Structural components for a resolver, and a method for manufacturing a resolver.

Abstract

The present invention relates to a group of structural components 2 and 3 for a resolver 1, the group of structural components comprising a base body 4.1 and 4.2 arranged along axis A, a plurality of metal sheet lamination core segments 5a to 5p and wire windings 6, and at least one closing means 7a to 7p connected to the metal sheet lamination core segments 5a to 5p. [Solution] The base bodies 4.1 and 4.2 are formed in a ring shape and have a housing means 4.1.1 along the inner circumference of the base bodies, and the metal sheet layered core segments 5a to 5p are housed in a shape-engaged state within this housing means. Winding spaces 8 are arranged between the housing means 4.1.1 and around the outer circumference of the base bodies 4.1 and 4.2, and the wire windings 6 partially extend inside these winding spaces.

Description

[Technical Field]

[0001] In electrical engineering, an electromagnetic measuring transducer used to convert the angular position of a rotor into an electrical quantity or electrical signal is called a resolver. In this usage, the concept of "resolver" also encompasses measuring transducers referred to as synchros, rotational displacement detectors (Drehmelders), or rotary variable differential transformers (RVDTs). [Background technology]

[0002] For absolute position detection, the resolver comprises, for example, a stator winding and a rotor winding, which are positioned opposite each other. These wire windings, usually made from copper wire, are wound around a metal sheet laminated core formed from a single component, which has cavities for the wire windings. The rotor cavity is typically located on the outer side of the rotor's metal sheet layered core and can be mounted from the outside in a well-automated manner. However, with regard to the mounting of the stator windings, it has been found that, in most cases, the windings in the cavity located on the inner circumference can only be achieved by complex mechanical winding methods or manually.

[0003] Resolvers of this type are usually mass-produced, and therefore, a simple, highly automated manufacturing method for the stator and rotor is required.

[0004] Patent Document 1 provides a known resolver having a stator structure, in which the wire winding is placed from the outside. For this purpose, firstly, the stator core, which is formed to consist of a single member, is provided with a concave portion on the outer peripheral surface of the stator core. After the stator windings are placed into the recessed portion from the outer peripheral side, the housing ring is assembled onto the stator stratified core from the outside. Finally, the stator core is machined and scraped from the inner peripheral side, thus exposing the previously inserted recessed portion.

[0005] This type of stator structure has a drawback in terms of the rate of defective products, because the wire winding can be damaged when exposed to the recessed area. In addition, the structure of the stator structural components described is relatively time-consuming to manufacture and is also disadvantageous in terms of measurement accuracy. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 05-292721A [Overview of the project] [Problems that the invention aims to solve]

[0007] The fundamental problem of this invention is to propose a set of structural components for resolvers, which can be manufactured relatively efficiently and optimally through automation. [Means for solving the problem]

[0008] This problem is solved according to the features of claim 1 or claim 12 in accordance with the present invention. The advantageous configuration and further configurations are presented within the dependent claims, respectively. [Effects of the Invention]

[0009] The structural components according to the present invention for resolvers are: The main foundation is arranged along the axis, Multiple layered metal sheet core segments and wire windings are arranged in the foundation body, It comprises a layered metal sheet core segment and at least one closing means connected to it. The foundation body is formed in a ring shape and has a housing means along its inner circumference, within which the metal sheet layered core segments are housed in a shape-engaged state. Between the housing means, winding spaces are arranged around the outer circumference of the foundation body, and the wire windings partially extend inside these winding spaces.

[0010] The housing of the metal sheet lamination core segment in a morphologically engaged state by the housing means of the foundation body is characterized by a play-free engagement between both mating parts. In this case, the relative movement of the metal sheet lamination core segment is blocked in at least two directions, and advantageously, in all directions.

[0011] The housing means are arranged at equal distances from one another and extend in the axial direction. The housing means are formed, for example, by rectangular structures arranged radially, which form cavities for housing the metal sheet layered core segments.

[0012] Under the concept of "cavity," open cavities should be understood in particular; that is, the layered metal sheet core segments do not necessarily need to be forcibly and completely surrounded by a structure enclosing the main foundation body.

[0013] The winding space is located on the outer perimeter of the foundation body, between the housing means. The winding space is used as a laying passage for wire winding. In particular, the winding space is also formed by the housing means, which in turn serve to accommodate the metal sheet layered core segments, and are used as winding space limits for wire windings positioned between the winding space limits.

[0014] According to a further advantageous configuration of the invention, the group of structural components is the stator of the resolver.

[0015] In yet another embodiment, the base body has at least one tab extending in the circumferential direction, which has a radially oriented direction component on at least one end face of the base body and, additionally or alternatively, an axially oriented direction component.

[0016] The tab can, for example, be formed continuously in the circumferential direction, so that a laying passage oriented in the circumferential direction is formed between the tab and the winding space, which is simultaneously used as a winding space limitation for the part of the wire winding extending in the circumferential direction.

[0017] Alternatively, it is also possible to provide a plurality of tabs, which are arranged discontinuously in the circumferential direction.

[0018] Advantageously, the base body is formed to consist of a plurality of members or, alternatively, of one member and is molded from a non-magnetic material.

[0019] In particular, it is possible for the base body to be formed to consist of two members, so that the base body comprises a first base body member and a second base body member, which can be connected to each other. In that case, this connection position or these connection positions are advantageously located along the circumferential direction of both base body members.

[0020] Advantageously, the non-magnetic material is a deformable material having no ferromagnetic properties, for example a chemically or thermally plastifiable material, or a synthetic substance mixture, a synthetic resin, a ceramic, or glass.

[0021] In yet another embodiment, the base body is manufactured by an injection molding process or a lamination process.

[0022] The lamination process used to manufacture the base body can also be referred to as a three-dimensional printing process.

[0023] Furthermore, Each layered metal sheet core segment has a peripheral portion located radially inward, a connecting portion located radially outward, and a supporting portion positioned between them. The closing mechanism has a coupling mechanism, These bonding means are formed complementaryly to the bonding portions of the metal sheet layered core segments. The joint portion of the metal sheet lamination core segment is combined with the joint means of at least one closing means so as to engage with each other. This is intended.

[0024] The joint portion of the metal sheet lamination core segment comprises, for example, at least one concave portion, in which, in addition, at least one closing means joint is formed as a complementary convex portion. Selectively, the joint portion of the metal sheet lamination core segment may have a convex portion that is complementary to the concave portion formed in at least one closing means.

[0025] Advantageously, the coupling of the coupling portion of the metal sheet layered iron core segment with the coupling means of the closing means is The joint is made by one or more convex parts, for example, in the form of a dovetail joint. However, other bonding techniques, such as the use of conductive material structural bonding means for integrated material bonding, or welding, can also be considered.

[0026] In particular, a convex coupling configuration with a circular contour is advantageous because it induces favorable magnetic conductivity between the metal sheet layered core segment and the closing means.

[0027] Advantageously, the metal sheet layered core segments are formed such that the width of the joint portion is smaller than the width of the surrounding portion.

[0028] This configuration of the coupling allows for more favorable transmission of the magnetic flux contained by the surrounding portion toward the closing mechanism.

[0029] In yet another embodiment, at least one closing means is formed as a metal sheet lamination core and is configured as a closed ring around its periphery, or as a plurality of individual ring segments or ring sectors.

[0030] The closing means in the form of a ring segment is, in particular, a partial sector of a circular ring, for example, two semicircular rings, or a plurality of partial circular sectors of a circular ring.

[0031] In configuring the closing mechanism as a semicircular ring, it is advantageous, for example, to form these semicircular rings with rotational symmetry exceeding 90° in some areas.

[0032] In one embodiment of the closing mechanism as a partial circular sector, each closing mechanism of the closing mechanism is connected in the circumferential direction to the joint portion of two metal sheet layered core segments. In particular, the connection for each closing mechanism is made at at least two connecting portions, and these connecting portions are part of adjacent metal sheet layered core segments in the circumferential direction.

[0033] Advantageously, the layered metal sheet core segments are embedded within the foundation body. Therefore, the surrounding area and the main foundation are, On the inner cover surface of the structural component group, a nearly flat surface is formed, and, The foundation body extends to the portion supporting the layered metal sheet core segments.

[0034] The concept of "flat" should be understood in a relatively broad sense, that is, the inner cover surface of a group of structural components, curved with a defined radius, is extremely flat and free of irregularities when fully attached to the foundation body, which is made of layered metal sheet segments. In no case should it be understood that the inner cover surface represents a two-dimensional, linear plane in this context.

[0035] Therefore, the radius of curvature of the peripheral portion of the metal sheet layered core segment is essentially the same as the radius of curvature of the inner cover surface (web) of the foundation body: R U =R M,i At that time, R U := radius of the surrounding area R M,i := Radius of the outer cover surface of the foundation body; That is the case.

[0036] The housing means of the foundation body is formed such that the contour of the housing means corresponds to the contour of the supporting portion of the metal sheet layered core segment, and that it is in close contact with the supporting portion throughout the entire depth of the housing means. The housing means of the foundation body functions as an insulator between the layered metal sheet core segment and the wire winding arranged within the region of the supported portion, within the portion of the foundation body. The contact of the receiving means of the foundation body with respect to the outer contour of the layered metal sheet core segment is performed particularly within the region between the surrounding portion and the supported portion. The connecting portion protrudes beyond the receiving means and is therefore not embedded within the foundation body.

[0037] In yet another embodiment, The foundation body has a plurality of first tabs and a plurality of second tabs, each having a radial directional component, and the first and second tabs are arranged alternately along the circumferential direction.

[0038] A method according to the present invention for manufacturing a resolver having two groups of structural components that are rotatable relative to each other about an axis, For the manufacture of at least one of these structural component groups, the following steps are taken for each: namely, - At least partially embedding a layered metal core segment into a foundation body formed by an injection molding process or a lamination process. • Placement of wire windings on the outer perimeter of the foundation body within the winding space formed between the layered metal sheet core segments. • Combination of exposed portions of metal sheet layered core segments with at least one closing mechanism, The following steps are performed.

[0039] The placement of the wire windings on the outer perimeter of the foundation body is carried out from the outside, particularly using automated winding techniques, such as flyer winding, needle winding, or linear winding (Linearwickeltechnik). For example, the wire windings extend in the circumferential direction, partially across more than one layered metal core segment.

[0040] In yet another embodiment, the embedding of the metal sheet layered core segment is performed by inserting the metal sheet layered core segment into the housing means of the foundation body.

[0041] In this process, individual metal sheet layered core segments can be inserted into the housing means of the foundation body by, for example, in the radial or axial direction, by insertion (Einschieben) or pressing (Einpressen). Due to the configuration of the encapsulating means in a morphologically engaged state, the metal sheet lamination core remains within the cavity and is held in place by the encapsulating means. In other words, the manufacture of the foundation body and the embedding of the metal sheet lamination core segments are carried out in two separate steps.

[0042] In order to fix the metal sheet lamination core segments in a non-detachable state, it is possible that, supplementarily, a material structural integral bonding means, such as an adhesive, may be applied to the housing means prior to the insertion of the metal sheet lamination core segments.

[0043] In yet another selective embodiment, the embedding of the metal sheet lamination core segment is carried out by forming a foundation body by extruding the metal sheet lamination core segment.

[0044] In other words, the manufacturing of the foundation body and the burying of the layered metal sheet core segments are carried out in the same step.

[0045] If the foundation body is manufactured, for example, by an injection molding process, individual metal sheet layered core segments are loaded into an injection molding tool, and subsequently, a fluid material is injected.

[0046] If the foundation body is manufactured selectively by a lamination process, the metal sheet lamination core segments are positioned on the foundation body precursor after the generation of the initial layers on the lower foundation, and the extrusion coating of the metal sheet lamination core segments is continued in parallel with the layers touching each other until the foundation body is completely formed.

[0047] Advantageously, the wire windings are mounted from the radially outward direction and along the outer perimeter of the structural components.

[0048] When the wire winding is installed, the winding wire is loaded into a winding space located around the outer perimeter of the structural components to be wound, such as the stator, using, for example, flyer winding technology (also known as "flying wire"). The wire windings are supplied via rollers, or through nozzles mounted on a rotating disc, i.e., a flyer that rotates at predetermined intervals relative to a group of structural components. The wire winding is defined and wound around at least one metal sheet lamination core segment, which is insulated by a housing means. The flyer is advantageously movable in the circumferential and radial directions with respect to the structural components.

[0049] The placement of wire windings, starting from the inner perimeter of the structural components, is therefore not intended. This is true both when the structural components are formed as a rotor and when they are formed as a stator.

[0050] The present invention will be described in more detail below, similarly with respect to other features and advantages, based on the description of the examples and in reference to the accompanying schematic diagrams. [Brief explanation of the drawing]

[0051] [Figure 1] This is a diagram illustrating an embodiment of a resolver having a stator and a rotor. [Figure 2] This is a diagram showing an example of the structural components of a resolver in an exploded view. [Figure 3] This is a perspective view showing an embodiment of the first base body member of the resolver. [Figure 4] This is a perspective view showing an embodiment of the second base body member of the resolver. [Figure 5] This is a diagram showing an embodiment of a metal thin sheet layered core segment in a front view. [Figure 6] This is a diagram showing an embodiment of the closing mechanism in the front view. [Figure 7] This is a diagram of the first work step for assembling the structural components of a resolver. [Figure 8] Figure 7 shows yet another work step for assembling the structural components of the resolver. [Figure 9] Figures 7 and 8 show yet another work step for combining the structural components of the resolver. [Figure 10]This is a cross-sectional view of the structural components of the resolver. [Modes for carrying out the invention]

[0052] A specific embodiment of the present invention will be described more precisely below, with reference to the figures.

[0053] In this case, Figure 1 shows a resolver 1 comprising a stator 3 and a rotor 2, with the stator and rotor arranged concentrically with respect to axis A. In the case of the resolver 1 shown, the stator 3 is formed to consist of multiple members, and therefore, winding can be done from the outside during the manufacture of this stator, which will be explained in more detail below. The rotor 2 shown is merely illustrative and is formed as a rotor core with a changing contour. However, in addition to the rotor type shown in Figure 1, other rotor types, such as the wound magnetic field type (Typ Wickelfeld), are also possible, in which case the excitation winding is located on top of the rotor 2.

[0054] Figure 2 shows an exploded view of a stator 3 according to the present invention, which is arranged along axis A. The stator 3 comprises a base body 4.1, 4.2 formed from multiple members, a group of metal sheet lamination core segment structural components (Blechpaketsegmentebaugruppe) 5, a group of closing means structural components (Schlussmittelbaugruppe) 7, and wire windings (Drahtwicklungen) 6 (not shown in Figure 2).

[0055] The foundation body consists of a first foundation body member 4.1 and a second foundation body member 4.2, which are connectable to each other.

[0056] The metal sheet layered core segment structural component group 5 comprises multiple metal sheet layered core segments 5a to 5p, which are arranged concentrically around axis A and at the same intervals relative to axis A.

[0057] For better visibility, each metal sheet layered core segment does not have its own unique reference code in Figure 2. However, it is self-evident that the alphanumeric reference code in the circumferential direction U is logically continued for each further metal sheet layered core segment.

[0058] The closing mechanism structural component group 7 comprises a plurality of closing mechanisms 7a to 7p according to the shown embodiment, which are arranged concentrically with respect to axis A and at the same intervals with respect to axis A.

[0059] For better visibility, each closing mechanism does not have its own unique reference code in Figure 2. However, it is self-evident that the alphanumeric reference code in the circumferential direction U is logically continued for each further closing mechanism.

[0060] The stator shown is not limited to the 16 metal sheet lamination core segments 5a to 5p or the 16 closing means 7a to 7p shown in Figure 2; that is, it is possible to have more or fewer metal sheet lamination core segments or closing means. In particular, the number of closing mechanisms does not necessarily have to correspond to the number of metal sheet layered core segments.

[0061] The individual structural components of stator 3 are interconnected in their assembled state, and this will be explained in more detail within the scope of the manufacturing process shown in Figures 7 through 9.

[0062] Embodiments of the foundation body, comprising first and second foundation body members 4.1 and 4.2, are shown in Figures 3 and 4.

[0063] The first base body member 4.1 is formed as a ring-shaped injection-molded member and is equipped with a plurality of rectangular housing means 4.1.1 extending in the axial direction, and these housing means extend spaced apart around the entire circumference of the first base body member. Each of the two directly adjacent housing means 4.1.1 is approximately U-shaped, connected to one another via a web 4.1.5 extending in the circumferential direction U, thereby forming a winding space 8 (see Figure 10) between these housing means.

[0064] The web 4.1.5 protrudes axially beyond the receiving means 4.1.1 at both ends of the web and includes a second tab 4.1.2 at one end that is radially aligned and another second tab 4.1.3 at the other end that is radially aligned. Both of the second tabs 4.1.2 and 4.1.3 are used as winding space limits or, in combination with the protruding portion of the web 4.1.5, as laying pathways for the portion of the wire winding 6 that is aligned in the circumferential direction U.

[0065] Each of the two adjacent accommodating means 4.1.1, which are not connected by a web 4.1.5, has a first tab 4.1.4 between them. This first tab 4.1.4 is rectangular in shape and extends perpendicular to the accommodating means 4.1.1 and in the circumferential direction U. These first tabs 4.1.4 advantageously project radially beyond the accommodating means 4.1.1. In addition, the first tab 4.1.4 extends only over the region located between two adjacent containment means 4.1.1 that are not connected by the web 4.1.5 in the circumferential direction U.

[0066] The radial direction is defined as a single direction, which points outward from axis A (the center point).

[0067] The receiving means 4.1.1, the web 4.1.5, the first tab 4.1.4, and the second tabs 4.1.2 and 4.1.3 are all connected and formed together, and together they form a first base body member 4.1 which consists of a single component.

[0068] Figure 4 shows a second base body member 4.2, which is similarly formed as a ring-shaped injection-molded member and has a first tab in the form of a ring-shaped disc 4.2.0 that is closed in the circumferential direction U. Multiple rectangular second tabs 4.2.2 are arranged on one of the end surfaces of the ring-shaped disc 4.2.0 and located radially inward. These second tabs 4.2.2 project axially perpendicular to the end surface of the ring-shaped disc 4.2.0 and are spaced apart from each other in the circumferential direction U.

[0069] The second base body member 4.2 is further provided with another second tab in the form of alignment pins 4.2.1 (Ausrichtestiften), which are positioned axially and perpendicular to the end face, and the second tab 4.2.2 is also located on this end face. The alignment pins 4.2.1 are located radially outward on the end surface of the ring-shaped disc 4.2.0. Advantageously, in this case, each alignment pin 4.2.1 is positioned opposite a second tab 4.2.2 and aligns with this second tab in the circumferential direction. The alignment pins (Zentrierstifte) 4.2.1 may have other suitable cross-sectional geometric shapes in addition to the semicircular cross-section illustrated in Figure 4, the cross-sectional geometric shapes of which are complementary to the concave portions 7.3 of the closing means 7a to 7p.

[0070] The ring-shaped disc 4.2.0, the second tab 4.2.2, and the centering pin 4.2.1 are all connected and formed together, and therefore together they form a second base body member 4.2 which consists of a single component.

[0071] The structure of the metal sheet layered core segment according to the present invention is described below, illustratively, with respect to the metal sheet layered core segment 5a shown in Figure 5, where the remaining metal sheet layered core segments 5b to 5p are formed identically.

[0072] The T-shaped layered metal core segment 5a comprises a peripheral portion 5.1, a connecting portion 5.3, and a supporting portion 5.2 positioned between the peripheral portion 5.1 and the connecting portion 5.3.

[0073] The supporting portion 5.2 is radially aligned and has an approximately rectangular cross-section. The supporting portion 5.2 has a first side surface 5.2.1 and a second side surface 5.2.2, which are in contact with the corresponding housing portion 4.1.1 after the metal sheet layered core segment 5a is embedded in the foundation body 4.1, 4.2.

[0074] A connecting portion 5.3 is positioned on the supporting portion 5.2, and this connecting portion is located radially outward with respect to axis A. The connecting portion 5.3 has a first side surface 5.3.1 and a second side surface 5.3.2, and these first and second sides are used as contact surfaces for one closing means 7a to 7p each. The first side surface 5.3.1 and the second side surface 5.3.2 of the connecting portion 5.3 each have one concave portion 5.4.1, 5.4.2, and these, or these concave portions, are formed complementary to the convex portions 7.4.1, 7.4.2 of the corresponding closing means 7a to 7p. The transition portion 5.3.3 between the first side surface 5.2.1 of the supporting portion 5.2 and the first side surface 5.3.1 of the connecting portion 5.3 is formed continuously and has a defined curvature. The same applies to the transition portion 5.3.4 between the second side surface 5.2.2 of the supporting portion 5.2 and the second side surface 5.3.2 of the connecting portion 5.3, which also has a defined curvature. The connecting portion 5.3 also includes a second side surface 5.3.5, which is positioned between the first side surface 5.3.1 and the second side surface 5.3.2. The second side surface 5.3.5 forms the outer cover surface of the stator 3 and is curved in the circumferential direction U.

[0075] As can be seen from Figure 5, the connecting portion 5.3 is formed to be wider than the supporting portion 5.2 in the circumferential direction U, that is, the connecting portion 5.3 protrudes beyond the supporting portion 5.2.

[0076] The width of the joint portion 5.3 in the circumferential direction U is the reference code width B in Figure 5. V And that's what's shown.

[0077] In addition to the supporting portion 5.2, a peripheral portion 5.1 is positioned thereon, which is formed by curving along the circumferential direction U and protrudes beyond the first and second sides 5.2.1, 5.2.2 of the supporting portion 5.2, as well as beyond the first and second sides 5.3.1, 5.3.1 of the connecting portion 5.3. The surrounding portion 5.1 is positioned radially on the connecting portion 5.3 and is closer to axis A than the connecting portion 5.3 or the supporting portion 5.2. The peripheral portion 5.1 includes a first side surface 5.1.1, which forms a partial surface of the inner cover surface of the stator 3. The first side surface 5.1.1 is formed to be curved in the circumferential direction U.

[0078] The width of the peripheral portion 5.1 in the peripheral direction U is the reference code width B in Figure 5. UAnd that's what's shown.

[0079] As can be clearly seen in Figure 5, the width B of the joint portion 5.3 V The surrounding portion has a width of 5.1 B. U It is smaller than this. This configuration of the coupling portion 5.3 allows for a more favorable transmission of the magnetic flux contained by the surrounding portion 5.1 to the closing means 7a-7p.

[0080] The metal sheet layered core segment 5a consists of a plurality of individual metal sheets, which are stacked in the direction of the illustrated plane in Figure 5 (i.e., the z-direction in Figure 1). The individual metal sheets of the metal sheet layered core segment 5a are punched out from soft magnetic metal sheets and have a thickness between 0.1 mm and 1.0 mm.

[0081] The structure of the closing means 7a according to the present invention will be described below, illustratively, with respect to the closing means 7a shown in Figure 6, where the remaining closing means 7b to 7p are formed identically.

[0082] The closing mechanism 7a is formed in a ring-fan shape with respect to the basic shape of the closing mechanism, and comprises a first radial side surface 7.1.1, a second radial side surface 7.1.2, and a first side surface 7.3.1 and a second side surface 7.3.2 curved in the circumferential direction U.

[0083] The first and second sides 7.1.1 and 7.1.2 are each used as contact surfaces for the joint portions 5.3 of the metal sheet lamination core segments 5a to 5p. For this purpose, the first and second sides 7.1.1 and 7.1.2 each have one (or more) convex portions 7.4.1 and 7.4.2, respectively, which are formed complementary to the corresponding concave portions 5.4.1 and 5.4.2 of the metal sheet lamination core segment 5a. The first side 7.3.1 and the second side 7.3.2 are positioned between the first side 7.1.1 and the second side 7.1.2.

[0084] The first side surface 7.3.1 is provided with a concave portion 7.3, which is used to accommodate the centering pin 4.2.1 of the second base body member 4.2 (see Figures 8 and 10).

[0085] The second side 7.3.2 is located further inward than the first side 7.3.1 in the radial direction with respect to axis A.

[0086] The closing mechanism 7a consists of a plurality of individual metal sheets, which are stacked in the direction of the illustrated plane in Figure 6 (i.e., the z-direction in Figure 1). The individual metal sheets of the closing mechanism 7a are punched out from soft magnetic metal sheets and have a thickness between 0.1 mm and 1.0 mm.

[0087] The method for manufacturing the stator 3 according to the present invention will be described in more detail below, in reference to Figures 7 to 9.

[0088] As shown in Figure 7, firstly, the group of metal sheet layered core segment structural components 5 is embedded into the foundation body 4.1 by inserting the individual metal sheet layered core segments 5a to 5p. For this purpose, individual metal sheet lamination core segments 5a to 5p are inserted such that these metal sheet lamination core segments are housed by the housing portion 4.1.1 in a morphologically engaged state and, advantageously, in a similarly frictional engaged state, and are protected against sliding displacement. Each individual metal sheet lamination core segment 5a to 5p is inserted axially until it contacts the first tab 4.1.4 of the first base body member 4.1.

[0089] The housing means 4.1.1 of the first base body member 4.1 allows the individual metal sheet layered core segments 5a to 5p to be positioned within the region of the surrounding portion 5.1, spaced apart from one another, that is, gaps exist between the individual metal sheet layered core segments 5a to 5p in the surrounding portion 5.1 in the form of voids. This ensures that, when resolver 1 is in operation, the magnetic resistance between the metal lamination core segments 5a, via at least one closing means 7a to 7p, to one adjacent metal lamination core segment 5b or 5p is smaller than that via a direct path, i.e., via the gap between metal lamination core segments 5a and 5b, or 5a and 5p, within the region of the surrounding portion 5.1. Needless to say, the same applies to all other metal sheet stratified core segments 5a to 5p. In other words, the gaps ensure that the magnetic field lines guided by the metal sheet stratified core segments 5a to 5p are closed off through the closing means 7a to 7p, and that they do not take any "shortcuts" from pole to pole within the region of the surrounding portion 5.1.

[0090] After the combination of the first base body member 4.1 with the group of metal sheet layered core segment structural components 5, the wire winding 6 can be mounted via a suitable winding technique which is advantageously automated. In this process, each individual wire winding 6 is wound onto the housing means 4.1.1 and the first tab 4.1.4 within the area of ​​each individual carrying portion 5.2 (not shown in Figures 7 and 9).

[0091] In this case, the configuration of the metal sheet layered core segments 5a to 5p according to the present invention, and the arrangement of these metal sheet layered core segments on a single metal sheet layered core segment structural component group 5 in combination with the first base body member 4.1, makes it possible to wind them from the outside. In other words, it is particularly advantageous that the filling of each winding space 8 is performed from the outside (the outer cover surface of the structural components) and not, as in the stator 3, via the otherwise conventional inner perimeter (the inner cover surface of the structural components).

[0092] As can be seen in Figure 8, the group of closing means structural components 7 is embedded within the second base body member 4.2 by inserting the individual closing means 7a to 7p. For this purpose, each of the individual closing means 7a to 7p is inserted into the cavity between the second tab 4.2.2 and the opposing alignment pin 4.2.1. Each of the closing means 7a to 7p is accordingly aligned via a centering pin 4.2.1 housed within a recessed portion 7.3, and is protected from sliding misalignment, with the second side 7.3.2 of the closing means contacting the second tab 4.2.2 and being housed within a recessed portion 7.3. Each of the closing means 7a to 7p is inserted axially until it contacts the ring-shaped disc 4.2.0 of the second base body member 4.2.

[0093] Figure 9 shows a second combined structural component group comprising a second base body member 4.2 and a closing means structural component group 7, into which This shows the insertion of a first combined structural component group, which comprises a first base body member 4.1 and a group of metal sheet layered core segment structural components 5.

[0094] In the insertion process shown in Figure 9, the connecting portion 5.3 of the metal sheet lamination core segments 5a to 5p is combined with the closing means 7a to 7p, and so the convex portions 7.4.1 and 7.4.2 of the closing means 7a to 7p and the concave portions 5.4.1 and 5.4.2 of the metal sheet lamination core segments 5a to 5p engage with each other, for example, by interference fit.

[0095] Figure 10 shows a cross-sectional view of the stator 3, including the wire windings 6 arranged within the winding space 8. The winding space 8 is demarcated in the axial direction by the second tabs 4.1.2 and 4.1.3 of the first base body member 4.1, and in the radial direction by the web 4.1.5 and the second tab 4.2.2 of the second base body member 4.2.

[0096] The present invention has been described above in relation to several currently advantageous embodiments. It is, however, self-evident that further modifications and embodiments can be realized without departing from the appended claims.

[0097] Therefore, for example, structural component groups 2 and 3 can also be a wound magnetic field type rotor 2 alongside the stator 3. In this case, the metal sheet layered core segments 5a to 5p are arranged in reverse in the radial direction, that is, the peripheral portion 5.1 is located radially outward with respect to axis A, and the connecting portion 5.3 is located radially inward. The peripheral portions 5.1 of the metal sheet layered core segments 5a to 5p, which are curved in the circumferential direction U, in this case form the outer circumference of the rotor 2. The coupling portion 5.3 and at least one closing means 7a to 7p are located in this case on the inner circumference of the ring-shaped rotor 2. [Explanation of Symbols]

[0098] 1 resolver 2 rotors 3 stator 4. Foundation 4.1 First Foundation Body Member 4.1.1 Housing means for the first foundation body member 4.1.2 Second tab of the first foundation main member 4.1.3 Another second tab of the first foundation body member 4.1.4 First tab of the first foundation main member 4.1.5 Web of the First Basic Body Member 4.2 Second Basic Body Member 4.2.0 Ring-shaped Disc of the Second Basic Body Member 4.2.1 Alignment Pin of the Second Basic Body Member 4.2.2 Second Tab of the Second Basic Body Member 5 Metal Sheet Laminated Core Segment Structural Parts Group 5a - 5p Metal Sheet Laminated Core Segments 5.1 Peripheral Portion of the Metal Sheet Laminated Core Segment 5.1.1 First Side of the Metal Sheet Laminated Core Segment 5.2 Support Portion of the Metal Sheet Laminated Core Segment 5.2.1 First Side of the Support Portion 5.2.2 Second Side of the Support Portion 5.3 Connection Portion of the Metal Sheet Laminated Core Segment 5.3.1 First Side of the Connection Portion 5.3.2 Second Side of the Connection Portion 5.3.3 First Transition Portion 5.3.3 5.3.4 Second Transition Portion 5.3.4 5.3.5 Second Side of the Metal Sheet Laminated Core Segment 6 Wire Winding 7 Closing Means Structural Parts Group 7a - 7p Closing Means 7.1.1 First Side of the Closing Means 7.1.2 Second Side of the Closing Means 7.3 Concave Portion of the Closing Means 7.3.1 First Side of the Closing Means 7.3.2 Second Side of the Closing Means 7.4.1 First Convex Portion of the Closing Means 7.4.1, 7.4.2 7.4.2 Second Convex Portion of the Closing Means 8 Winding Space A Axis U Peripheral Direction B V Width of the Connection Portion B U Width of the Peripheral Portion R URadius of the surrounding area R M,i Radius of the outer cover surface of the foundation body

Claims

1. A group of structural components (2, 3) for resolver (1), and this group of structural components is The foundation bodies (4.1, 4.2) are arranged along the axis (A), Multiple metal sheet layered core segments (5a to 5p) and wire windings (6), It comprises a layered metal sheet core segment (5a to 5p) and at least one closing means (7a to 7p) connected thereto, The foundation body (4.1, 4.2) is formed in a ring shape and has a housing means (4.1.1) along the inner circumference of the foundation body, and the metal thin sheet layered core segments (5a to 5p) are housed within this housing means in a shape-engaged state. Between the housing means (4.1.1), winding spaces (8) are arranged around the outer perimeter of the base body (4.1, 4.2), and the wire windings (6) partially extend inside these winding spaces. A group of structural components characterized by the following features.

2. The structural component group (3) is a stator for the resolver (1), as described in claim 1.

3. The structural component group according to any one of claims 1 to 2, characterized in that the foundation body (4.1, 4.2) has at least one tab (4.1.2, 4.1.3, 4.1.4, 4.2.2) extending in the circumferential direction (U) having radial and / or axially aligned directional components on at least one end surface of the foundation body.

4. The structural component group according to any one of claims 1 to 3, characterized in that the base body (4) is made up of multiple members and is formed from a non-magnetic material.

5. The structural components according to any one of claims 1 to 4, characterized in that the base body (4.1, 4.2) is manufactured by an injection molding process or an additive manufacturing process.

6. A group of structural components according to any one of claims 1 to 5, Each of the layered metal sheet core segments (5a to 5p) has a peripheral portion (5.1) located radially inward, a connecting portion (5.3) located radially outward, and a supporting portion (5.2) positioned between them. - The closing means (7a to 7p) has coupling means (7.4.1, 7.4.2), These bonding means are formed complementaryly to the bonding portions (5.3) of the metal thin sheet layered core segments (5a to 5p). - The connecting portion (5.3) of the metal sheet layered core segment (5a-5p) is combined with the connecting means (7.4.1, 7.4.2) of the closing means (7a-7p) so as to engage with each other. A group of structural components characterized by the following features.

7. The layered metal sheet core segments (5a to 5p) have a joint portion (5.3) with a width (B Ｖ ) is the width of the surrounding part (5.1) (B Ｕ The group of structural components according to claim 6, characterized in that they are formed to be smaller than ).

8. The structural component group according to any one of claims 1 to 7, characterized in that at least one closing means (7a to 7p) is formed as a metal sheet layered core and is formed as a closed ring around its periphery, or comprises a plurality of ring segments.

9. The structural components according to claims 6 and 8, characterized in that each ring segment of at least one closing means (7a to 7p) is connected in the circumferential direction (U) to two connecting portions (5.3) of the metal sheet layered core segments (5a to 5p).

10. The layered metal sheet core segments (5a to 5p) are embedded within the foundation body (4.1). Therefore, the surrounding portion (5.1) and the foundation body (4.1) form a flat surface, and The foundation body (4.1) extends to the supporting portion (5.2) of the layered metal sheet core segments (5a to 5p). The group of structural components according to feature 6.

11. The foundation body (4.1, 4.2) has a plurality of first tabs (4.1.4) and a plurality of second tabs (4.1.2, 4.1.3) having a radial directional component, The first and second tabs (4.1.4; 4.1.2, 4.1.3) are arranged alternately along the circumferential direction U. The group of structural components according to feature 3.

12. A method for manufacturing a resolver (1) having two groups of structural components (2, 3) that are rotatable relative to an axis (A), For the manufacture of at least one of these structural component groups (2, 3), the following steps are taken: - At least partially embedding metal sheet layered core segments (5a to 5p) into a base body (4.1) formed by an injection molding process or a lamination process, - Placement of the wire winding (6) on the outer circumference of the foundation body (4.1) within the winding space (8) formed between the layered metal sheet core segments (5a to 5p), - Combination of exposed portions of metal sheet layered core segments (5a to 5p) by at least one closing means (7a to 7p), A method characterized by the following steps being performed.

13. The method according to 12, characterized in that the burying of the metal sheet layered core segments (5a to 5p) is performed by inserting the metal sheet layered core segments (5a to 5p) into the housing means (4.1.1) of the foundation body (4.1).

14. The method according to 12, characterized in that the burying of the metal sheet layered core segments (5a to 5p) is carried out by forming the foundation body (4.1, 4.2) by extruding the metal sheet layered core segments (5a to 5p).

15. The method according to any one of 12 to 14, characterized in that the wire winding (6) is placed from the radially outward direction and along the outer circumference of the structural component group (2, 3).

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