angle sensor

Abstract

An angle sensor capable of reducing the amount of resin of a connector housing is provided. A resolver (1) includes a stator core (11), a rotor, a wire wound around the stator core (11), a terminal pin (150) for connecting the wire, a connector housing (140) for fixing the terminal pin (150), and a connecting portion (160) connecting the stator core (11) and the connector housing (140). The terminal pin (150) is fixed inside the connecting portion (160), and the connecting portion (160) has a recess (161) opposed to the stator core (11) in the direction of the rotation axis of the rotor.

Description

Technical Field

[0001] This invention relates to angle sensors such as rotary transformers, and particularly to improving the moldability of resins. Background Technology

[0002] Previously, rotary transformers were known as a means of detecting the rotation angle of rotating electrical machines such as motors and generators. A rotary transformer has a stator formed by molding insulating inserts into stator laminations, and a connector housing integrally formed on the insulating parts.

[0003] Terminal leads are molded into the connector housing insert. There are typically six terminal leads, and they are L-shaped or crank-shaped, thus increasing the volume of resin in the connector housing with embedded terminal leads. Patent Document 1 discloses a structure that reduces the amount of resin by forming recesses in the connector housing.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Invention Patent No. 5970355 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] In the rotary transformer of Patent Document 1, the connector housing protrudes towards the rotor's rotation axis, and the terminal pins also extend towards the rotation axis. Therefore, the connector housing is positioned radially away from the stator, and the recess is also positioned radially away from the stator. Consequently, the amount of resin from the stator to the recess increases.

[0009] The present invention was made in view of the above circumstances, and its object is to provide an angle sensor that can improve the moldability of resin.

[0010] Solution for solving the problem

[0011] The present invention is an angle sensor comprising a stator, a rotor, a wire wound around the stator, a terminal for connecting the wire, and a connector housing for fixing the terminal, and having a connecting portion for connecting the stator and the connector housing, wherein the terminal is fixed inside the connecting portion, and a portion of the connecting portion has a recess that is opposite to the stator in the direction of rotation axis of the rotor.

[0012] According to the present invention, since the recess is located opposite the stator, the distance from the stator to the recess is short, which can improve the moldability of the resin. Attached Figure Description

[0013] Figure 1This is an exploded perspective view showing a rotary transformer according to an embodiment of the present invention.

[0014] Figure 2 This is a top view showing a rotary transformer according to an embodiment of the present invention.

[0015] Figure 3 This is a rear view of the rotary transformer illustrating the implementation method.

[0016] Figure 4 This is a perspective view of the rotary transformer as seen from the rear side.

[0017] Figure 5 In the diagram, (A) is a side view of the rotary transformer according to the embodiment, and (B) is a front view.

[0018] Figure 6 This is a cross-sectional view of the rotary transformer according to the embodiment.

[0019] Figure 7 This is a perspective view of the rotary transformer in the embodiment without its cover installed.

[0020] Figure 8 This is a top view of the rotary transformer in the embodiment without its cover installed.

[0021] Figure 9 This is a rear view of the rotary transformer in the embodiment without the cover installed.

[0022] Figure 10 This is a cross-sectional view of the periphery of the connector housing of the rotary transformer according to the embodiment.

[0023] Figure 11 This is a perspective view of the periphery of the terminal pins of the rotary transformer in the embodiment, viewed from the rear side.

[0024] Figure 12 This is a perspective view showing the terminal pins of the rotary transformer according to the embodiment.

[0025] Figure 13 This is a perspective view of a modified example of the rotary transformer described in the embodiment, viewed from the rear side. Detailed Implementation

[0026] 1. Overall structure of a rotary transformer

[0027] Figures 1-12 A rotary transformer (angle sensor) 1, according to an embodiment of the present invention, is shown. Figures 1-6 The rotary transformer 1 shown is in the state with the cover 200 installed. Figures 7-9 This shows the state where the cover 200 is not installed.

[0028] Rotary transformer 1 is a VR (variable reluctance) type rotary transformer. Rotary transformer 1 has a rotor 30 and a stator 10. The rotor 30 is fixed to the output shaft of a rotating electric machine (not shown). The rotor 30 has a structure consisting of multiple thin-plate rotor cores stacked axially. It should be noted that in the following description, the direction of the output shaft is referred to as "axial," the direction orthogonal to the axial direction is referred to as "radial," and the direction of rotation around the output shaft is referred to as "circumferential." Furthermore, the terms indicating "up" and "down" directions are... Figure 1 The up and down directions.

[0029] The thin-plate rotor core constituting rotor 30 is manufactured by stamping a plate made of electromagnetic steel into a non-circular shape. Multiple rotor cores are stacked axially and fixed by riveting, thereby constituting rotor 30.

[0030] The stator 10 is disposed outside the rotor 30 and fixed to the housing of the rotary electric machine (not shown). A gap is provided between the rotor 30 and the stator 10, so that the rotor 30 can rotate inside the stator 10. The housing is a component that assembles the stator 10 of the rotary transformer 1, and is provided with threaded holes for fixing the stator 10 of the rotary transformer 1. The stator 10 of the rotary transformer 1 is assembled to the housing by screwing bolts into the threaded holes.

[0031] The stator 10 has stator laminations 11. The stator laminations 11 have a structure formed by stacking multiple thin plate-like stator cores axially. For example... Figures 7-9 As shown, the thin-plate stator core has an annular core back 12, a plurality of teeth 13 protruding radially inward from the core back 12, and a plurality of flanges 14 protruding radially outward from the core back 12. On the flanges 14, elongated through holes 14a are formed in concentric circles along the circumferential direction.

[0032] Between adjacent flanges 14, a plurality of U-shaped notches 15 (seven in this example) are formed, opening radially outward. The stator core is manufactured by stamping a sheet made of electromagnetic steel. Multiple stator cores are stacked axially and riveted together to form stator laminations 11. Bolts for fixing to the housing are inserted through the notches 15, and the bolts have a diameter such that they do not contact the stator laminations 11 when inserted into the notches 15.

[0033] like Figures 7-9As shown, insulating members 100 are fixed to both axial sides of the stator lamination 11. The insulating members 100 are made of insulating resin and are injection molded with the stator lamination 11 as an insert. The insulating member 100 has a winding portion 110. The winding portion 110 is formed to surround the entire circumference of the tooth 13 and has a cylinder (not shown) with a radially central portion, a flange 111 extending axially and circumferentially along the radially inner side of the cylinder, and a wall 112 protruding vertically and axially along the radially outer side of the cylinder. Furthermore, a coil 115 is formed by winding a wire around the cylinder. It should be noted that the insulating member 100 is not limited to injection molding; the insulating member 100 formed separately can also be fixed to the stator lamination 11.

[0034] like Figures 7-9 As shown, the insulating member 100 has annular protrusions 120 that project vertically in the axial direction. A terminal block 130, which is rectangular in plan view, is formed on one side of the insulating member 100, protruding radially outward from both ends of the annular protrusion 120. A connector housing 140 is integrally formed on the terminal block 130. The connector housing 140 has a hollow connector receiving portion 141.

[0035] like Figure 10 As shown, terminal pins (terminals) 150 are integrally formed on the terminal block 130 and the connector housing 140 by insert molding. Figure 11 As shown, terminal pin 150 in this example has a shape where all six pins are bent. Therefore, Figure 10 The sectional view shows a section along terminal pin 150.

[0036] like Figure 12 As shown, the terminal pin 150 includes: a first member 151 having an axially parallel portion for wire connection (hereinafter referred to as the first exposed portion 151a); and a second member 152 having a portion located within the connector receiving portion 141 (hereinafter referred to as the second exposed portion 152a). These first members 151 and second members 152 are interconnected by a third member 153.

[0037] The third component 153 includes: an inclined portion 153a extending from the axial lower end of the first component 151 in a direction inclined relative to the radial direction toward the adjacent terminal pin 150; a parallel portion 153b extending from the end of the inclined portion 153a in a direction parallel to the radial direction; and a vertical portion 153c extending downward from the end of the parallel portion 153b.

[0038] On the outermost side of the circumference (e.g.) Figure 12In the second terminal pin 150 adjacent to the leftmost first terminal pin 150, the inclination of the inclined portion 153a relative to the radial direction is slightly smaller than that of the first terminal pin 150. Furthermore, in the adjacent third terminal pin 150 located further inward in the circumferential direction, the inclination of the inclined portion 153a relative to the radial direction is smaller than that of the second terminal pin 150. The structure of the portion other than the inclined portion 153a is the same in the first to third terminal pins 150. Moreover, the remaining terminal pins 150 are formed symmetrically with respect to the three terminal pins 150.

[0039] like Figure 4 and Figure 10 As shown, the connector housing 140 and the terminal block 130 are interconnected by a connecting portion 160. The connecting portion 160 has an axially recessed portion (weight reduction portion) 161. The recess 161 is axially opposed to the stator lamination 11 and the terminal pin 150. That is, when viewed from the axial direction, the recess 161 is positioned at the point where it overlaps with the stator lamination 11 and the terminal pin 150. The recess 161 has a radially extending transverse wall 162 and an axially extending longitudinal wall 163. Furthermore, posts 164 are provided on both circumferential sides of the recess 161, and each post 164 has an inclined surface 164a that slopes downward toward the radially inward side.

[0040] like Figure 10 As shown, the connecting portion 160 includes: a first region 16, including an inclined portion 153a and a parallel portion 153b of the third member 153; and a second region 166, including a vertical portion 153c. The axial dimension of the first region 165 is shorter than the axial dimension of the longitudinal wall 163, and the radial dimension of the second region 166 is shorter than the radial dimension of the transverse wall 162.

[0041] Relative to the recess 161 described above, the terminal pin 150 is configured as follows: The inclined portion 153a and the parallel portion 153b of the third member 153 of the terminal pin 150 are arranged along the transverse wall 162 of the recess 161 of the connecting portion 160, and the vertical portion 153c of the third member 153 is arranged along the longitudinal wall 163 of the recess 161. Furthermore, the first exposed portion 151a of the first member 151 protrudes and is exposed on the upper surface of the terminal block 130, where the end of the wire led out from the coil 115 is wound and fixed by means of welding or brazing. In addition, the second exposed portion 152a of the second member 152 protrudes and is exposed in the connector receiving portion 141.

[0042] Next, the cover 200 includes an upper cover 210 and a lower cover 220. The upper cover 210 has an annular plate 211 and a rectangular terminal pin cover 212 that protrudes radially outward from one side of the plate 211. An inner cylinder 213 extends axially from the radially inner edge of the plate 211. The inner cylinder 213 has a recess 213a with the same shape as the flange 111 of the insulating member 100 and the teeth 13 of the stator lamination 11.

[0043] An outer cylinder 214 extends axially from the radially outer edge of the flat plate 211. The inner circumference of the outer cylinder 214 contacts the outer circumference of the annular protrusion 120 of the insulating member 100. Figure 1 As shown, a plurality of flanges 214a (two in this example) protruding radially outward are formed on the lower edge of the outer periphery of the outer cylinder 214. The flanges 214a are rectangular in shape. In addition, a plurality of protrusions 214b (five in this example) protruding radially outward are formed on the outer periphery of the outer cylinder 214.

[0044] like Figures 7-9 As shown, a plurality of flanges 126 (two in this example) protruding radially outward are formed on the annular protrusion 120 of the insulating member 100, and pins 127 protruding axially are formed on the flanges 126. Figure 9 As shown, an upwardly recessed recess 127a is formed in the flange 126. The recess 127a is formed in such a way as to penetrate the through hole 12a into the core back 12, and a pin 127 is formed by making a portion of the flange 126 on the surface side protrude upward.

[0045] Furthermore, a pin 127 protruding axially is formed at the center of the radially outer side of the terminal block 130. For example... Figure 1 and Figure 2 As shown, the flange 126 of the insulating member 100 engages with the inner side of the flange 214a of the upper cover 210. Furthermore, the pin 127 formed in the terminal block 130 passes through the through hole 214c formed in the terminal pin cover 212 of the upper cover 210 (see reference). Figure 1 The above structure enables the upper cover 210 to be positioned relative to the insulating component 100.

[0046] Next, as Figure 3 and Figure 4 As shown, the lower cover 220 includes an annular flat plate 221 and a rectangular terminal cover 222 that protrudes radially outward from one side of the flat plate 221 and covers the radially inner portion of the terminal block 130. An inner cylinder 223 extends axially from the radially inner edge of the flat plate 221. The inner cylinder 223 has a recess 223a with the same shape as the flange 111 of the insulating member 100 and the teeth 13 of the stator lamination 11. An outer cylinder 224 extends axially from the radially outer edge of the flat plate 221. The inner periphery of the outer cylinder 224 contacts the outer periphery of the annular protrusion 120 of the insulating member 100.

[0047] Multiple (five in this example) protrusions 224b are formed on the outer periphery of the outer cylinder 224, protruding radially outward. An upwardly protruding boss 225 is formed on each of the protrusions 224b (see reference). Figure 1 The boss 225 passes through the through hole 12a formed in the core back 12 of the stator lamination 11 (see reference). Figures 7-9 The protrusion 214b of the upper cover 210 is heat-riveted there. This achieves the positioning of the lower cover 220, and the upper cover 210 and the lower cover 220 are fixed to each other and also fixed to the insulating member 100.

[0048] In the rotary transformer 1 with the above-described structure, a connecting portion 160 is provided to connect the stator 10 and the connector housing 140, and the connecting portion 160 has a recess 161. Furthermore, since the recess 161 is axially opposed to the stator laminations 11, the distance between the recess 161 and the stator laminations 11 is short. Therefore, the amount of resin between the stator laminations 11 and the recess 161 can be reduced.

[0049] In particular, in the above embodiment, the terminal pin 150 has: a first member 151 having a first exposed portion 151a for wire connection; a second member 152 having a second exposed portion 152a exposed in the connector receiving portion 141; and a third member 153 connecting the first member 151 and the second member 152. The third member includes an inclined portion 153a and a parallel portion 153b along the transverse wall 162 and a vertical portion 153c along the longitudinal wall 163. By setting the terminal pin 150 in this shape instead of the conventional L-shape, the recess 161 can be shaped with the transverse wall 162 and the longitudinal wall 163 to be arranged opposite to the stator lamination 11.

[0050] Furthermore, in the above embodiment, the first exposed portions 151a of the terminal pins 150 in the circumferential direction are widely spaced, while the second exposed portions 152a in the circumferential direction are narrowly spaced. Therefore, the distance from the coil 115 to the first exposed portion 151a is short, which can shorten the length of the wire led out from the coil 115, and on the other hand, it can reduce the size of the connector connected to the second exposed portion 152a.

[0051] 2. Example of Change

[0052] The present invention is not limited to the above-described embodiments, and various modifications can be made as described below.

[0053] i) If Figure 13As shown, a rib 167 with the same side shape as the post 164 can be formed in the recess 161 of the connecting portion 160. The strength of the connecting portion 160 is increased by the rib 167. It should be noted that the number of ribs 167 can be one or more. It should also be noted that a structure can be adopted that neither the post 164 nor the ribs 167 are provided. In this case, the amount of resin used can be further reduced.

[0054] ii) In the above embodiment, the third member 153 of the terminal pin 150 has a shape having an inclined portion 153a and a parallel portion 153b, but instead of the inclined portion 153a and the parallel portion 153b, a portion extending linearly from the lower end of the first member 151 to the upper end of the vertical portion 153c may be provided.

[0055] This invention is an angle sensor that can be used to detect the rotation angle of rotating motors such as motors and generators.

[0056] Explanation of reference numerals in the attached figures

[0057] 1: Rotary transformer (angle sensor); 10: Stator; 11: Stator laminations; 12: Core back; Through hole 12a; 13: Tooth; 14: Flange; 14a: Through hole; 15: Notch; 30: Rotor; 100: Insulator; 110: Winding section; 111: Flange; 112: Wall; 115: Coil; 120: Annular protrusion; 126: Flange; 127: Pin; 127a: Recess; 130: Terminal block; 140: Connector housing; 141: Connector receiving section; 150: Terminal pin (terminal); 151: First component; 151a: First exposed portion; 152: Second component; 152a: Second exposed portion; 153: Third component; 153a: Inclined portion; 153b: Parallel portion; 153c: Vertical portion; 160: Connecting portion; 161: Recess (weight reduction portion); 162: Horizontal wall; 163: Longitudinal wall; 164a: Inclined surface; 164: Column; 165: First region; 166: Second region; 200: Cover; 210: Upper cover; 220: Lower cover; 211: Flat plate; 212: Terminal pin cover; 213: Inner cylinder; 213a: Recess; 214: Outer cylinder; 214a: Flange; 214b: Protrusion; 214c: Through hole; 221: Flat plate; 222: Terminal block cover; 223: Inner cylinder; 223a: Recess; 224: Outer cylinder; 224b: Protrusion; 225: Boss.

Claims

1. An angle sensor, comprising: stator; Rotor; The conductor is wound around the stator; Terminals for connecting the wires; Connector housing for securing the terminals; as well as The connecting part connects the stator and the connector housing. The terminal is fixed inside the connecting part. The connecting portion has a recess. The recess is opposite the stator in the direction of the rotor's rotation axis.

2. The angle sensor according to claim 1, The recess is a weight-reducing portion extending toward the stator direction and the connector housing direction.

3. The angle sensor according to claim 2, The recess has a transverse wall extending radially orthogonal to the direction of the rotation axis and a longitudinal wall extending along the direction of the rotation axis. The recess is located opposite the terminal.

4. The angle sensor according to claim 3, The connecting portion has a radially extending post located adjacent to the recess.

5. The angle sensor according to claim 4, The terminal has a portion along the transverse wall and a portion along the longitudinal wall. The portion along the transverse wall is connected to the portion along the longitudinal wall.

6. The angle sensor according to claim 5, The terminal has: The first component has a first exposed portion for connecting the wire; The second component has a second exposed portion protruding inside the connector housing; as well as The third component connects the first component and the second component. The third component has a portion along the transverse wall and a portion along the longitudinal wall. The portion along the transverse wall is connected to the first component. The portion along the longitudinal wall is connected to the second component.

7. The angle sensor according to claim 3, The connecting portion includes a first region extending radially and a second region extending axially. The terminals are disposed inside the first region and the second region. The axial dimension of the first region is smaller than the dimension of the longitudinal wall. The radial dimension of the second region is smaller than the dimension of the transverse wall.

8. The angle sensor according to claim 6, The terminal is provided in multiple parts, and the spacing between the first components is wider than the spacing between the second components.

9. The angle sensor according to claim 8, The third component includes an inclined portion that is inclined toward the radial side, a parallel portion that extends substantially parallel to the radial direction from the end of the inclined portion, and a vertical portion that extends toward the direction of the rotation axis from the end of the parallel portion.

10. The angle sensor according to claim 8, The third component has an inclined portion that tilts toward the radial side and a vertical portion that extends from the end of the inclined portion toward the direction of the rotation axis.

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