An angle sensor

Abstract

The application provides an angle sensor and relates to the technical field of sensors.The angle sensor comprises a stator PCB plate and a rotor PCB plate;the stator PCB plate and the rotor PCB plate are both circular annular, and the two are coaxially designed and a preset air gap is arranged between the two;the stator PCB plate is integrated with a first excitation coil, a sine winding and a cosine winding;the rotor PCB plate is integrated with a second excitation coil, an N-pole winding and an S-pole winding;the first excitation coil and the second excitation coil are correspondingly arranged in the axial direction;the sine winding and the cosine winding are orthogonally arranged in the space where the stator PCB plate is located, and are correspondingly arranged in the axial direction with the N-pole winding and the S-pole winding respectively.Through the two excitation coils, an excitation energy coupling path is formed, and through the sine winding, the cosine winding, the N-pole winding and the S-pole winding, a signal sensing path is formed, so that the miniaturization and light weight of the sensor are realized under the condition of realizing the angle measurement function.

Description

Technical Field

[0001] This application relates to the field of sensor technology, and more particularly to an angle sensor. Background Technology

[0002] Rotary transformers, as high-precision angle sensors, are widely used in various technological applications such as automotive main drives, aerospace, industrial servo systems, and robot joints. Traditional rotary transformers typically use laminated silicon steel sheets to form the magnetic circuit, and a metal frame to wind coils to create the excitation and signal windings.

[0003] However, the silicon steel sheets and winding skeletons constructed in this way result in sensors that are bulky and heavy, making it difficult to meet the increasingly demanding miniaturization and lightweight requirements of modern devices. Furthermore, the winding process is complex, relies on manual labor or specialized equipment, and has high production costs with inconsistent performance. In addition, the overall structure formed by this method is assembled from multiple discrete parts, resulting in a complex structure that is not conducive to integration and mass production. Summary of the Invention

[0004] The main objective of this application is to provide an angle sensor that addresses the technical problem of reducing the size and structural complexity of the angle sensor.

[0005] To achieve the above objectives, this application provides an angle sensor, which includes a stator PCB board and a rotor PCB board;

[0006] Both the stator PCB and the rotor PCB are annular in shape, and they are coaxially designed with a pre-set air gap between them. The stator PCB integrates the first excitation coil, the sine winding, and the cosine winding. The rotor PCB board integrates a second excitation coil, an N-pole winding, and a S-pole winding; The first excitation coil and the second excitation coil are arranged correspondingly in the axial direction; The sine and cosine windings are arranged orthogonally in the space of the stator PCB board, and are respectively set to correspond axially with the N-pole winding and the S-pole winding.

[0007] In one embodiment, the angle sensor further includes: a first magnetic yoke and a second magnetic yoke; Both the first and second magnetic yokes are circular in shape, made of soft magnetic material, and are designed to be coaxial with the stator PCB and rotor PCB. The first magnetic yoke is located on the non-air gap side of the stator PCB board, and the second magnetic yoke is located on the non-air gap side of the rotor PCB board.

[0008] In one embodiment, both the stator PCB and the rotor PCB adopt a multi-level wiring design, and the number of layers is even. The first excitation coil, the sine winding, and the cosine winding are respectively set on the same wiring layer or different wiring layers of the stator PCB board; And / or, the second excitation coil, the N-pole winding, and the S-pole winding are respectively disposed on the same wiring layer or different wiring layers on the rotor PCB.

[0009] In one embodiment, the second excitation coil, the N-pole winding, and the S-pole winding are connected in series.

[0010] In one embodiment, the sine winding and the cosine winding are 90° out of phase by electrical angle; The N-pole winding and the S-pole winding are 180° out of phase.

[0011] In one embodiment, in each coil unit of a sine or cosine winding, the two tooth traces are at a 120° electrical angle.

[0012] In one embodiment, the N-pole winding and the S-pole winding are disposed inside the second excitation coil; Alternatively, the N-pole winding and the S-pole winding may be located outside the second excitation coil; Alternatively, the N-pole winding and the S-pole winding can be divided into two groups, one group located inside the second excitation coil and the other group located outside the second excitation coil.

[0013] In one embodiment, the lead of the first excitation coil is drawn out from the gap between the sine winding and the cosine winding, and the lead is parallel to the routing of the adjacent sine winding or cosine winding.

[0014] In one embodiment, the stator PCB board is circumferentially provided with multiple sets of sine windings and cosine windings, while the rotor PCB board is also circumferentially provided with a corresponding number of N-pole windings and S-pole windings, forming a multi-pole structure.

[0015] In one embodiment, in the multi-pole structure, each set of sine and cosine windings serves as a signal coil, and each set of N-pole and S-pole windings serves as a signal coil. A set of corresponding signal coils is arranged on the inner and outer sides of the first excitation coil or the second excitation coil, respectively. The signal coil on the inner side adopts a one-pole design as a roughing machine, and the signal coil on the outer side adopts a multi-pole design as a finishing machine. The roughing and finishing processes occupy the same area on their respective PCB boards.

[0016] This application provides an angle sensor, which includes a stator PCB board and a rotor PCB board. Both the stator PCB board and the rotor PCB board are annular and coaxial, with a preset air gap between them. The stator PCB board integrates a first excitation coil, a sine winding, and a cosine winding. The rotor PCB board integrates a second excitation coil, a N-pole winding, and a S-pole winding. The first excitation coil and the second excitation coil are axially aligned. The sine winding and the cosine winding are orthogonally arranged in the space occupied by the stator PCB board and are axially aligned with the N-pole winding and the S-pole winding, respectively.

[0017] The excitation energy coupling path is formed by two excitation coils arranged axially on the stator and rotor PCBs. The signal sensing path that changes with the rotor angle is formed by the sine winding, cosine winding, N-pole winding, and S-pole winding designed axially on the stator and rotor PCBs. Based on the above structure, the miniaturization and weight reduction of the sensor are achieved while realizing the high-precision angle measurement function. Attached Figure Description

[0018] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a structural schematic diagram of the first embodiment of the angle sensor in this application; Figure 2 Schematic diagrams of two wiring structures: sine winding and cosine winding; Figure 3 This is a schematic diagram of the wiring structure of the first excitation coil or the second excitation coil; Figure 4 This is a schematic diagram of the rotor PCB board traces provided in Embodiment 2 of the angle sensor of this application; Figure 5 This is a schematic diagram of the stator PCB board traces provided in Embodiment 2 of the angle sensor of this application; Figure 6 This is a schematic diagram of the overall structure of the rotor PCB board or stator PCB board provided in Embodiment 2 of the angle sensor of this application.

[0021] Attached image labels: 10, Stator PCB board; 11, First excitation coil; 111, Lead of the first excitation coil; 12, Sine winding; 121, Lead of the sine winding; 13, Cosine winding; 131, Lead of the cosine winding; 141, First interlayer connection hole; 142, Second interlayer connection hole; 20, Rotor PCB board; 21, Second excitation coil; 22, N-pole winding; 23, S-pole winding; 31, First yoke; 32, Second yoke; 40, Signal coil.

[0022] The purpose, features, and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0023] It should be understood that the specific embodiments described herein are merely illustrative of the technical solutions of this application and are not intended to limit this application.

[0024] To better understand the technical solution of this application, a detailed description will be provided below in conjunction with the accompanying drawings and specific implementation methods.

[0025] This application presents an angle sensor according to a first embodiment; please refer to... Figure 1 , Figure 2 as well as Figure 3 The angle sensor includes: stator PCB board 10 and rotor PCB board 20; Both the stator PCB board 10 and the rotor PCB board 20 are annular in shape, and they are coaxially designed with a preset air gap between them. The stator PCB board 10 integrates a first excitation coil 11, a sine winding 12, and a cosine winding 13. The rotor PCB board 20 integrates a second excitation coil 21, an N-pole winding 22, and an S-pole winding 23. The first excitation coil 11 and the second excitation coil 21 are arranged correspondingly in the axial direction; The sine winding 12 and the cosine winding 13 are orthogonally arranged in the space where the stator PCB board 10 is located, and are respectively axially corresponding to the N-pole winding 22 and the S-pole winding 23.

[0026] It should be understood that, in this embodiment, the stator PCB board 10 refers to the printed circuit board inside the sensor used to form the stator structure, and the rotor PCB board 20 refers to the printed circuit board inside the sensor used to form the rotor structure.

[0027] It should be noted that in this embodiment, both the stator PCB board 10 and the rotor PCB board 20 are annular in shape. The rotation center axes of the two annular components are aligned and assembled. They are spaced at a specific distance from each other and a gap filled with air (i.e., the aforementioned preset air gap) is reserved to achieve a coaxial design.

[0028] It is easy to understand that, in this embodiment, the first excitation coil 11 refers to a planar conductive image fabricated on the stator PCB board 10. It is mainly used to receive the alternating excitation current provided by the external circuit and to excite an axial, constant-amplitude alternating magnetic field (i.e., a pulsating magnetic field) in the sensor working air gap (i.e., the aforementioned preset air gap), providing an energy source for the entire sensor magnetic field. The second excitation coil 21 refers to a planar conductive image fabricated on the rotor PCB board 20. It mainly couples (receives) the axial alternating magnetic field formed by the first excitation coil 11 through electromagnetic induction, thereby inducing an alternating voltage in the rotor circuit as an energy source for the rotor-side circuit. The first excitation coil 11 and the second excitation coil 21 are axially aligned. After the stator PCB board 10 and the rotor PCB board 20 are coaxially mounted, in the direction perpendicular to the plane of the PCB board (axial direction), the axial planar projections of the first excitation coil 11 on the stator PCB board 10 and the second excitation coil 21 on the rotor PCB board 20 essentially overlap. Combined with a preset air gap, this forms a highly efficient excitation energy coupling path for energy coupling, enabling non-contact wireless energy transmission from the stator to the rotor. As a specific approach, both the first excitation coil 11 and the second excitation coil 21 can be designed as planar helical coils.

[0029] It should be noted that, in this embodiment, the sine winding 12 and the cosine winding 13 refer to two independent planar conductive images fabricated on the stator PCB board 10, which together serve as signal sensing windings on the stator side. Both can sense the spatial magnetic field generated on the rotor side that varies with angle, thereby outputting two corresponding induced voltage signals. Ideally, the amplitude envelopes of the two induced voltage signals have a sine function relationship with the rotor angle and a cosine function relationship, respectively.

[0030] It is worth noting that in this embodiment, the sine winding 12 and the cosine winding 13 are arranged orthogonally on the stator PCB board 10, which means that the arrangement of these two windings on the stator circumference makes the center line or equivalent magnetic axis of their effective conductors differ by 90° electrical angle in space.

[0031] It should be noted that, in this embodiment, the N-pole winding 22 and the S-pole winding 23 refer to two sets of planar conductive images fabricated on the rotor PCB board 20, which together serve as the signal sensing windings on the rotor side. Driven by the induced voltage generated by the second excitation coil, they are energized, thereby generating an equivalent composite magnetic field on the rotor surface, whose spatial distribution rotates synchronously with the rotor's mechanical angle. This magnetic field can be decomposed into two spatially opposite components, generated by the N-pole winding 22 and the S-pole winding 23, respectively. Specifically, the wiring topology of the N-pole winding 22 and the S-pole winding 23 is similar to that of the signal sensing windings (sine winding 12 and cosine winding 13) on the stator side. However, unlike the spatial orthogonality of the sine winding 12 and the cosine winding 13, the N-pole winding 22 and the S-pole winding 23 are spatially opposite, with the two windings differing by 180° electrical angle on the rotor circumference.

[0032] In practical implementation, when the external excitation signal drives the first excitation coil 11 on the stator PCB board 10 to generate an axial alternating magnetic field, this alternating magnetic field passes through a preset air gap and is induced by the second excitation coil 21 on the axially aligned rotor PCB board 20, converting it into an induced current. Subsequently, the induced current drives the N-pole winding 22 and S-pole winding 23, also located on the rotor PCB board 20, to generate a composite magnetic field whose spatial orientation rotates synchronously with the rotor's mechanical angle. This composite magnetic field is coupled by the stator sine and cosine windings 13 on the stator PCB board 10, which are arranged orthogonally in space (90° electrical angle apart), inducing two modulation signals whose amplitude envelopes are proportional to the sine and cosine values ​​of the rotor angle, respectively. Finally, by demodulating these two orthogonal signals and performing arctangent calculations, the absolute angle of the rotor can be accurately calculated.

[0033] Based on the above structural design, by reconstructing the discrete, three-dimensional winding structure of traditional resolvers into planar PCB wiring and integrating it onto the stator and rotor boards, the methods of silicon steel sheet stacked cores and manual winding are fundamentally eliminated. This achieves a significant simplification of the sensor structure, a substantial reduction in size and weight, laying the foundation for low-cost mass production. The entire process achieves non-contact energy and information transfer through PCB-integrated planar windings coupled with the axial magnetic field, enabling high-precision angle measurement within a single, compact structure.

[0034] Furthermore, in this embodiment, the angle sensor further includes: a first magnetic yoke 31 and a second magnetic yoke 32; Both the first magnetic yoke 31 and the second magnetic yoke 32 are circular in shape and made of soft magnetic material. They are coaxial with the stator PCB board 10 and the rotor PCB board 20. The first magnetic yoke 31 is disposed on the non-air gap side of the stator PCB board 10, and the second magnetic yoke 32 is disposed on the non-air gap side of the rotor PCB board 20.

[0035] It should be understood that, in this embodiment, the first magnetic yoke 31 and the second magnetic yoke 32 are annular components made of high permeability materials (such as soft magnetic alloys, ferrites, etc.) in the sensor, used to guide and constrain magnetic flux to form a low magnetic resistance magnetic circuit.

[0036] It should be noted that the non-air gap surface refers to the surface of the rotor PCB board 20 and the stator PCB board 10 that is far from the surface corresponding to the other PCB board. In this embodiment, the first magnetic yoke 31 is disposed on the non-air gap surface side of the stator PCB board 10, and the second magnetic yoke 32 is disposed on the non-air gap surface side of the rotor PCB board 20. This means that the first magnetic yoke 31, the stator PCB board 10, the preset air gap, the rotor PCB board 20, and the second magnetic yoke 32 are stacked sequentially to form a complete closed magnetic circuit structure. The magnetic flux generated by the two excitation coils is effectively constrained in the above-mentioned closed magnetic circuit structure, which significantly reduces the magnetic reluctance of the magnetic circuit. This not only enhances the mutual inductance between the stator and the rotor and improves the signal strength, but also serves to shield external stray magnetic field interference, thereby improving the signal-to-noise ratio and measurement accuracy of the sensor. As a specific method, the annular design of the first magnetic yoke 31 and the second magnetic yoke 32 is coaxial with the PCB board, ensuring the uniformity of the magnetic circuit in the circumferential direction.

[0037] Furthermore, in this embodiment, both the stator PCB board 10 and the rotor PCB board 20 adopt a multi-level wiring design, and have an even number of layers. The first excitation coil 11, the sine winding 12, and the cosine winding 13 are respectively disposed on the same wiring layer or different wiring layers of the stator PCB board 10. And / or, the second excitation coil 21, the N-pole winding 22 and the S-pole winding 23 are respectively disposed on the same wiring layer or different wiring layers on the rotor PCB board 20.

[0038] It should be understood that in this embodiment, both the stator PCB board 10 and the rotor PCB board 20 include multiple wiring layers, which are generally an even number. In this case, multiple conductive images can be fabricated on the same PCB board, and inter-layer electrical interconnection can be achieved through metallized vias. As a specific approach, the accompanying drawings of the embodiments of this application mainly illustrate the case where there are two wiring layers. The solid lines in the wiring topology of the figures indicate that the routing design of the corresponding component is the first layer, and the dashed lines in the figures indicate that the routing design of the corresponding component is the second layer.

[0039] It should be noted that, in this embodiment, the excitation coil (first excitation coil 11 or second excitation coil 21) and the corresponding signal winding 40 (sine winding 12 and cosine winding 13, or N-pole winding 22 and S-pole winding 23) can be flexibly arranged on the same layer or different layers. When arranged on the same wiring layer (for example, the first excitation coil 11, sine winding 12, and cosine winding 13 are located on the same wiring layer, or the second excitation coil 21, N-pole winding 22, and S-pole winding 23 are located on the same wiring layer), the parasitic capacitance introduced by the interlayer dielectric can be minimized, thereby reducing displacement current interference generated by the high-frequency excitation signal and optimizing signal quality. This provides an important anti-interference design option. Alternatively, the above components can also be arranged on different wiring layers, or any one component can be arranged on different wiring layers simultaneously.

[0040] In one specific case, the stator PCB board 10 can be designed with two layers, and either the sine winding 12 or the cosine winding 13 can be placed on two layers, such as... Figure 2 As shown, Figure 2 This demonstrates two wiring methods: sine winding 12 or cosine winding 13. Among them, Figure 2 The diagram on the left shows the wiring method for the outer connection, which is mainly used for connecting an external decoding circuit. Figure 2 The diagram on the right shows the wiring method corresponding to the inner wiring. Regardless of the wiring method, the sine winding 12 or the cosine winding 13 can be designed on two layers of the stator PCB board 10, and each layer is electrically connected through the first interlayer connection hole 141.

[0041] In one specific case, the rotor PCB board 20 can also be designed as a two-layer structure, and either the first excitation coil 11 or the second excitation coil 21 can also be located on two layers, such as... Figure 3 As shown, Figure 3 This demonstrates the wiring configuration of the first excitation coil 11 and the second excitation coil 21. Among them, Figure 3 The diagram on the left corresponds to the wiring method on layer 1. Figure 3 The diagram on the right corresponds to the wiring method on the second layer, with the spiral directions of the two coils being opposite. The first excitation coil 11 or the second excitation coil 21 can be designed on both layers of the stator PCB board 10, with each layer electrically connected to the other through the second interlayer connection hole 142.

[0042] It is readily understood that, in this embodiment, the use of multilayer PCB wiring makes it possible to achieve complex winding patterns with multiple turns, high density, and mutual insulation within a circular annular board of limited area. The symmetrical structure of even-numbered layers helps to balance stress during manufacturing and ensure the flatness of the PCB board, which is crucial for maintaining the uniformity of small air gaps and ensuring the accuracy of angle measurements.

[0043] This application provides an angle sensor comprising a stator PCB board and a rotor PCB board. Both the stator and rotor PCB boards are annular and coaxially arranged with a pre-defined air gap between them. The stator PCB board integrates a first excitation coil, a sine winding, and a cosine winding. The rotor PCB board integrates a second excitation coil, a north pole winding, and a south pole winding. The first and second excitation coils are axially aligned. The sine and cosine windings are orthogonally arranged in the space occupied by the stator PCB board and axially aligned with the north pole winding and south pole winding, respectively. The two axially aligned excitation coils on the stator and rotor PCB boards form an excitation energy coupling path. The axially aligned sine, cosine, north pole, and south pole windings on the stator and rotor PCB boards form a signal sensing path that changes with the rotor angle. Based on this structure, the sensor achieves high-precision angle measurement while miniaturizing and reducing its weight.

[0044] Based on the first embodiment of the angle sensor of this application, in the second embodiment of the angle sensor of this application, the content that is the same as or similar to the first embodiment of the angle sensor described above can be referred to the above description, and will not be repeated hereafter. Based on this, please refer to... Figure 4 , Figure 5 as well as Figure 6 In this embodiment, the N-pole winding 22 and the S-pole winding 23 are disposed inside the second excitation coil 21; Alternatively, the N-pole winding 22 and the S-pole winding 23 are located outside the second excitation coil 21; Alternatively, the N-pole winding 22 and the S-pole winding 23 can be divided into two groups, one group located inside the second excitation coil 21 and the other group located outside the second excitation coil 21.

[0045] It should be understood that, in this embodiment, the inner and outer sides of the winding on the PCB board are relative to the center of the ring; the area closer to the center is the inner side, and the area farther from the center is the outer side.

[0046] It should be noted that, in this embodiment, the three topologies provided are options for the rotor-side winding arrangement. To achieve effective electromagnetic coupling, the windings on the stator PCB board 10 must adopt the exact same topology as the rotor PCB board 20. Therefore, if the rotor PCB board 20 adopts a structure with the second excitation coil 21 inside and the signal coils (N-pole winding 22 and S-pole winding 23) outside, the stator PCB board 10 must also correspondingly arrange the first excitation coil 11 inside and the signal coils (sine winding 12 and cosine winding 13) outside.

[0047] It is readily understood that different topology options are provided in this embodiment, allowing the design to flexibly adapt to different installation space constraints and electromagnetic performance requirements. For example, placing the signal coil on the outside makes it easier to bring out the wiring; while placing it on the inside may help to achieve a more compact overall diameter.

[0048] Furthermore, in this embodiment, the second excitation coil 21, the N-pole winding 22, and the S-pole winding 23 are connected in series.

[0049] It should be noted that in the rotor PCB board 20, the second excitation coil, the N-pole winding 22, and the S-pole winding 23 are connected in series, ensuring that the current has only one path. In this embodiment, the connection relationship can be found in [reference needed]. Figure 4 The wiring diagram is shown below. The first excitation coil 11 on the stator PCB board 10 is supplied with an excitation current to generate a magnetic field. This magnetic field is cut by the second excitation coil 21 on the rotor PCB board 20 to induce a voltage. This induced voltage drives the current in the series circuit, thereby forming a working magnetic field in the N-pole winding 22 and the S-pole winding 23.

[0050] It is easy to understand that, in this embodiment, the series connection means that the rotor signal winding 40 (N pole winding 22 and S pole winding 23) does not require an external power supply. Its energy comes entirely from the magnetic field energy transmitted by the first excitation coil 11 on the stator side through electromagnetic induction, realizing non-contact energy and signal transmission, simplifying the rotor structure and improving reliability.

[0051] Furthermore, in this embodiment, the sine winding 12 and the cosine winding 13 are 90° out of phase by electrical angle; The N-pole winding 22 and the S-pole winding 23 are 180° out of phase.

[0052] It should be understood that, in this embodiment, the electrical angle is an angle describing the phase of a periodic electromagnetic phenomenon. For the annular structure sensor proposed in this embodiment, in the case of a single pair of poles, its mechanical angle 360° is equal to the electrical angle 360°; while in the case of multiple pairs of poles, the electrical angle can be the product of the number of poles and the mechanical angle.

[0053] It should be noted that, in this embodiment, the 90° electrical angle difference between the sine winding 12 and the cosine winding 13 on the stator side is the physical basis for achieving orthogonality (i.e., a 90° phase difference) between the two output signals. This is a necessary condition for subsequently calculating the absolute angle using algorithms such as arctangent. The 180° electrical angle difference between the N-pole winding 22 and the S-pole winding 23 on the rotor side means that the magnetic fields generated by the two are opposite in spatial direction, forming a composite magnetic field whose direction changes with the rotor angle.

[0054] It is easy to understand that, in this embodiment, it is precisely because of the specific spatial relationship formed by the orthogonal winding of the stator PCB board 10 and the anti-phase winding of the rotor PCB board 20 that when the rotor PCB board 20 rotates, the coupling degree (mutual inductance) of the sine winding 12 and cosine winding 13 of the stator PCB board 10 and the combined magnetic field of the rotor PCB board 20 will change according to the sine and cosine laws respectively, thereby outputting a signal whose amplitude envelope is related to the rotation angle in a sine and cosine manner, thus realizing angle detection.

[0055] Furthermore, in this embodiment, in each coil unit of the sine winding 12 or the cosine winding 13, the two tooth traces are at an electrical angle of 120°.

[0056] It should be understood that, in this embodiment, the toothed trace refers to the effective conductor portion arranged radially in the coil, which is the main part that generates electromagnetic induction.

[0057] It should be noted that it can be combined Figure 2 In this embodiment, either the sinusoidal winding 12 or the cosine winding 13 can be a distributed winding composed of several coil units. Each coil unit has two toothed traces, with a 120° electrical angle between them, which can suppress harmonics. This design can effectively weaken the third and other specific harmonics in the induced electromotive force, thereby improving the sinusoidal nature of the output signal and ultimately improving the accuracy of angle calculation.

[0058] Based on the above structure, harmonics can be suppressed by optimizing the distribution factor of the winding itself, thereby improving signal quality from the source and helping to achieve high precision while simplifying the signal processing circuit.

[0059] Furthermore, in this embodiment, the lead 111 of the first excitation coil 11 is led out from the gap between the sine winding 12 and the cosine winding 13, and the lead is parallel to the routing of the adjacent sine winding 12 or cosine winding 13.

[0060] It should be understood that, in this embodiment, a lead refers to a conductive trace extending from the end of the coil for connecting to an external circuit. A gap refers to the blank area between different winding conductor patterns.

[0061] It should be noted that, as Figure 5As shown, the sine winding 12 is electrically connected to the outside via lead 121, the cosine winding 13 is electrically connected to the outside via lead 131, and the first excitation coil 11 is electrically connected to the outside via lead 111. In this embodiment, when the first excitation coil 11 is surrounded within the internal signal winding 40 (sine winding 12 or cosine winding 13), its lead 111 needs to pass through the signal winding 40 area to reach the board edge. At this time, the lead 111 of the first excitation coil 11 can pass through the natural gap between the sine winding 12 or cosine winding 13 on the same wiring layer and remain parallel to the adjacent signal line.

[0062] Based on the above structure, the crossing of lead 111 and signal winding 40 is avoided, minimizing parasitic coupling and potential short-circuit risks introduced by the crossing. This allows for crucial details such as electrical isolation and layout optimization of each winding in high-density, multi-layer PCB routing, ensuring a clean electromagnetic environment inside the sensor and improving its stability and reliability.

[0063] Furthermore, in this embodiment, the stator PCB board 10 is circumferentially provided with multiple sets of sine windings 12 and cosine windings 13, while the rotor PCB board 20 is also circumferentially provided with a corresponding number of multiple sets of N-pole windings 22 and S-pole windings 23, forming a multi-pole structure.

[0064] It should be understood that a multi-pole structure refers to the repeated arrangement of multiple sets of signal winding pole pairs 40 on the circumference of the sensor. In this embodiment, each pair of N-pole winding 22 and S-pole winding 23 constitutes a pole pair, or each corresponding sine winding 12 and cosine winding 13 constitutes a pole pair, forming a multi-pole structure on the stator PCB board 10 and rotor PCB board 20 respectively.

[0065] It should be noted that in this embodiment, when a multi-pole structure is used, the electrical angle will change by the product of the number of pole pairs and 360° for every 360° mechanical rotation of the rotor. This means that within one mechanical cycle, the output signal will experience several complete electrical cycles corresponding to the number of pole pairs, greatly improving the resolution of angle measurement and enabling incremental angle measurement.

[0066] Based on the above structure, without changing the physical dimensions and basic working principle, minute changes in mechanical angle can be adjusted by increasing the multiple of the electrical cycle, thereby achieving high-resolution angle detection.

[0067] Furthermore, in this embodiment, in the multi-pole structure, each set of sine winding 12 and cosine winding 13 serves as a signal coil, and each set of N-pole winding 22 and S-pole winding 23 serves as a signal coil. A set of corresponding signal coils is arranged on the inner and outer sides of the first excitation coil 11 or the second excitation coil 21 respectively. The signal coil on the inner side adopts a one-pole design as a roughing machine, and the signal coil on the outer side adopts a multi-pole design as a finishing machine. The roughing and finishing processes occupy the same area on their respective PCB boards.

[0068] It should be noted that the coarse position measurement machine can provide a wide range (low precision) of absolute position information, while the precision measurement machine can provide high precision information within a small range. Combining the two enables high-precision absolute position measurement. In this embodiment, the two sets of signal coils—the coarse position machine (one pair of poles) and the precision measurement machine (multiple pairs of poles)—can be cleverly arranged at different radial positions on the same PCB board (stator PCB board 10 or rotor PCB board 20), i.e., on the inner and outer sides of the first excitation coil 11 or the second excitation coil 21), achieving a compact single-axis dual-channel design. Furthermore, the coarse and precision measurement machines occupy equal areas on their respective PCB boards, achieving magnetic circuit symmetry and making the magnetic field strength and uniformity of the inner and outer coils more consistent, thereby improving the matching accuracy and the final angle calculation accuracy.

[0069] Based on the above structure, absolute position detection and high-resolution subdivision functions are integrated into a single sensor, eliminating the need for mechanical splicing of two separate sensors. This further optimizes the structure, saves space, reduces costs, and achieves higher-performance angle measurement.

[0070] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent scope of this application.

Claims

1. An angle sensor, characterized in that, The angle sensor includes: a stator PCB board and a rotor PCB board; Both the stator PCB board and the rotor PCB board are annular in shape, and they are coaxially designed with a preset air gap between them. The stator PCB board integrates a first excitation coil, a sine winding, and a cosine winding, all of which have planar conductive images. The rotor PCB board integrates a second excitation coil, an N-pole winding, and an S-pole winding, all of which are planar conductive images. The first excitation coil and the second excitation coil are arranged axially to form an excitation energy coupling path; The sine winding and the cosine winding are orthogonally arranged in the space where the stator PCB board is located, and are respectively axially corresponding to the N-pole winding and the S-pole winding to form a signal sensing path; In each coil unit of the sine winding or the cosine winding, the two tooth traces are at an electrical angle of 120°. Both the stator PCB and the rotor PCB adopt a multi-level wiring design and have an even number of layers. For the sine winding or the cosine winding, each layer is electrically connected to the other through a first inter-layer connection hole. The second excitation coil, the N-pole winding, and the S-pole winding are connected in series. The lead wire of the first excitation coil is drawn out from the gap between the sine winding and the cosine winding, and the direction of the lead wire is parallel to the routing of the adjacent sine winding or cosine winding.

2. The angle sensor as described in claim 1, characterized in that, The angle sensor further includes: a first magnetic yoke and a second magnetic yoke; Both the first and second magnetic yokes are annular in shape, made of soft magnetic material, and are coaxial with the stator PCB board and the rotor PCB board. The first magnetic yoke is disposed on the non-air gap side of the stator PCB board, and the second magnetic yoke is disposed on the non-air gap side of the rotor PCB board.

3. The angle sensor as described in claim 1, characterized in that, The first excitation coil, the sine winding, and the cosine winding are respectively disposed on the same wiring layer or different wiring layers of the stator PCB board; And / or, the second excitation coil, the N-pole winding, and the S-pole winding are respectively disposed on the same wiring layer or different wiring layers on the rotor PCB board.

4. The angle sensor as described in claim 1, characterized in that, The sine winding and the cosine winding are 90° out of phase. The N-pole winding and the S-pole winding are 180° out of phase.

5. The angle sensor as described in claim 1, characterized in that, The N-pole winding and the S-pole winding are located inside the second excitation coil; Alternatively, the N-pole winding and the S-pole winding may be disposed outside the second excitation coil; Alternatively, the N-pole winding and the S-pole winding can be divided into two groups, one group located inside the second excitation coil and the other group located outside the second excitation coil.

6. The angle sensor as described in claim 1, characterized in that, The stator PCB board is circumferentially provided with multiple sets of sine windings and cosine windings, while the rotor PCB board is also circumferentially provided with a corresponding number of sets of N-pole windings and S-pole windings, forming a multi-pole structure.

7. The angle sensor as described in claim 6, characterized in that, In the multi-pole structure, each group of the sine winding and the cosine winding serves as a signal coil, and each group of the N-pole winding and the S-pole winding serves as a signal coil. A set of corresponding signal coils is arranged on the inner and outer sides of the first excitation coil or the second excitation coil, respectively. The signal coil on the inner side adopts a one-pole design as a roughing machine, and the signal coil on the outer side adopts a multi-pole design as a finishing machine. The roughing machine and the finishing machine occupy the same area on their respective PCB boards.

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