second output winding are wound around one pin so as not to cover the other windings from the outside. This more reliably prevents the windings from interfering with each other and making the windings thinner during the welding process.

  (3) The other end of the excitation winding, the other end of the first output winding, and the other end of the second output winding are respectively wound around three pins different from the one pin. It is preferable to be welded in the state where it is made.

  The other end of the excitation winding, the other end of the first output winding, and the other end of the second output winding are welded in a state of being wound around different pins. For this reason, the other end part of each coil | winding does not become thin in the case of a welding process.

  (4) It is preferable that each end of the excitation winding, the first output winding, and the second output winding is TIG welded to the pin.

  (5) Further, a resolver according to the present invention includes the resolver stator and a resolver rotor that is rotatably arranged inside or outside a plurality of teeth included in the resolver stator.

  According to the present invention, one end of the excitation winding, one end of the first output winding, and one end of the second output winding are aligned and wound in the extending direction of the pin with respect to one pin. In this state, it is welded to the pin. Thereby, since the windings do not interfere with each other during the welding process, it is possible to prevent the windings from being easily disconnected due to the common pin to which the windings are welded.

  Hereinafter, the present invention will be described in detail based on preferred embodiments with appropriate reference to the drawings. In addition, this embodiment is only an example of this invention and can be suitably changed in the range which does not change the summary of this invention.

  In the present embodiment, a mode in which the resolver 30 according to the embodiment of the present invention is applied to the brushless motor 10 will be described. However, the resolver 30 is applicable not only to the brushless motor 10 but also to a generator, for example.

  FIG. 1 is a schematic diagram showing the configuration of the brushless motor 10.

  The brushless motor 10 is mounted on, for example, EPS (electric power steering). As shown in FIG. 1, the brushless motor 10 includes a motor body 11 and a control unit 12. The motor body 11 and the control unit 12 are electrically connected by a power cable 14 and a sensor cable 15.

  The motor body 11 is roughly divided into a motor unit 17 mainly composed of a stator 21 and a rotor 22, and a resolver 30 (an example of a resolver of the present invention) that detects a rotation angle of the rotor 22. The motor unit 17 and the resolver 30 are integrally provided in the housing 19.

  FIG. 2 is a cross-sectional view of the motor unit 17.

  As shown in FIG. 2, the motor unit 17 is a so-called inner rotor type in which a rotor 22 is rotatably provided inside a cylindrical stator 21. A rotor 22 is disposed in a space inside the stator 21 with a predetermined magnetic gap therebetween. The rotor 22 is rotatably supported by the housing 19 (see FIG. 1).

  The stator 21 includes a split core 18. In the present embodiment, one cylindrical stator core is configured by connecting twelve divided cores 18. A motor coil 20 is wound around each divided core 18. The motor coil 20 is formed by continuously winding one copper wire around the plurality of divided cores 18. For the copper wire winding, for example, a flyer type or nozzle type winding machine is used. A divided core group in which one copper wire is wound into one group is formed for each of the U phase, the V phase, and the W phase. And three division | segmentation core groups are connected with the annular | circular shape by predetermined arrangement | positioning, and are connected suitably. Thereby, the stator 21 of 12 slots is comprised. The stator 21 forms a magnetic field by U-phase, V-phase, and W-phase currents supplied from the control unit 12 through the power cable 14. The rotor 22 is rotated by this magnetic field.

  The rotor 22 includes a shaft 23 and a rotor yoke 27. The shaft 23 constitutes an axis of the brushless motor 10. The rotor yoke 27 is formed by laminating steel plates punched in a disk shape and integrating them by caulking or the like, and a through hole is formed at the center. By inserting the shaft 23 into the through hole, the rotor yoke 27 is fixed to the shaft 23 so as to be concentric with the shaft 23. An 8-pole magnet 16 is fixed to the outer periphery of the rotor yoke 27. The magnet 16 is a permanent magnet in which magnet particles are sintered in a cylindrical shape, and N poles and S poles are alternately formed in the circumferential direction to form eight poles.

  The configuration of the motor unit 17 is not limited to that described in the present embodiment. In other words, the number of poles and the number of slots of the brushless motor 10 and whether or not the stator core is composed of divided cores are arbitrary.

  The resolver 30 (see FIG. 1) is for detecting the rotation angle of the rotor 22 of the motor unit 17. As will be described in detail later, an excitation voltage is applied to the excitation coil 31 (an example of the excitation winding of the present invention) of the resolver 30 by the control unit 12 (see FIG. 4). When the rotor 22 is rotated in this state, the excitation voltage becomes the SIN output voltage and the COS output voltage as the first coil 32 (an example of the first output winding of the present invention) and the second coil 33 (the second output of the present invention). It is output from an example of a winding. This output voltage is transmitted to the control unit 12 via the sensor cable 15 (see FIG. 1).

  The control unit 12 (see FIG. 1) is a so-called motor driver that controls the rotation of the rotor 22 of the motor unit 17. The control unit 12 is electrically connected to the motor body 11 by the power cable 14 and the sensor cable 15. Specifically, the control unit 12 is electrically connected to the motor unit 17 by the power cable 14 and is electrically connected to the resolver 30 by the sensor cable 15. Based on the SIN output voltage and COS output voltage output from the resolver 30 via the sensor cable 15, the control unit 12 rotates the rotation angle of the resolver rotor 29 (an example of the resolver rotor of the present invention, see FIG. 3), that is, the rotor 22. Find the rotation angle of. Then, the control unit 12 applies a current corresponding to the rotation angle of the rotor 22 to the three-phase motor coil 20.

  Hereinafter, the configuration of the resolver 30 will be described. FIG. 3 is a schematic diagram showing the configuration of the resolver 30.

  As shown in FIG. 3, the resolver 30 includes a resolver rotor 29 and a resolver stator 28 (an example of a resolver stator of the present invention). The resolver 30 in this embodiment is a so-called variable reluctance type resolver in which the resolver rotor 29 does not have a winding.

  A resolver rotor 29 is disposed inside each tooth 24 of the resolver stator 28 (an example of the teeth of the present invention). The resolver rotor 29 is formed by laminating a plurality of substantially elliptical steel plates (see FIG. 3) in plan view and fixing them by caulking or the like. The outer periphery of the resolver rotor 29 is formed in a shape in which the cap permeance between the resolver rotor 29 and the resolver stator 28 changes in a sinusoidal shape with respect to the angle θ in the rotational direction of the resolver rotor 29. The resolver rotor 29 is coaxially fixed to the shaft 23 (see FIG. 2) of the motor unit 17. That is, the resolver rotor 29 is configured to be rotatable integrally with the shaft 23. Note that the resolver rotor 29 is not provided with a winding. In the present embodiment, the resolver rotor 29 has salient poles formed at two locations on the outer shape, but the number of salient poles is not limited to two. For example, salient poles may be formed at three locations on the outer shape of the resolver rotor 29.

  The resolver stator 28 roughly includes a stator body 25, a sensor coil 26, and pins 41 to 44 (an example of the pins of the present invention).

  The stator body 25 is formed in a substantially cylindrical shape, and as shown in FIG. 3, eight teeth 24 protrude from the inner peripheral surface thereof inward in the radial direction. Thereby, the eight teeth 24 are arranged in an annular shape. The resolver rotor 29 is disposed inside these eight teeth 24. For example, the stator body 25 is formed by pressing a steel plate having a predetermined thickness into a plan view shape shown in FIG. 3, laminating a plurality of the steel plates, and fixing them together by caulking or the like. The number of teeth 24 is not limited to eight. The stator body 25 may have ten teeth 24, for example. The number of teeth 24 is appropriately changed according to the number of salient poles of the resolver rotor 29, for example.

  FIG. 4 is a connection diagram of the coils 31 to 33. FIG. 5 is a schematic view of the base 46 and shows a state before the coils 31 to 33 entwined with the pins 41 to 44 are welded. FIG. 6 is a schematic diagram of the base 46 and shows a state after the coils 31 to 33 entangled with the pins 41 to 44 are welded. 7A and 7B are side views of the pin 44, where FIG. 7A shows a state before the welding process, and FIG. 7B shows a state after the welding process.

  An excitation coil 31, a first coil 32, and a second coil 33 are wound around each tooth 24 (see FIG. 3) of the stator body 25 in a predetermined winding direction. Thereby, the sensor coil 26 is configured in the stator body 25. The first coil 32 and the second coil 33 are wound around the teeth 24 so that the phases are different by 90 °. For the winding of the exciting coil 31, the first coil 32, and the second coil 33, for example, a flyer type or nozzle type winding machine is used. In FIG. 3, the excitation coil 31, the first coil 32, and the second coil 33 are all shown as the sensor coil 26.

  As shown in FIG. 3, a base 46 is fixed to the stator body 24. Although not shown in the figure, the base 46 is configured integrally with the housing 19. On this stand 46, pins 41 to 44 are erected at predetermined intervals. The pins 41 to 44 are terminals for electrically connecting the sensor cable 15 and the sensor coil 26. The pins 41 to 44 are formed of, for example, phosphor bronze in an elongated rectangular column shape. As will be described later, the coils 31 to 33 are welded in a state of being entangled with the pins 41 to 44. As shown in FIGS. 3 and 4, the sensor cable 15 is a multicore cable including four lead wires 51 to 54. Each of the lead wires 51 to 54 is obtained by insulatingly covering a copper wire with a vinyl resin or the like. The lead wire 51 is welded to the pin 41. The lead wire 52 is welded to the pin 42. The lead wire 53 is welded to the pin 43. The lead wire 54 is welded to the pin 44.

  An excitation coil 31, a first coil 32, and a second coil 33 are entangled with each pin 41 to 44 as follows. As shown in FIG. 5, the first end 38 (the other end) of the exciting coil 31 is spirally wound around the pin 41. In this state, the first end 38 of the exciting coil 31 is TIG (Tungsten Insert Gas) welded to the pin 41. TIG welding is a welding method in which an arc is generated between a tungsten electrode and an object to be welded (here, the first end 38 and the pin 41), and welding is performed by the heat. When the first end portion 38 of the exciting coil 31 is TIG welded to the pin 41, both the pin 41 and the first end portion 38 are melted to form a welded portion 61 (see FIG. 6). As a result, the first end portion 38 of the exciting coil 31 is electrically connected to the pin 41. A lead wire 51 is welded to the pin 41. Therefore, the first end 38 of the exciting coil 31 is electrically connected to the control unit 12 via the pin 41 and the lead wire 51 (see FIG. 4).

  As shown in FIG. 5, the first end 39 (the other end) of the first coil 32 is spirally wound around the pin 42. In this state, the first end 39 of the first coil 32 is TIG welded to the pin 42. When the first end 39 of the first coil 32 is TIG welded to the pin 42, both the pin 42 and the first end 39 are melted to form a weld 62 (see FIG. 6). As a result, the first end 39 of the first coil 32 is electrically connected to the pin 42. A lead wire 52 is welded to the pin 42. Accordingly, the first end 39 of the first coil 32 is electrically connected to the control unit 12 via the pin 42 and the lead wire 52 (see FIG. 4).

  As shown in FIG. 5, the first end 40 (the other end) of the second coil 33 is spirally wound around the pin 43. In this state, the first end 40 of the second coil 33 is TIG welded to the pin 43. When the first end 40 of the second coil 33 is TIG welded to the pin 43, both the pin 43 and the first end 40 are melted to form a weld 63 (see FIG. 6). As a result, the first end 40 of the second coil 33 is electrically connected to the pin 43. A lead wire 53 is welded to the pin 43. Accordingly, the first end 40 of the second coil 33 is electrically connected to the control unit 12 via the pin 43 and the lead wire 53 (see FIG. 4).

  Thus, the first end portion 38 of the exciting coil 31, the first end portion 39 of the first coil 32, and the first end portion 40 of the second coil 33 are composed of the pins 41 to 43 (three pins of the present invention). TIG welding is performed in the state of being wound around each example.

  On the other hand, the second end 35 (one end) of the exciting coil 31, the second end 36 (one end) of the first coil 32, and the second end 37 (one end) of the second coil 33 are the pins 41. .. To 43 (an example of one pin of the present invention) different from .about.43. As shown in FIG. 7A, the second end 35 of the exciting coil 31, the second end 36 of the first coil 32, and the second end 37 of the second coil 33 are composed of one pin 44. Are wound in parallel to each other. Accordingly, the second end portions 35 to 37 of the coils 31 to 33 are aligned in the extending direction 47 of the pin 44. In this state, the second end 35 of the excitation coil 31, the second end 36 of the first coil 32, and the second end 37 of the second coil 33 are TIG welded to the pin 44. The second end portion 35 of the exciting coil 31, the second end portion 36 of the first coil 32, and the second end portion 37 of the second coil 33 are TIG welded to the pin 44, and as shown in FIG. As shown, both the pin 44 and the second end portions 35 to 37 are melted to form the welded portion 64. A lead wire 54 is welded to the pin 44 (see FIG. 3). Therefore, the second end portion 35 of the exciting coil 31, the second end portion 36 of the first coil 32, and the second end portion 37 of the second coil 33 are electrically connected to the control unit 12 via the pins 44 and the lead wires 54. Connected (see FIG. 4). That is, the lead wire 54 is used as a common line for the coils 31 to 33.

  Thus, the pin 44 has the second end 35 of the exciting coil 31, the second end 36 of the first coil 32, and the second end 37 of the second coil 33 in the extending direction 47 (FIG. 5). TIG welding is performed in a state of being wound in an aligned manner.

  As shown in FIG. 4, a predetermined excitation voltage is applied between the pins 41 and 44, that is, the excitation coil 31 via the lead wire 51 and the lead wire 54. As a result, the SIN output voltage is transmitted between the first output coil 32 and the control unit 12 through the lead wires 52 and 54. Accordingly, the COS output voltage is transmitted between the second output coil 33 and the control unit 12 through the lead wires 53 and 54. The control unit 12 detects the rotation angle of the resolver rotor 29, that is, the rotor 22 (see FIG. 2) based on the output voltage transmitted from the resolver 30 in this way. And the control part 12 provides the electric current determined based on the detection result to the motor coil 20 via the power cable 14. The current applied to the motor coil 20 is appropriately changed according to the output voltage output from the resolver 30 to the control unit 12. As described above, in the brushless motor 10, the rotation of the rotor 22 is controlled based on the detection result by the resolver 30.

  As described above, the second end 35 of the exciting coil 31, the second end 36 of the first coil 32, and the second end 37 of the second coil 33 are aligned with the pin 44 in the extending direction 47. Then, it is welded to the pin 44 in a wound state. For this reason, the second end portions 35 to 37 interfere with each other and tension is applied to the outer coil, which prevents any of the second end portions 35 to 37 from becoming thin during TIG welding. Therefore, it is prevented that any of the coils 31 to 33 is easily disconnected due to the common pin to which the coils 31 to 33 are welded.

  In the present embodiment, the second end portions 35 to 37 are TIG welded in a state where the second end portions 35 to 37 are wound around the pins 44 so as not to cover other coils from the outside by the parallel windings of the second end portions 35 to 37. Yes. This more reliably prevents any of the coils 31 to 33 from becoming thinner during TIG welding.

  In the present embodiment, the first end 38 of the exciting coil 31, the first end 39 of the first coil 32, and the first end 40 of the second coil 33 are entangled with different pins. TIG welded. That is, the first end 38 is entangled with the pin 41 and TIG welded, the first end 39 is entangled with the pin 42 and TIG welded, and the first end 40 is entangled with the pin 43 and TIG Welded. For this reason, the 1st end parts 38-40 of each coil 31-33 do not become thin in the case of TIG welding.

  In the present embodiment, since the motor unit 17 is of an inner rotor type, the resolver rotor 29 is disposed inside the resolver stator 28. However, when the motor unit 17 is of the outer rotor type, the resolver rotor of the present invention is disposed outside the resolver stator.

  In the present embodiment, the second end portion 35 of the exciting coil 31, the second end portion 36 of the first coil 32, and the second end portion 37 of the second coil 33 are wound around the pin 44 in parallel. However, the second end portions 35 to 37 do not necessarily have to be parallel to each other unless another coil is wound from the outside so as to cover the coil entangled with the pin 44.

  Further, as a method for welding the coils 31 to 33 to the pins 41 to 44, for example, soldering or laser beam welding other than TIG welding can be expected to have the same effect as that of the present embodiment. However, in TIG welding, welding is possible even if the position of the tungsten electrode and the work piece is slightly shifted in order to fly the arc in a non-contact manner, so that a poor connection between the pins 41 to 44 and the coils 31 to 33 occurs. It is difficult, and disconnection of the coils 31 to 33 can be more reliably prevented as compared with other welding methods.

FIG. 1 is a schematic diagram showing the configuration of the brushless motor 10. FIG. 2 is a cross-sectional view of the motor unit 17. FIG. 3 is a schematic diagram showing the configuration of the resolver 30. FIG. 4 is a connection diagram of the coils 31 to 33. FIG. 5 is a schematic view of the base 46 and shows a state before the coils 31 to 33 entwined with the pins 41 to 44 are welded. FIG. 6 is a schematic diagram of the base 46 and shows a state after the coils 31 to 33 entangled with the pins 41 to 44 are welded. 7A and 7B are side views of the pin 44, where FIG. 7A shows a state before the welding process, and FIG. 7B shows a state after the welding process. FIG. 8 is an enlarged view of a main part of the pin 80 in which three windings 81 to 83 are entangled, (A) shows a state before the welding process, and (B) shows a state after the welding process. .

24 ... Teeth 28 ... Resolver stator 29 ... Resolver rotor 30 ... Resolver 31 ... Excitation coil (Excitation winding)
32 ... 1st coil (1st output winding)
33 ... Second coil (second output winding)
35 ... Second end (one end)
36 ... Second end (one end)
37 ... Second end (one end)
38 ... 1st end part (other end part)
39 ... 1st end part (other end part)
40: First end (other end)
41, 42, 43... Pin (an example of three pins of the present invention)
44... Pin (an example of one pin of the present invention)
47 ... Extension direction

Claims (5)

A plurality of teeth arranged in an annular shape and wound with an excitation winding, a first output winding, and a second output winding; and a pin with which each of the windings is wound,
One end portion of the excitation winding, one end portion of the first output winding, and one end portion of the second output winding are wound in alignment with one pin in the extending direction of the pin Is welded to the pin ,
One end portion of the excitation winding, one end portion of the first output winding, and one end portion of the second output winding are arranged on the one pin as one bundle arranged in the extending direction. A resolver stator wound in a spiral with a gap .   2. The resolver stator according to claim 1, wherein one end portion of the excitation winding, one end portion of the first output winding, and one end portion of the second output winding are wound in parallel with the one pin. .   The other end of the excitation winding, the other end of the first output winding, and the other end of the second output winding are respectively wound around three pins different from the one pin. The resolver stator according to claim 1 or 2, which is welded by the method.   4. The resolver stator according to claim 1, wherein each end of the exciting winding, the first output winding, and the second output winding is TIG welded to a pin. 5. The resolver stator according to any one of claims 1 to 4,
A resolver comprising: a resolver rotor rotatably disposed inside or outside a plurality of teeth included in the resolver stator.

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