The present invention relates to a magnetoelectronic angle sensor, in particular a reluctance resolver with a rotationally symmetrical, at least partially soft magnetic stator and a rotationally symmetrical, at least partially soft magnetic rotor which oppose each other by forming an air gap. The magnetic resistance in the air gap changes periodically on account of a configuration of the rotor that varies over the circumference. The angle sensor has a magnetic flux transmitter which is arranged on the stator and generates a predefined magnetic flux distribution in the air gap via at least one pair of poles. Furthermore, a magnetic flux receiver, which measures the intensity of the magnetic field via at least two pairs of signal poles arranged offset from one another at an angle, is arranged on the stator, wherein an angle value for a position of the rotor in relation to the stator can be derived from the two receiver signals.
Angle sensors of this type, which are based on the principle of a variable magnetic flux intensity in the air gap between the stator and rotor, are known in a broad range of forms. Basically, these draw on different principles for generating the magnetomotive force in the transmitting part and also different principles for measuring the magnetic field in the receiver part. In rotary indicators (resolvers, synchros), electromagnetic coils are used in the form of primary and secondary windings. Rotary indicators of this type in the form of resolvers or synchros have long been known as accurate and robust angle sensors. Also known in this regard are what are referred to as passive reluctance resolvers in which both the primary winding and the secondary winding are accommodated in the stator, whereas the rotor influences the magnetic flux circuit in a windingless manner, i.e. passively, merely with soft magnetic parts. As a result of a non-uniform configuration of the soft magnetic rotor, for example by providing lobes, the magnetic flux between the primary windings and the secondary windings in the stator is influenced differently; the angular position of the rotor may be derived from this via the induced voltage.
Reluctance resolvers of this type can be manufactured economically owing to the lack of an active rotor provided with windings and the concomitant saving of a transformer part. However, most known reluctance resolver arrangements have the drawback that the arrangement of the windings on the stator leads to comparatively complex assembly methods. Furthermore, reluctance resolvers in which the variation of the magnetic resistance is achieved by a club or kidney-shaped rotor, wherein the height of the air gap between the circumference of the rotor on the one hand and the stator teeth on the other hand changes markedly with the circumferential angle, have the problem that tolerances, in particular a radial offset, can have a particularly pronounced effect on the accuracy of measurement. The reason for this may be identified above all in the fact that the height of air gap in the radial direction is decisive for the magnetic coupling.
The aim of the present invention is to disclose an angle sensor which can be manufactured particularly simply and economically and in addition has improved accuracy.
A passive reluctance resolver according to the present invention is constructed in such a way that the soft magnetic stator has a predefined number of grooves and teeth distributed in alternation over the circumference and that a primary winding is arranged in the grooves of the stator by partial windings connected in series. Also arranged in the grooves are two secondary windings which are offset from each other at an angle and each form, by partial windings which are connected in series and alternate in opposite directions, pairs of poles, the numbers of which differ from that of the primary winding by an integral factor. The soft magnetic rotor changes its cross sectional shape with a number of periods corresponding to the speed number of the angle sensor.
In this case, what is known as the speed number or number of pairs of signal poles denotes the number of complete periods through which the electrical signal, which can be tapped off at the secondary windings, passes during a complete mechanical revolution, i.e. 360°, of the rotor. That means that in a one-speed resolver the electrical angle corresponds to the angle of mechanical revolution, while in a three-speed resolver the electrical angle of 360° is already reached on a mechanical revolution of 120°.
According to the invention, the primary windings are arranged in such a way that in each case at least one tooth which carries no primary windings is located between the teeth carrying them. On the one hand, this arrangement allows the resolver to be machine wound in a simple manner. On the other hand, in the case of an eccentricity of the rotor caused by tolerances, the errors which occur can be reduced. Finally, the winding can also be carried out on loose coil bodies with just one coil, the loose coil bodies subsequently being fitted on the stator and connected to one another via a circuit board or a lead frame, for example.
According to an advantageous embodiment of the present invention, the partial windings of the primary windings do not have an alternating winding direction, but are all wound in the same direction, for example in a manner such that the magnetic flux is directed inward in the direction toward the axis of rotation of the rotor.
Nevertheless, the inverse orientation could also be provided and in some cases a certain number of poles can also be wound in the opposite direction in order to compensate for asymmetrical magnetic fluxes.
According to the invention, the expression
is an odd number. In this case, n is the number of phases (for conventional resolvers this is usually two, namely sine and cosine), p is equal to the number of lobes which form the signal-generating shaping on the rotor, and t is the number of teeth of the stator.
According to a first advantageous embodiment, the partial windings of the primary winding (referred to hereinafter in most cases simply as the “primary windings”) are arranged on the even-numbered teeth and all wound in such a way that the magnetic flux is oriented in the direction toward the axis of rotation of the resolver when the voltage at the primary winding is positive. The magnetic flux is fed back through the odd-numbered teeth. The odd-numbered teeth carry as secondary windings the cosine secondary winding and sine secondary winding. Output voltages are induced in the windings around the odd-numbered teeth.
If a symmetrical construction is selected, i.e. a construction in which the windings of mutually opposing teeth are each the same, the sensitivity to an eccentricity of the rotor with regard to the stator is reduced.
In order to increase the accuracy and the insensitivity to tolerances still further, provision may also be made, in accordance with a further advantageous embodiment, for two windings to be arranged on each tooth of the stator. Again, the primary winding is located in each case on teeth which are in each case not adjacent to one another, thus providing for the teeth that either a primary winding with a sine winding, a primary winding with a cosine winding or two secondary windings, namely a sine and a cosine winding, are accommodated with each other on one and the same tooth. Again, according to the invention, the expression
is intended to be an odd number. According to the invention, the rotor and the winding diagram are symmetrical, so that eccentricities can be compensated for even more effectively.
According to an advantageous development of the present invention, the resolver can furthermore comprise at least one return path for returning the electrical signal, the return path being arranged in a plane transverse to the axis of rotation of the rotor. This return path can easily prevent the occurrence in the direction of the axis of rotation of a magnetic flux which might influence the output signals in an undesirable manner.
In order to better understand the present invention, the invention will be described in greater detail based on the exemplary embodiments illustrated in the following figures. In this case, like parts are provided with like reference symbols and like component designations. Furthermore, individual features or combinations of features from the shown and described embodiments may also be solutions which are, on their own merits, independent inventive solutions or solutions according to the invention. In the drawings:
The six-speed resolver arrangement shown in this figure provides a total of sixteen teeth 110 which in
Furthermore, the arrangement is point-symmetrical to the axis of rotation 106, so that in each case the same winding is present at mutually opposing poles. The receiver windings, i.e. the secondary windings, in which the induced magnetic flux which is influenced by the position of the rotor occurs, are attached to the odd-numbered poles. In this case, the dash arrows 114 denote the magnetic flux of the sine windings and the dot-dash arrows 116 denote the magnetic flux through the cosine windings. The output voltage to be measured is induced in the windings at these poles.
Although in the embodiment shown the primary windings are arranged in such a way that the magnetic flux for the positive primary current is directed in the direction toward the axis of rotation 106 of the resolver 100, the inverse direction of flux may also be provided and in some cases provision may also be made for individual coils to be wound in such a way that they stimulate an inverse flux in order to compensate for asymmetrical magnetic fluxes.
According to the invention, the expression
is an odd number. In this case, n denotes the number of phases, which for conventional resolvers with a sine and cosine signal is equal to 2, p is the number of lobes on the rotor and t denotes the number of teeth on the stator. In the arrangement shown in
Adding up the cosine voltages or sine voltages connected in series produces the simulated conditions illustrated in
As also shown in
It may be demonstrated that the ideal case of an eccentric rotor is in reality unachievable and that, as will be described in detail with reference to the second embodiment of
In
If the number of windings on the sides opposing each other in each case by 180° is the same, this offers the advantage that the signals react less sensitively to an eccentricity of the rotor with regard to the stator. If, for example, a horizontal displacement by z mm is assumed, then the size of the air gap between the rotor and stator at pole 5 is reduced by exactly z mm, but the size of the air gap at pole 13 will be greater by z mm. If the magnetic flux and, therefrom, the induced voltage are then calculated, the induced voltages at the poles 5 and 13 will compensate for each other, as may be seen from
According to the invention, the reluctance resolver has a characteristic number which is calculated in accordance with the formula
A conventional resolver with a two-phase output signal (sine and cosine) requires at least 4 poles with sine, −sine, cosine and −cosine. In a rotor with p lobes, the lobes are each arranged at 360°/p. The windings on the stator are then arranged at the locations designated in the following Table 1, wherein X is a natural number:
The poles of a resolver with t teeth are located at the locations Y·360°/t, wherein Y assumes values of from 0 to t−1. According to this approach, a cosine winding and subsequently a primary winding are arranged on the first tooth, and a sine or −sine winding are arranged on the third tooth. 2·360°/t should then be located accordingly at the rotor position for sine or −sine.
As shown in the following Table 2, sine and −sine secondary windings are located at the positions x/2·360°/n·p, wherein x is an odd number. In the arrangement shown in Table 2, the following applies: 4·n·p/t=3 (n=2, p=6, t=16).
A six-speed resolver with 48 teeth would of course also work (4·n·p/t=1), but would be much more expensive and complex to manufacture.
A further example of the resolver according to the invention of the first embodiment will be described hereinafter with reference to
Again, all the partial windings of the primary winding are wound in one direction and are not located on teeth of the stator that are positioned next to one another.
If the following is calculated for this case:
then 2, i.e. an even number, is obtained.
The regular pattern of two primary windings and one secondary winding therefore cannot be maintained at the poles 11 to 16 and 27 to 32. In these poles, the number of windings is altered in order to achieve a similar magnetic field in the poles next to these regions as everywhere else. All the partial windings of the primary winding are wound in the same direction, so that the transmitted magnetic flux points everywhere along the circumference of the stator in the direction toward the rotor.
According to an advantageous embodiment of the present invention, such as is shown in
In order to connect the individual coil connections 120, 122 to one another, a wiring board 124 is installed in a next operation, such as is shown in
As mentioned hereinbefore, an eccentricity between the rotor and the stator can lead in the previously discussed first embodiment to considerable inaccuracies. A second embodiment therefore proposes an arrangement in which two respective windings are arranged on each stator pole.
Again, only the even-numbered poles carry primary windings and all the primary windings are wound in such a way that the direction of the magnetic flux points toward the axis of rotation 106 of the rotor. The magnetic flux returns through the odd-numbered poles. However, in contrast to the foregoing embodiment, according to the embodiment shown in
The advantage of this second embodiment may be seen on examination of
However, as is clear from
An alternative winding diagram with in each case two windings on each stator pole for a four-speed resolver is shown in
As may also be seen from
Finally,
Although the foregoing discussion has assumed in all cases loose coil bodies, the windings according to the present invention can also be wound directly onto the stator, wherein additional plastics material parts may (but do not necessarily have to) be used. Most connections can then be carried out directly with the aid of the magnetic wire. The return path for the electrical signal is then also implemented with a magnetic wire or cable.
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