Rotation angle detecting device

Abstract

A rotation angle detecting device includes a magnetic member for providing a magnetic field, a magnetic sensor for sensing a change in the magnetic field when the magnetic member rotates relative to the magnetic sensor about a rotation axis. The magnetic sensor is disposed at a single position and includes a pair of sensor elements. The pair of sensor elements is disposed on an imaginary plane that is perpendicular to the rotation axis so that sensing surfaces of the sensor elements have 90 degrees in angle to each other and so that each of the sensing surfaces inclines by 45 degrees in angle to a line intersecting the rotation axis at right angles.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, features and characteristics of the present invention as well as the functions of related parts of the present invention will become clear from a study of the following detailed description, the appended claims and the drawings. In the drawings:

FIG. 1A is a plan view of a rotation angle detecting device according to the first embodiment of the invention;

FIG. 1B is an enlarged view of a magnetic sensor of the rotation angle detecting device shown in FIG. 1A;

FIG. 2 is a side view of the rotation angle detecting device viewed from portion II in FIG. 1A;

FIG. 3 is a graph showing a pair of output signal curves of a pair of magnetic sensor elements of the rotation angle detecting device according to the first embodiment of the invention when a permanent magnet rotor of the same makes full rotation;

FIG. 4 is a graph showing a relation between the rotation angle and trigonometric angles;

FIG. 5 is a graph showing output signal curves of the magnetic sensor elements when the permanent magnet rotor makes full rotation in case the magnetic sensor elements are shifted from a normal position;

FIG. 6A is a graph showing output signal curves of the magnetic sensor elements when the permanent magnet rotor makes full rotation in case the magnetic sensor elements are shifted from a normal position;

FIG. 6B is a graph showing deviations in rotation angle when the magnetic sensor elements are shifted from a normal position;

FIG. 7A is a graph showing output signal curves of the magnetic sensor elements after the phase difference is adjusted;

FIG. 7B is a graph showing deviations in rotation angle when the phase difference between the output signals of the pair of magnetic sensor elements are adjusted;

FIG. 8 is a graph showing a relation between the phase difference in the output signals and deviations in the rotation angle;

FIG. 9A is a plan view of a rotation angle detecting device according to the second embodiment of the invention;

FIG. 9B is an enlarged view of a pair of magnetic sensor elements of the rotation angle detecting device shown in FIG. 9A;

FIG. 10A is a plan view of a rotation angle detecting device according to the third embodiment of the invention;

FIG. 10B is an enlarged view of a pair of magnetic sensor elements of the rotation angle detecting device shown in FIG. 10A;

FIG. 11A is a plan view of a rotation angle detecting device according to the fourth embodiment of the invention;

FIG. 11B is an enlarged view of a pair of magnetic sensor elements of the rotation angle detecting device shown in FIG. 11A;

FIG. 12A is a plan view of a rotation angle detecting device according to the fifth embodiment of the invention;

FIG. 12B is a side view of the rotation angle detecting device viewed from portion B in FIG. 12A;

FIG. 13 is a plan view of a rotation angle detecting device according to the sixth embodiment of the invention;

FIG. 14 is a plan view of a rotation angle detecting device according to the seventh embodiment of the invention;

FIG. 15 is a graph showing a difference in detecting direction of the magnetic flux between the magnetic sensor of a prior art and that according to the embodiments of the present invention;

FIG. 16 is a plan view of a rotation angle detecting device of a prior art;

FIG. 17 is a graph showing a pair of output signal curves of a magnetic sensor of the rotation angle detecting device of a conceptive structure when a permanent magnet rotor of the same makes full rotation; and

FIG. 18 is a schematic diagram illustrating magnetic fields formed inside and around a magnetic rotor.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Some preferred embodiments according to the present invention will be described with reference to the appended drawings.

A rotation angle detecting device 10 according to the first embodiment of the invention will be described with reference to FIGS. 1-8.

The rotation angle detecting device 10 is connected to a rotating object, such as an engine crank shaft or a steering wheel of a vehicle in order to detect the rotation angle of the crankshaft or the steering wheel. The rotation angle detecting device 10 includes a disk-shaped permanent magnet rotor 12, a magnetic sensor (hereinafter referred to as the Hall IC ) 20, and an electronic control unit (hereinafter referred to as ECU ) 30. The permanent magnet rotor 12 is constructed of a pair of semicircular permanent magnets and a rotary shaft 14 that rotates about its rotation axis 200. The permanent magnet rotor 12 is magnetized in a radial direction, as shown in FIG. 18.

The Hall IC 20 is disposed at a place around the circumference of the permanent magnet rotor 12. The Hall IC 20 includes a pair of Hall elements 22, 22′ and the ECU 30 so as to provide the ECU with the output signals of the Hall elements 22, 22′. The ECU 30 may be separated form the Hall IC, however.

Each of the Hall elements 22, 22′ has a magnetic sensor surface 23, 23′ and is arranged to be placed on an imaginary plane that is perpendicular to the rotation axis 200 so that the magnetic sensor surface 23 inclines by 45 degrees in angle toward a normal line 202 that intersects the rotation axis 200 of the permanent magnet rotor 12 at right angles, as shown in FIGS. 1A, 1B, and so that the magnetic sensor surfaces 23 of the pair of magnetic sensor elements 22 are positioned to have 90 degrees in angle between them. Therefore, the Hall elements 23 are disposed symmetric with respect to the normal line 202.

The ECU 30 includes a CPU, a ROM, an EEPROM, etc. so that the ECU 30 can calculate a rotation angle of a rotating object from the output signals of the Hall IC 20 using a rotation angle calculation program that is stored in the EEPROM or the ROM.

A rotation angle of a rotating object is calculated from the output signals of the Hall elements in one of the following ways.

(Calculation 1)

If the permanent magnet rotor 12 rotates relative to the Hall elements 22, 22′ of the Hall IC 20 by a rotation angle θ, magnetic flux densities B₁x, B₁y that are detected by the pair of Hall elements 22, 22′ are expressed from the expression (5), (6) and (12) as follows:

B ₁ x=V×sin(θ+β)   (20)

wherein: V is a maximum value of the magnetic density detected by the magnetic sensor elements, or equal to ((A²+B²)/2)^1/2.

$\begin{array}{cc}\begin{array}{c}{B}_1y=V\times \sin \left(\theta +\gamma \right)\\ =V\times \sin \left(\theta +\left(180°-\beta \right)\right)\\ =-V\times \sin \left(\theta -\beta \right)\end{array}& \left(21\right)\\ \begin{array}{c}{B}_1x+B_1y=V\times \sin \left(\theta +\beta \right)-V\times \sin \left(\theta -\beta \right)\\ =2V\times \cos \theta \sin \beta \end{array}& \left(22\right)\\ \begin{array}{c}{B}_1x-B_1y=V\times \sin \left(\theta +\beta \right)+V\times \sin \left(\theta -\beta \right)\\ =2V\times \sin \theta \cos \beta \end{array}& \left(23\right)\end{array}$

Then, the following expression is provided from the expressions (22) and (23):

$\begin{array}{c}\left(B_1x+B_1y\right)/\left(B_1x-B_1y\right)=\sin \theta \cos \beta /\cos \theta \sin \beta \\ =\tan \theta \cot \beta \end{array}$

Therefore,

θ=tan⁻¹(tan β×(B₁x+B₁y)/(B₁x−B₁y))   (24)

which is shown in FIG. 4.

(Calculation 2)

If the maximum flux densities A and B are measured beforehand, the rotation angle θ can be expressed as follows:

θ=−tan⁻¹(−(B/A)×(B₁x−B₁y)/(B₁x+B₁y)   (30)

(Calculation 3)

Since tan β=cot (90°−β), the expression (24) can be expressed as follows:

θ=tan⁻¹(cot(90−β)×(B₁x+B₁y)/(B₁x−B₁y))   (40)

Assuming that the phase difference between the output signals of the pair of magnetic sensor elements 22 is α, then α=β−γ=−(180°−2β).

Therefore,

−β/2=90°−β  (41)

The following expression is provided from the expressions (40) and (41):

$\begin{array}{cc}\begin{array}{c}\theta ={\tan }^{-1}\left(\cot \left(-\alpha /2\right)\times \left(B_1x-B_1y\right)/\left(B_1x+B_1y\right)\right)\\ =-{\tan }^{-1}\left(\cot \left(\alpha /2\right)\times \left(B_1x-B_1y\right)/\left(B_1x+B_1y\right)\right)\end{array}& \left(42\right)\end{array}$

(Calculation 4)

If the Hall IC 20 is shifted in a radial direction from the permanent magnet rotor 12, the phase of each of the output signals 300, 312 of the pair of Hall elements 22, 22′ varies as shown in FIG. 5. If the phase difference between two output signals increases to near 90 degrees in angle, the deviation of the rotation angle becomes smaller as shown in FIG. 8. In case that the phase difference is much smaller than 90 degrees in angle, the deviation of the rotation angle varies as shown in FIG. 6B. On the other hand, the deviation of the rotation angle is smaller than the former case, as shown in FIG. 7B, in case that the phase difference is 90 degrees in angle. Incidentally, broken lines in FIGS. 6A and 7A show the output signals of the Hall elements 22 when the Hall IC 20 is shifted.

In this case, the phase difference between the output signals of the Hall elements 22 is adjusted to 90 degrees in angle by using a map.

Thus, the rotation angle can be calculated by one of the above ways of calculation.

(Temperature Characteristic Correction)

Temperature characteristics of the sensor elements are taken into account, the rotation angle can be calculated as follows.

Assuming that: (i) the magnetic flux densities detected by the magnetic sensor elements 412, 412′ shown in FIG. 16 are B₂x, B₂y; (ii) the magnetic flux densities detected by the magnetic sensor elements 22, 22′ shown in FIG. 1 are B₃x, B₃y; (iii) the phase angle of the magnetic sensor elements are β, γ; and (iv) the temperature characteristic coefficient of the magnetic sensor elements is k (t), the following expression can be formed from expression (1), (2), (5) and (6):

$\begin{array}{cc}{B}_2x=k\left(t\right)\times B_0x=A\times k\left(t\right)\times \sin \theta & \left(50\right)\\ B_2y=k\left(t\right)\times B_0y=-B\times k\left(t\right)\times \cos \theta & \left(51\right)\\ \begin{array}{c}{B}_3x=B_2x/\left(2^{1/2}\right)+B_2y/\left(2^{1/2}\right)\\ =A\times k\left(t\right)\times \sin \theta /\left(2^{1/2}\right)-B\times k\left(t\right)\times \cos \theta /\left(2^{1/2}\right)\\ {=k\left(t\right)\times \left(A^2+B^2\right)/2)}^{1/2}\times \sin \left(\theta +{\beta }_3\right)\end{array}& \left(52\right)\\ \begin{array}{c}{B}_3y=B_2x/\left(2^{1/2}\right)+B_2y/\left(2^{1/2}\right)\\ =A\times k\left(t\right)\times \sin \theta /\left(2^{1/2}\right)-B\times k\left(t\right)\times \cos \theta /\left(2^{1/2}\right)\\ {=k\left(t\right)\times \left(A^2+B^2\right)/2)}^{1/2}\times \sin \left(\theta +{\gamma }_3\right)\end{array}& \left(53\right)\end{array}$

Then, the following expression is formed from the expression (52):

cos β₃=A/(A²+B²)^1/2

Therefore, the following expression can be formed from the expressions (8) and (9):

β₃=cos⁻¹(A/(A²+B²)^1/2)=β  (54)

The following expression can be formed from the expression (53):

cos γ₃=A/(A²+B²)^1/2

Further, the following expression is formed from expressions (11) and (12):

$\begin{array}{cc}{\gamma }_3={\cos }^{-1}\left(-A/{\left(A^2+B^2\right)}^{1/2}\right)=\gamma =180-\beta & \left(55\right)\end{array}$

It is understood from the expressions (52)-(55) that the phase angles of the output signals of the magnetic sensor elements 22, 22′ will not change although the amplitude of the output signals are multiplied by k (t). That is, the phase difference between the magnetic sensor elements 22, 22′ will not change.

The following expression can be formed from the expressions (5), (6) and (52)-(55):

$\begin{array}{cc}{B_3x=k\left(t\right)\times \left(A^2+B^2\right)/2)}^{1/2}\times \sin \left(\theta +{\beta }_3\right)=k\left(t\right)\times B_1x& \left(56\right)\\ {B_3y=k\left(t\right)\times \left(A^2+B^2\right)/2)}^{1/2}\times \sin \left(\theta +{\gamma }_3\right)=k\left(t\right)\times B_1y& \left(57\right)\end{array}$

If B₁x and B₁y in the expression (24) are respectively changed to B₃x and B₃y and the expressions (56) and (57) are substituted therefor, the rotation angle θ is expressed as follows:

$\begin{array}{cc}\begin{array}{c}\theta ={\tan }^{-1}(\tan \beta \times \left(B_3x-B_3y\right)/\left(B_3x+B_3y\right)\\ ={\tan }^{-1}(\tan \beta \times k\left(t\right)\times \left(B_1x-B_3y\right)/\left(k\left(t\right)\times \left(B_1x+B_1y\right)\right)\\ ={\tan }^{-1}\left(\tan \beta \times \left(B_1x-B_3y\right)/\left(B_1x+B_1y\right)\right)\end{array}& \left(58\right)\end{array}$

Thus, even if the temperature surrounding the magnetic sensor elements change, the rotation angle θ will not change.

A rotation angle detecting device according to the second embodiment of the invention is shown in FIGS. 9A and 9B.

The rotation angle detecting device 40 includes a pair of Hall elements 22, 22′. Each of the Hall elements 22, 22′ has a magnetic sensor surface 23 or 23′ and is arranged to be on an imaginary plane that is perpendicular to the rotation axis 200 of the permanent magnet rotor 12 so that each of the magnetic sensor surfaces 23, 23′ inclines by 45 degrees in angle toward a normal line 202 that intersects the rotation axis 200 at right angles and so that the magnetic sensor surfaces 23 of the pair of magnetic sensor elements 22 are positioned to have 90 degrees in angle between them. Therefore, the Hall elements 23 are disposed symmetric with respect to the line 202.

However, the sensor surfaces 23, 23′ are arranged to face the permanent magnet rotor 12, which is opposite to the sensor surfaces of the first embodiment.

A rotation angle detecting device according to the third embodiments of the invention will be described with reference to FIGS. 10A, 10B.

As shown in FIGS. 10A and 10B, the rotation angle detecting device 50 includes a pair of Hall elements 22, 22′. Each of the Hall elements 22, 22′ has a magnetic sensor surface 23 or 23′ and is arranged to be disposed on an imaginary plane that is perpendicular to the rotation axis 200 of the permanent magnet rotor 12 so that each of the magnetic sensor surfaces 23, 23′ inclines by 45 degrees in angle toward a line 202 that intersects the rotation axis 200 at right angles and so that the magnetic sensor surfaces 23, 23′ of the pair of magnetic sensor elements 22, 22′ are positioned to have 90 degrees in angle between them. However, the Hall elements 23, 23′ are disposed not symmetric with respect to the line 202 but disposed symmetric with respect to a line 204 that extends in parallel with a tangential line of the outer circumference of the permanent rotor 12 that intersects the line 202 at right angles.

A rotation angle detecting device 60 according to the fourth embodiment of the invention is shown in FIGS. 11A and 11B.

Each of the Hall elements 22, 22′ is disposed in the same manner as the fourth embodiment except that the sensor surfaces 23, 23′ are arranged to face in the opposite direction.

A rotation angle detecting device according to the fifth embodiment of the invention will be described with reference to FIGS. 12A and 12B.

The rotation angle detecting device 70 includes a pair of Hall elements 22, 22′. Each of the Hall elements 22, 22′ has a magnetic sensor surface 23 or 23′ and is arranged to be disposed on an imaginary plane that is perpendicular to the rotation axis 200 of the permanent magnet rotor 12 so that each of the magnetic sensor surfaces 23, 23′ inclines by 45 degrees in angle toward the normal line 202 that intersects the rotation axis 200 at right angles and so that the magnetic sensor surfaces 23, 23′ of the pair of magnetic sensor elements 22, 22′ are positioned to have 90 degrees in angle between them. Therefore, the Hall elements 23, 23′ are disposed symmetric with respect to the line 202. However, the Hall IC 20 is not disposed at a position around the permanent magnet rotor 12 but is disposed at a position above and within the circumference of the permanent magnet rotor 12.

A rotation angle detecting device according to the sixth embodiment of the invention will be described with reference to FIG. 13.

The rotation angle detecting device 80 includes a pair of Hall elements 22, 22′ and a ring-shaped permanent magnet rotor 82, which is different from the disk-shaped permanent magnet rotor 12 in that the magnet rotor 82 is constructed of a pair of arc-shaped permanent magnets. Each of the Hall elements 22, 22′ has a magnetic sensor surface 23 or 23′ and is arranged to be disposed on an imaginary plane that is perpendicular to the rotation axis 200 of the permanent magnet rotor 82 so that each of the magnetic sensor surfaces 23, 23′ inclines by 45 degrees in angle toward the normal line 202 that intersects the rotation axis 200 at right angles and so that the magnetic sensor surfaces 23, 23′ of the pair of magnetic sensor elements 22, 22′ are positioned to have 90 degrees in angle between them. Therefore, the Hall elements 23, 23′ are disposed symmetric with respect to the line 202.

A rotation angle detecting device according to the seventh embodiment of the invention will be described with reference to FIG. 14.

The rotation angle detecting device 90 has the same structure as the sixth embodiment except that the Hall IC 20 is disposed at a position above and within the circumference of the permanent magnet rotor 82.

The Hall elements 22, 22′ can be formed separately. The ring-shaped permanent magnets 82 may be constructed of a pair of short bar-like permanent magnets and a pair of arc-shaped members that support the permanent magnets instead of the pair of arc-shaped permanent magnets.

In the foregoing description of the present invention, the invention has been disclosed with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made to the specific embodiments of the present invention without departing from the scope of the invention as set forth in the appended claims. Accordingly, the description of the present invention is to be regarded in an illustrative, rather than a restrictive, sense.

Claims

1. A rotation angle detecting device comprising: a magnetic member for providing a magnetic field;a magnetic sensor for sensing a change in the magnetic field when the magnetic member rotates relative to the magnetic sensor about a rotation axis, wherein:the magnetic sensor is disposed at a single position and comprises a pair of sensor elements;the pair of sensor elements is disposed on an imaginary plane that is perpendicular to the rotation axis so that sensing surfaces of the sensor elements have 90 degrees in angle to each other; andeach of the sensing surfaces inclines by 45 degrees in angle to a line intersecting the rotation axis at right angles.

2. A rotation angle detecting device as in claim 1, wherein the magnetic member comprises a disk-shaped permanent magnet.

3. A rotation angle detecting device as in claim 1, wherein the magnetic member comprises a ring-shaped permanent magnet.

4. A rotation angle detecting device as in claim 1, wherein each of the sensor elements is a Hall element.

5. A rotation angle detecting device as in claim 1, wherein the pair of sensor elements is integrally formed on an IC chip.

6. A rotation angle detecting device as in claim 1, further comprising means for calculating a rotation angle of the rotating object by converting the output signals of the sensor elements to trigonometric functions.

7. A rotation angle detecting device as in claim 6, wherein the means for calculating a rotation angle adjusts the phase difference between the output signals to 90 degrees in angle.

8. A rotation angle detecting device as in claim 6, the means for calculating a rotation angle calculates the rotation angle based on both of the output signals and the phase angle of one of the output signals.

9. A rotation angle detecting device as in claim 6, the means for calculating a rotation angle calculates the rotation angle based on both of the output signals and a phase difference between the output signals.

10. A rotation angle detecting device as in claim 6, wherein assuming that: a first maximum value of the output signal of first one of the sensor elements that is disposed on the imaginary plane perpendicular to the rotation axis so that the sensing surface thereof is parallel to the line intersecting the rotation axis is A; and a maximum value of the output signal of the second one of the sensor elements that is disposed on the imaginary plane perpendicular to the rotation axis so that the sensing surface thereof is perpendicular to the sensing surface of the first one of sensor elements is B, the means for calculating a rotation angle calculates the rotation angle based on A, B and both of the output signals thereof.