This application claims the benefit of Japanese Priority Patent Application No. JP2023-137159 filed on Aug. 25, 2023, the entire contents of which are incorporated herein by reference.
The present disclosure relates to a magnetic sensor, a method for designing the same, and an assembly thereof.
Magnetic sensors that measure the rotation angle of a rotating body are known. JP 2004-361119 A (hereinbelow referred to as “Patent Document 1”) discloses a magnetic sensor that includes four magnets arranged around the periphery of a rotor attached to a rotating shaft and a magnetoresistance effect element arranged away from the magnets. The four magnets are divided into two groups, and the two groups are provided with a magnetic field detection element between them when viewed in a direction parallel to the central axis of rotation. Each of the two groups has two magnets adjacent to each other, with the surfaces of the magnets in one group that face the magnetic field detection element being an N-pole and the surfaces of the magnets in the other group that face the magnetic field detection element being an S-pole. Patent Document 1 describes that a magnetic sensor configured in this manner can reduce detection errors even if the magnets and magnetic field detection element are misaligned in a direction perpendicular to the central axis of rotation due to installation errors.
Although the magnetic sensor described in Patent Document 1 has the above-mentioned effects, the magnetic flux density applied to the magnetic field detection element is small.
A magnetic sensor comprises first to fourth magnets that are rotatable around a central axis of rotation and that have fixed positional relationships with each other, and a magnetic field detection element. In an XY coordinate system perpendicular to the central axis of rotation and that passes through the origin, the first to fourth magnets are located in first to fourth quadrants, respectively, and the first to fourth magnets include first to fourth element-facing surfaces, respectively, that face the magnetic field detection element, and the first to fourth element-facing surfaces have elongated shapes with first to fourth long axes, respectively. The first element-facing surface and the second element-facing surface have the same polarity, and the third element-facing surface and the fourth element-facing surface have a polarity different from that of the first and second element-facing surfaces. When straight lines that are parallel to the first to fourth long axes, that have the origin as their ends, and that pass through the first to fourth quadrants are defined as first to fourth imaginary lines and the angles that the first to fourth imaginary lines make counterclockwise with respect to the boundary line between the first and fourth quadrants are θ1 to θ4, respectively, θ1 is greater than or equal to 0 degrees and less than or equal to 90 degrees, θ2 is greater than or equal to 90 degrees and less than or equal to 180 degrees, θ3 is greater than or equal to 180 degrees and less than or equal to 270 degrees, and θ4 is greater than or equal to 270 degrees and less than or equal to 360 degrees.
The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate example embodiments and, together with the specification, serve to explain the principles of the technology.
In the following, some example embodiments and modifications of the technology are described in detail with reference to the accompanying drawings. Note that the following description is directed to illustrative examples of the disclosure and not to be construed as limiting the technology. Factors including, without limitation, numerical values, shapes, materials, components, positions of the components, and how the components are coupled to each other are illustrative only and not to be construed as limiting the technology. Further, elements in the following example embodiments which are not recited in a most-generic independent claim of the disclosure are optional and may be provided on an as-needed basis. The drawings are schematic and are not intended to be drawn to scale. Like elements are denoted with the same reference numerals to avoid redundant descriptions.
An object of the present disclosure is to provide a magnetic sensor in which detection error due to misalignment between a magnet and a magnetic field detection element can be reduced and a larger magnetic field can be applied to the magnetic field detection element.
An embodiment of a magnetic sensor according to the present disclosure will be described with reference to the drawings.
Magnetic sensor 1 includes first to fourth magnets M1 to M4, magnetic field detection element 3, and yoke 5. First to fourth magnets M1 to M4 are supported by yoke 5 and are rotatable around central axis C of rotating shaft 2. Magnetic field detection element 3 is provided away from rotating shaft 2 and first to fourth magnets M1 to M4. First to fourth magnets M1 to M4 may be made of the same material and may have the same shape and size. Yoke 5 is a plate-shaped member made of a soft magnetic material and is fixed to end surface 21 of rotating shaft 2. Yoke 5 increases the strength of the magnetic field generated by first to fourth magnets M1 to M4. Other structures (not shown) may be interposed between yoke 5 and end surface 21 of rotating shaft 2. First to fourth magnets M1 to M4 are sealed with sealing material 6 made of resin. First to fourth magnets M1 to M4 are attracted to yoke 5 by magnetic force and are further held by sealing material 6, so that their relative positions are fixed. Instead of using sealing material 6, first to fourth magnets M1 to M4 may be fixed to yoke 5 with an adhesive.
End surface 21 of rotating shaft 2, i.e., the mounting surface of first to fourth magnets M1 to M4, is parallel to the XY coordinate system. The XY plane of the XY coordinate system is perpendicular to the central axis of rotation C, and the central axis of rotation C passes through the origin 0 of the XY coordinate system. The X-axis and the Y-axis are parallel to end surface 21 of rotating shaft 2 and are perpendicular to each other. The Z-axis coincides with central axis C of rotation of rotating shaft 2 and is perpendicular to the X-axis and the Y-axis. The directions parallel to the X-axis, Y-axis, and Z-axis may be referred to as the X-direction, Y-direction, and Z-direction, respectively.
Magnetic field detection portion 31 of magnetic field detection element 3 is composed of a magnetoresistance effect element (for example, an AMR element, a TMR element, or a GMR element) or a Hall element. Magnetic field detection unit 31 passes through the central axis of rotation C (Z-axis) but may be slightly offset from the Z-axis. Magnetic field detection element 3 is provided on substrate 32, and the drive voltage and output signal of magnetic field detection element 3 are input and output through substrate 32. Magnetic field detection element 3 measures the magnetic field strength in two orthogonal directions (e.g., the X-direction and Y-direction) in the XY coordinate system, but may also measure the magnetic field strength in one direction (e.g., the X-direction).
Magnetic sensor 1 generally operates as follows: The direction of the magnetic field applied to magnetic field detection element 3 changes as first to fourth magnets M1 to M4 rotate. That is, the strength of the magnetic field applied in the magnetic sensing direction of magnetic field detection element 3 changes in accordance with the rotation of first to fourth magnets M1 to M4. By detecting this change in magnetic field strength, magnetic sensor 1 can detect the rotation angle of rotating shaft 2.
As shown in
H shown in
Referring to
First long axis A1 and second long axis A2 are line-symmetric with respect to the Y-axis, and third long axis A3 and fourth long axis A4 are line-symmetric with respect to the Y-axis. First long axis A1 and fourth long axis A4 are line-symmetric with respect to the X-axis, and second long axis A2 and third long axis A3 are line-symmetric with respect to the X-axis. That is, if α2=180 degrees−θ2, α3−θ3−180 degrees, and α4=360 degrees−θ4, then θ1=α2=α3=α4. Furthermore, centers C1 to C4 of first to fourth element-facing surfaces S1 to S4 of first to fourth magnets M1 to M4 may lie on single circle CC centered on the origin 0 in the XY coordinate system. With the above configuration, the magnetic flux is linearly symmetrical with respect to the X-axis and Y-axis, and the Z-direction component of the magnetic flux in magnetic field detection element 3 is substantially zero.
As described above, in this embodiment, once angle θ1 is determined, angles θ2 to θ4 are also determined. Therefore, the following description will focus on angle θ1. However, within the above range, angles θ1 to θ4 may be different from each other. Furthermore, centers C1 to C4 of first to fourth element-facing surfaces S1 to S4 of first to fourth magnets M1 to M4 do not have to be on a single circle with the origin 0 as its center.
In Comparative Example 1, the magnetic flux mainly enters and exits from the side surfaces of the magnet, so the shape of the magnetic flux tends to be flat along the magnet. Therefore, applying a sufficient magnetic field to magnetic field detection element 3 becomes difficult when distance H in the Z-direction between the magnet and magnetic field detection element 3 is large. In Comparative Example 2, the magnetic flux mainly enters and exits from the element-facing surface of the magnet, but since the magnetic flux path is short, the shape tends to be small in the Z-direction. Therefore, when distance H in the Z-direction between the magnet and magnetic field detection element 3 is large, applying a sufficient magnetic field to magnetic field detection element 3 becomes difficult. In Comparative Example 3, magnetic flux mainly enters and exits from the element-facing surfaces of the magnets. Because the two magnets are separated, the magnetic flux is dispersed in the Z-direction. Therefore, a sufficient magnetic field can be applied to magnetic field detection element 3 regardless of distance H in the Z-direction between the magnet and magnetic field detection element 3. Working Example 1 shows the same tendency as Comparative Example 3.
Next, the angle measurement error will be described. Since magnetic field detection element 3 and first to fourth magnets M1 to M4 are attached to different structures, there is a possibility that misalignment may occur between these components, for example, during assembly. Here, the positional deviation in the XY coordinate system is considered. Since first to fourth magnets M1 to M4 rotate around the Z axis, the positional deviation can be considered as the radial deviation of magnetic field detection element 3 from the Z-axis. Therefore, for Comparative Examples 1 to 3 and Working Example 1, magnetic field detection element 3 is shifted radially from the Z-axis by 1 mm, and the rotation angle detected by magnetic sensor 1 is obtained while changing the rotation angle of first to fourth magnets M1 to M4. The maximum value of the difference between the calculated rotation angle and the actual rotation angle is then determined as the angle measurement error. The above calculation is performed for H=3, 4, 5, 6, 7, and 8 (mm). The dimensions and volumes of the magnets used in the calculations are shown in
Next, a description will be given of a suitable range for angle θ1 and the aspect ratio of first to fourth element-facing surfaces S1 to S4 (the ratio of the length of long side SA to the length of short side SB of first to fourth element-facing surfaces S1 to S4).
Referring to
The lines of the magnetic flux emitted from short sides SB of the two N-poles repel each other while first moving in a direction away from magnetic field detection element 3, then reverse direction at point A and move toward the S-pole, and after passing the S-pole, reverse direction at point B and are absorbed by short sides SB of the two S-poles. Since the path of this magnetic flux is relatively long, it rises upward in the Z-direction, and the magnetic field strength at magnetic field detection element 3 becomes large. The magnetic field strength in magnetic field detection element 3 is the sum of these lines of magnetic flux emitted from two short sides SB, but since the magnetic flux emanating from short side SB is small, the sum is small. In contrast, although the path of magnetic flux in the embodiment is the same as in the comparative example, more magnetic flux emanates from long side SA and the magnetic field strength in magnetic field detection element 3 is therefore also greater.
As described above, the angle measurement error depends on distance H in the Z-direction, but distance H in the Z-direction is restricted by both the configuration of rotating body 2 on which magnetic sensor 1 is attached and the surrounding arrangement. Distance H in the Z-direction can be difficult to adjust and is often a given. On the other hand, as shown in
As described above, according to the present disclosure, a magnetic sensor can be provided in which detection error due to misalignment between a magnet and a magnetic field detection element is reduced and a large magnetic field can be applied to the magnetic field detection element.
Number | Date | Country | Kind |
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2023-137159 | Aug 2023 | JP | national |