Angle sensor and rotary device

Abstract

An angle sensor (1) is provided with: a rotor (2); a base (4) that faces the rotor (2) in the direction of an axis x; a plurality of conductive wires (5) that extend in the circumferential direction; and an electronic component (6) that is electrically connected to the conductive wires (5). The base (4) is provided with a first region (4A) and a second region (4B) surrounding the first region (4A). The electronic component (6) is provided in the first region (4A), and the plurality of conductive wires (5) which are provided in the second region (4B) form undulating shapes in the radial direction.

Description

Angle sensors and rotating devices

[0001] The present invention relates to an angle sensor and a rotating device, and more particularly to an inductive angle sensor and a rotating device equipped with an inductive angle sensor.

[0002] 2. Description of the Related Art Conventionally, in rotating devices, various sensors have been used to detect the rotation angle of a shaft (see, for example, Patent Document 1).

[0003] Japanese Patent Application Laid-Open No. 2022-068860

[0004] Conventional sensors have room for improvement in terms of space saving.

[0005] Therefore, an object of the present invention is to provide an angle sensor and a rotating device that can reduce the space they occupy.

[0006] The angle sensor of the present invention comprises a rotor, a base facing the rotor in the axial direction, a plurality of conductors extending circumferentially, and electronic components electrically connected to the conductors, wherein the base comprises a first region and a second region surrounding the first region, the electronic components are provided in the first region, and the plurality of conductors provided in the second region form an undulating shape in the radial direction.

[0007] FIG. 1 is an exploded perspective view of an angle sensor according to an embodiment of the present invention; FIG. 2 is an exploded perspective view showing a portion of the angle sensor in a see-through manner; FIG. 3 is a front view of a rotor in the angle sensor; FIG. 4 is a rear view of a stator in the angle sensor; FIG. 5 is a front view of the stator; FIG. 6 is a side view of the stator; FIG. 7 is a front view of the stator in an angle sensor in a see-through manner showing a base; FIG. 8 is a perspective view showing a schematic configuration of a plurality of conductors in the angle sensor; FIG. 9 is a front view of a stator according to a modified example; FIG. 10 is an exploded perspective view of a specific example of a rotating device to which the angle sensor is applied; FIG. 11 is an exploded perspective view of a rotating device according to a modified example.

[0008] An embodiment of the present invention will now be described with reference to the accompanying drawings. Note that in the drawings, not all components are designated by reference numerals, and some of the reference numerals of the components may be omitted. FIG. 1 is an exploded perspective view of an angle sensor 1 according to an embodiment of the present invention, and FIG. 2 is a partially see-through exploded perspective view of the angle sensor 1. As shown in FIG. 1, the angle sensor 1 includes a rotor 2, a base 4 facing the rotor 2 in the direction of the axis x, a plurality of conductors 5 extending circumferentially, and an electronic component 6 electrically connected to the conductors 5. The base 4 includes a first region 4A and a second region 4B surrounding the first region 4A. The electronic component 6 is provided in the first region 4A, and the plurality of conductors 5 provided in the second region 4B form an undulating shape in the radial direction. The configuration of the angle sensor 1 will now be described in detail. The illustrated axis x is the rotation axis of the angle sensor 1. The radial direction is a direction perpendicular to the axis x, and the circumferential direction is a direction around the axis x. The base 4 is also shown in perspective in Figure 2. When the angle sensor 1 is attached to an application target and in use, the rotor 2 and the base 4 face each other with a predetermined gap in the direction of the axis x.

[0009] FIG. 3 is a front view of the rotor 2. As shown in FIGS. 1 to 3, the rotor 2 is a roughly disk-shaped member and has a plurality of protrusions 11, which are portions extending in the radial direction. The rotor 2 also has a ring 12, as shown in FIGS. 1 to 3, for example. The ring 12 is a portion extending annularly around the axis x. The plurality of protrusions 11 are connected to the outer peripheral surface 12a of the ring 12. Each of the plurality of protrusions 11 is plate-shaped and has a pair of surfaces, an opposing surface 11a and a back surface 11b, facing back to back. The opposing surface 11a faces the axis x direction and faces the base 4 in the axis x direction. The ring 12 has an inner peripheral surface 12b. The inner peripheral surface 12b is a surface facing back to the outer peripheral surface 12a and is a cylindrical surface extending in the axis x direction. The inner peripheral surface 12b forms a through hole in the ring 12 extending in the axis x direction. 1 to 3, an opening 13 is provided between two adjacent protrusions 11 among the plurality of protrusions 11. The opening 13 forms a space between the two adjacent protrusions 11 that penetrates the rotor 2 in the direction of the axis x. The plurality of protrusions 11 are, for example, arranged at equal or approximately equal angular intervals in the circumferential direction. For example, as shown in FIG. 3, the plurality of protrusions 11 have a fan-shaped or approximately fan-shaped shape.

[0010] The protrusions 11 have a conductor at least in part. The conductor may be any member having a conductive material, such as a metal body 10 made of metal. The member having a conductive material is a member capable of generating so-called eddy currents or induced currents (electric currents) within one surface. As an example, the protrusions 11 are entirely made of metal. That is, the entire protrusions 11 are the metal body 10. As an example, the ring 12 is made of the same metal as the multiple protrusions 11, and the rotor 2 is, for example, the integrally formed metal body 10. The multiple protrusions 11 and the ring 12 may be formed separately, and the rotor 2 may be formed by connecting the multiple protrusions 11 and the ring 12. In this case, the ring 12 may be made of a different material from the protrusions 11. For example, the ring 12 may be made of a resin material. As described above, the protrusions 11 may have a conductor in at least a portion, and a portion of the protrusions 11 may be the metal body 10. 3, the rotor 2 may have a plurality of metal bodies 10, and the plurality of metal bodies 10 may be attached to portions of a plurality of protrusions 11 that face the base 4 in the direction of the axis x. In this case, the metal bodies 10 may be embedded in the protrusions 11 or attached to the surfaces of the protrusions 11. The metal bodies 10 may also be embedded in the protrusions 11 so that a portion of the metal bodies 10 is exposed. For example, the metal bodies 10 may be embedded in or attached to the opposing surfaces 11a of the protrusions 11 that face the conductor wires 5 in the direction of the axis x, or may be embedded in or attached to the back surfaces 11b.

[0011] As shown in Figures 1 and 2, the angle sensor 1 has a stator 3. The stator 3 has a base 4, a plurality of conductors 5, and electronic components 6. Figure 4 is a rear view of the stator 3, Figure 5 is a front view of the stator 3, Figure 6 is a side view of the stator 3, and Figure 7 is a front view of the stator 3 showing the base 4 through perspective. Note that lead wires 30, which will be described later, are not shown in Figure 7. Figures 4 to 6 also respectively show a rear view, a front view, and a side view of the base 3. The base 4 is, for example, integrally molded from the same material. The base 4 is an insulating member, for example, made of resin.

[0012] The base 4 is made of, for example, a resin material, a non-magnetic material, a non-conductive material, or the like. The non-magnetic material may be non-conductive. As shown in Fig. 7, a plurality of conductive wires 5 are embedded inside the base 4. As shown in Fig. 5, some of the plurality of conductive wires 5 may be exposed from the base 4.

[0013] The base 4 has one surface (hereinafter referred to as the front surface) 21 and the other surface (hereinafter referred to as the back surface) 22 in the direction of the axis x. The front surface 21 faces the rotor 2, and the other surface, the back surface 22, is provided with lead wires 30, which will be described later. For example, as shown in FIGS. 4 to 6 , the base 4 is a plate-shaped member, and the front surface 21 and the back surface 22 face back to back. The base 4 also has an outer edge 23, which is its radially outer edge. The base 4 is a solid member and does not have a through-hole on its inner circumferential side. As shown in FIGS. 1 and 2 , the front surface 21 faces the rotor 2 in the direction of the axis x. The front surface 21 extends, for example, along a plane perpendicular to the axis x. The outer edge 23 faces outward in the radial direction.

[0014] As described above, the base 4 has a first region 4A and a second region 4B surrounding the first region. As shown in FIGS. 4, 5, and 7, the second region 4B is a portion of the base 4 that is annular about the axis x and extends radially outward (hereinafter also referred to as the outer peripheral side) to the outer edge 23. Also, as shown in FIGS. 4, 5, and 7, the first region 4A is a portion of the base 4 that is radially inward (hereinafter also referred to as the inner peripheral side) of the second region 4B. Thus, the region of the base 4 extending from the axis x to a predetermined position toward the outer periphery is the first region 4A, and the region extending from this predetermined position toward the outer periphery is the second region 4B. This predetermined position, which is the boundary between the first region 4A and the second region 4B (the imaginary line L in FIGS. 4, 5, and 7), is determined based on, for example, the region that faces the multiple protrusions 11 or the multiple metal bodies 10 of the rotor 2 in the direction of the axis x during use. Specifically, the above-mentioned predetermined position (boundary L) is set so that, for example, the area of ​​the base 4 that faces the multiple protrusions 11 or multiple metal bodies 10 of the rotor 2 in the axial x direction is included in the second area 4B.

[0015] As described above, the plurality of conducting wires 5 are provided in the second region 4B. Therefore, when the angle sensor 1 is in use, the plurality of conducting wires 5 face the plurality of protrusions 11 of the rotor 2 or the metal body 10 in the direction of the axis x. The plurality of conducting wires 5 are embedded in the second region of the base 4, for example, as shown in FIGS. 4 to 7 . The plurality of conducting wires 5 may be entirely embedded in the second region 4B of the base 4, or may be partially embedded in the second region 4B of the base 4. Specifically, for example, as shown in FIG. 5 , the plurality of conducting wires 5 may be partially exposed from the surface 21 of the base 4 in the second region 4B of the base 4. The plurality of conducting wires 5 do not have to be embedded in the base 4 in the second region 4B. In this case, for example, the plurality of conducting wires 5 are provided on the surface 21 or the back surface 22 in the second region 4B of the base 4.

[0016] As shown in FIG. 7 , the base 4 has an annular excitation coil 8 in the second region 4B. The excitation coil 8 is made of a conductive material. The excitation coil 8 forms a magnetic circuit that generates a periodically changing magnetic flux acting on each of the plurality of conductors 5. As shown in FIG. 7 , the excitation coil 8 surrounds the plurality of conductors 5 in the radial direction. That is, in the second region 4B of the base 4, the plurality of conductors 5 are located on the inner periphery of the excitation coil 8. For example, as shown in FIG. 7 , the excitation coil 8 is embedded in the second region 4B of the base 4. Note that the excitation coil 8 may be entirely embedded in the second region 4B of the base 4, or may be partially embedded in the second region 4B of the base 4. Specifically, for example, as shown in FIG. 5 , a portion of the excitation coil 8 may be exposed from the surface 21 of the base 4 in the second region 4B. The excitation coil 8 does not have to be embedded in the base 4 in the second region 4B. In this case, for example, the excitation coil 8 is provided on the front surface 21 or the back surface 22 of the base 4 in the second region 4B.

[0017] As shown in Fig. 7 , the outer edge 23 of the base 4 is located on the outer periphery of the excitation coil 8 and surrounds the excitation coil 8. In other words, the outer edge 23 of the base 4 surrounds the excitation coil 8 on the inner periphery. For example, as shown in Fig. 7 , the outer edge 23 of the base 4 extends along the excitation coil 8 and extends in the vicinity of the excitation coil 8. Specifically, for example, the outer edge 23 of the base 4 is a cylindrical surface or an approximately cylindrical surface with the axis x as the central axis or approximately the central axis.

[0018] FIG. 8 is a perspective view showing a schematic configuration of multiple conductors 5. As described above, each of the multiple conductors 5 forms an undulating shape in the radial direction. Furthermore, each of the multiple conductors 5 extends circumferentially and is annular around the axis x. As shown in FIG. 7 , each of the multiple conductors 5 forms a shape with multiple undulations alternately in the radial direction, i.e., alternately on the inner and outer circumferential sides, when viewed in the direction of the axis x. Furthermore, as shown in FIG. 8 , each of the multiple conductors 5 has a two-layer structure, with a portion forming a planar structure on the front surface 21 side in the direction of the axis x and a portion forming a planar structure on the back surface 22 side in the direction of the axis x. Furthermore, the multiple conductors 5 are arranged sequentially offset around the axis x, with one layer of one conductor 5 passing through a position spaced apart from the other layer of another conductor 5 in the direction of the axis x. As a result, one conductor 5 and another conductor 5 do not contact each other but intersect when viewed in the direction of the axis x. The conductor wire 5 is made of a conductive material and is produced by, for example, press molding. Alternatively, the conductor wire 5 may be made of a magnet wire. The conductor wire 5 may be covered with an insulating material (an insulating film or a coating).

[0019] As shown in Figures 7 and 8 , each of the multiple conductors 5 forms multiple coils 7a to form a coil structure 7. Each coil 7a has an annular shape when viewed in the axial direction x, and the coil structure 7 is formed by connecting multiple annular coils 7a in a circumferential direction around the axis x. Specifically, as shown in Figures 7 and 8 , in each conductor 5, when viewed in the axial direction x, an inner undulating portion (hereinafter referred to as an inner undulating portion 5A) is circumferentially connected to form a ring, and an outer undulating portion (hereinafter referred to as an outer undulating portion 5B) is circumferentially connected to form a ring. Furthermore, one inner undulating portion 5A and one outer undulating portion 5B form a pair and are radially opposed to each other. That is, in each conductor 5, a pair of an inner undulating portion 5A and an outer undulating portion 5B surrounds a planar space facing the axial direction x, forming one coil 7a. In each conductor 5, the plurality of coils 7a are formed in a ring shape arranged in the circumferential direction, and a coil structure 7 is formed in which the plurality of coils 7a are arranged and connected in the circumferential direction around the axis x.

[0020] 7 and 8 , the angle sensor 1 has three conducting wires 5 and three coil structures 7. For example, each conducting wire 5 has inner undulating portions 5A on the inner circumferential side and outer undulating portions 5B on the outer circumferential side alternately formed in the circumferential direction, and after completing one revolution, the conducting wire is turned around to alternately form outer undulating portions 5B on the outer circumferential side and inner undulating portions 5A on the inner circumferential side, and after completing one revolution, returns to the starting point to form a ring-shaped coil structure 7.

[0021] 7 and 8, the conductor 5 has a plurality of conductor pieces 5a, which are portions of the conductor 5 extending from the inner undulating portion 5A to the outer undulating portion 5B in one circumferential direction, and a plurality of conductor pieces 5b, which are portions of the conductor 5 extending from the inner undulating portion 5A to the outer undulating portion 5B in the other circumferential direction. Also, as shown in Figures 7 and 8, the conductor 5 has connection pieces 5c and 5d, which are portions of the conductor 5 extending in the direction of the axis x, with connection piece 5c connecting connection piece 5a to connection piece 5b on the inner circumferential side and connection piece 5d connecting connection piece 5a to connection piece 5b on the outer circumferential side. As shown in Figure 8, one of the conductor pieces 5a, 5b, for example, conductor piece 5a, extends toward the front surface 21 of the base 4 in the direction of axis x, while the other of the conductor pieces 5a, 5b, for example, conductor piece 5b, extends toward the back surface 22 of the base 4 in the direction of axis x. That is, conductor piece 5a is connected to connection pieces 5c, 5d on the front surface 21 side of the base 4, and conductor piece 5b is connected to connection pieces 5c, 5d on the back surface 22 side of the base 4. Furthermore, connection piece 5c is located, for example, at or near the apex of the inner undulating portion 5A, and similarly, connection piece 5d is located, for example, at or near the apex of the outer undulating portion 5B. Note that the apex of the inner undulating portion 5A is the portion that protrudes most inward of the inner undulating portion 5A, and the apex of the outer undulating portion 5B is the portion that protrudes most outward of the outer undulating portion 5B.

[0022] As shown in Figures 7 and 8, the conductor piece 5a is connected to the conductor piece 5b via the connection piece 5d to form the outer undulating portion 5B, and then the conductor piece 5b is connected to the conductor piece 5a via the connection piece 5c to form the inner undulating portion 5A, and the conductor pieces 5a, 5b are connected in this manner on the outer and inner sides in sequence to form the coil structure 7.

[0023] 7 and 8 , in the coil structure 7, at the start point of the conductor 5 and the portion where the conductor 5 reverses, for example, a start piece 5e and a reverse piece 5f, which are portions of the conductor 5 extending in the direction of the axis x, similar to the connection pieces 5c and 5d, are formed. The start piece 5e and the reverse piece 5f are adjacent to each other and are located at the middle or approximately the middle of the radial width of the coil structure 7. Furthermore, from the start piece 5e, for example, a half-conductor piece 5a1, which is a portion of the conductor piece 5a on the connection piece 5d side, and a half-conductor piece 5b1, which is a portion of the conductor piece 5b on the connection piece 5c side, extend to the connection piece 5d and the connection piece 5c, respectively. Meanwhile, from the reverse piece 5f, for example, a half-conductor piece 5a2, which is a portion of the conductor piece 5a on the connection piece 5c side, and a half-conductor piece 5b2, which is a portion of the conductor piece 5b on the connection piece 5d side, extend to the connection piece 5c and the connection piece 5d, respectively.

[0024] 7 and 8, in the coil structure 7, the conductor piece 5a of the portion of the conductor 5 before reversal and the conductor piece 5b of the portion of the conductor 5 after reversal are separated in the direction of the axis x but overlap when viewed in the direction of the axis x. In the coil structure 7, the conductor piece 5b of the portion of the conductor 5 before reversal and the conductor piece 5a of the portion of the conductor 5 after reversal are separated in the direction of the axis x but overlap when viewed in the direction of the axis x. The overlap of the conductor piece 5a and the conductor piece 5b forms the coil 6.

[0025] 7 and 8 , the three coil structures 7 are offset from one another in the circumferential direction so that the inner undulating portions 5A or outer undulating portions 5B of one coil structure 7 are spaced apart from the inner undulating portions 5A or outer undulating portions 5B of the other two coil structures 7. For example, the three coil structures 7 are offset from one another in the circumferential direction so that the inner undulating portions 5A or outer undulating portions 5B of one coil structure 7 are spaced apart from the inner undulating portions 5A or outer undulating portions 5B of the other two coil structures 7 at equal or approximately equal angular intervals in the circumferential direction.

[0026] 7 and 8 , one coil structure 7 and the other two coil structures 7 have portions of the spaces surrounded by the coils 6 that are offset from each other in the circumferential direction, and other portions of the spaces surrounded by the coils 6 overlap each other in the circumferential direction. Specifically, for example, as shown in Fig. 7 , between two circumferentially adjacent coil structures 7, the space surrounded by the coil 6 of the other coil structure 7 is offset from the space surrounded by the coil 6 of one coil structure 7 in the circumferential direction by one-third of the circumferential width of the space surrounded by the coil 6 of the other coil structure 7.

[0027] In this embodiment, as described above, three coil structures 7 are formed by three conductors 5, and the detection coils are three-phase. Waveform signals obtained from the three-phase coils are processed by electronic components 6, and sin and cos analog information is finally output.

[0028] In the above example, each conductor 5 is formed by connecting the conductor pieces 5a, 5b and the half-conductor pieces 5a1, 5a2, 5b1, and 5b2 together to form one full turn, but the shape of each conductor 5 is not limited to this. Each conductor 5 may be formed by connecting the conductor pieces 5a, 5b and the half-conductor pieces 5a1, 5a2, 5b1, and 5b2 together to form two or more full turns. In other words, each conductor 5 may have, for example, one layer, two, three, four, five, or more layers. In this case, the output signal or the signal to be detected (e.g., the amplitude of the signal waveform) can be amplified compared to a coil structure 7 formed from a single turn or single layer of conductor 5.

[0029] 7 and 8 , lead wires 5g, 5h extend from the ends of the conductor wires 5 of each coil structure 7, and the lead wires 5g, 5h are connected to the electronic component 6. The lead wires 5g, 5h extending from the conductor wire 5 are formed, for example, from the same conductive material as the conductor wire 5. Furthermore, the lead wires 5g, 5h extending from the conductor wire 5 are formed, for example, by extending the conductor wire 5.

[0030] As described above, the electronic component 6 is provided in the first region 4A of the base 4. The electronic component 6 is, for example, an IC (integrated circuit). As described above, the electronic component 6 is electrically connected to the conductors 5, and detection signals are input to the electronic component 6 from each conductor 5 (coil structure 7). The electronic component 6 calculates the rotation angle of the rotor 2 based on the detection signals, or calculates and outputs a value corresponding to the rotation angle of the rotor 2. The electronic component 6 is mounted on the back surface 22 in the first region 4A, as shown in FIGS. 6 and 7 , for example. Note that the electronic component 6 may also be mounted on the front surface 21 in the first region 4A.

[0031] 1 and other figures, a plurality of lead wires 30 electrically connected to the electronic component 6 are fixed to the first region 4A. The lead wires 30 are electric wires for electrically connecting the electronic component 6 to the outside of the angle sensor 1. The lead wires 30 include, for example, those for outputting an output value from the electronic component 6 and those for supplying an operating voltage to the electronic component 6.

[0032] The angle sensor 1 has the above-described configuration, in which the rotor 2 and the stator 3 including the base 4 form an inductive angle sensor, and the multiple coils 7a forming a space facing the axis x direction form detection coils. A magnetic space or magnetic gap is also formed between the rotor 2 and the base 4. In the angle sensor 1, magnetic flux of periodically changing magnitude directed toward the axis x direction acts on the multiple coils 7a from the excitation coil 8. Meanwhile, the multiple protrusions 11 (metal bodies 10) are arranged in the circumferential direction around the axis x as described above, and cross the magnetic flux generated by the excitation coil 8 as the rotor 2 rotates. Furthermore, the projection of the protrusions 11 (metal bodies 10) having radially extending portions onto the coils 7a in the axis x direction moves as the rotor 2 rotates. For this reason, the magnetic flux from the excitation coil 8 acting on each of the multiple coils 7a formed by the conductor 5 is affected by the magnetic flux due to the eddy current generated in the protrusions 11 (metal body 10) and cancels out, thereby changing periodically with the rotation of the rotor 2. As a result, an electromotive force that changes with the rotation of the rotor 2 is generated in the multiple coils 7a due to electromagnetic induction, and a signal that changes with the rotation of the rotor 2 is detected from each of the multiple conductors 5. The rotation angle of the rotor 2 is detected in the electronic component 6 based on this detection signal from each of the multiple conductors 5.

[0033] The angle sensor 1 has the above-described configuration, and the base 4 has a first region 4A on the inner periphery side of the second region 4B of the base 4 in which the plurality of conducting wires 5 are provided. Furthermore, the electronic component 6 is provided in this first region 4A of the base 4. Therefore, it is not necessary to provide a portion for attaching the electronic component 6 on the outer periphery side of the first region 4A of the base 4, and the area occupied by the base 4 in space can be reduced. Furthermore, because the first region 4A of the base 4 is effectively utilized, the first region 4A of the base 4 does not need to be removed, and the amount of material emitted in the manufacture of the base 4 can be reduced.

[0034] Furthermore, the outer edge 23 of the base 4 surrounds the excitation coil 8, and the outer edge 23 of the base 4 can be brought close to the excitation coil 8. This also makes it possible to reduce the area occupied by the base 4 in space.

[0035] Furthermore, the lead wires 5g, 5h, and 9 connected to the electronic component 6, as well as resistors, capacitors, and other components related to the electronic component 6 (not shown) can be provided or attached to the first region 4A of the base 4. This also makes it possible to reduce the spatial area occupied by the base 4 or the spatial area occupied by the stator 3.

[0036] As described above, the angle sensor 1 according to the embodiment of the present invention can occupy a small space.

[0037] Next, a modified example of the stator 3 of the angle sensor 1 will be described. Fig. 9 is a rear view of a stator 3A according to the modified example. Note that lead wires are not shown in Fig. 9. The stator 3A according to the modified example of the stator 3 differs from the stator 3 described above in that it has a base 9 that is different from the base 4 of the stator 3 described above. In the following, regarding the configuration of the stator 3A, the same reference numerals will be used for the same configurations or configurations having similar functions as the stator 3 described above, and a description thereof will be omitted, and only configurations different from the stator 3 described above will be described.

[0038] As shown in FIG. 9 , the plurality of conducting wires 5 also form coils 7a wound around the base 9 of the stator 3A, extending in the circumferential direction. For example, the base 9 has a plurality of protruding portions 24 protruding from the rear surface 22 in the second region 4B. The protruding portions 24 are arranged in the circumferential direction. The plurality of conducting wires 5 are wound around the plurality of protruding portions 24, respectively, to form coils 7a around each of the protruding portions 24. The coils 7a are also formed by the conducting wires 5, arranged in the circumferential direction, similar to the plurality of protruding portions 24, thereby forming a coil structure 7 in which the plurality of coils 7a are arranged in the circumferential direction. The plurality of protruding portions 24 are arranged, for example, at equal or approximately equal angular intervals around the axis x.

[0039] As shown in FIG. 9 , the base 9 has an annular protrusion 25 surrounding the multiple protrusions 24 on the back surface 22 in the second region 4B. The protrusion 25 protrudes from the back surface 22 and is located on the outer periphery of the multiple protrusions 24. The protrusion 25 is located on the inner periphery of the outer edge 23 of the base 9, close to the outer edge 23. An excitation coil 8 is embedded in the protrusion 25. As with the stator 3 described above, the excitation coil 8 may be entirely or partially embedded in the protrusion 25. The excitation coil 8 does not have to be embedded in the protrusion 25. In this case, for example, the excitation coil 8 is wound around the outer periphery 25 a of the protrusion 25. The outer periphery 25 a of the protrusion 25 is an annular surface facing the outer periphery of the protrusion 25. The protrusion 25 may not be annular, but may extend intermittently in an annular shape.

[0040] The base 9 is integrally formed from the same material as the base 4. The protrusions 24 and 25 are part of the integrally formed base 9, and the protrusions 24 and 25 are integrally connected to each other on the base 9. Note that the protrusion 24 may be formed separately from the other components of the base 9 and fixed to the other components of the base 9, and similarly, the protrusion 25 may be formed separately from the other components of the base 9 and fixed to the other components of the base 9.

[0041] Note that the base 9 may not have the protrusion 25, similar to the base 4 described above. In this case, the excitation coil 8 is provided on the base 9, similar to the stator 3 described above. Specifically, for example, the excitation coil 8 is embedded between the front surface 21 and the back surface 22 of the base 9. The excitation coil 8 is located radially outward of the plurality of conductors 5 wound around the protrusion 24. Alternatively, an annular groove may be formed instead of the annular protrusion 25. In this case, the excitation coil 8 is fixed to the annular groove.

[0042] The conductor wire 5 is, for example, a magnet wire. The conductor wire 5 is electrically insulated by being coated with, for example, an insulating material (an insulating film or a coating). Each of the multiple conductor wires 5 has an undulating shape in the radial direction. For example, as shown in FIG. 9 , the conductor wire 5 is wound around each of the protrusions 24, thereby forming a planar shape with multiple undulations in the radial direction. For example, the conductor wire 5 forms multiple annular coils 7 a around the axis x along the multiple protrusions 21, thereby forming the coil structure 7 on the base 9.

[0043] Specifically, for example, the stator 3A has two conducting wires 5. Each conducting wire 5 is wound around the protruding portions 24 alternately from the inner circumferential side and the outer circumferential side for every two adjacent protruding portions 21 toward one side in the circumferential direction, turns back after making one full turn around the plurality of protruding portions 24, and is wound around the protruding portions 24 again toward the other side in the circumferential direction to form the coil structure 7. In this case, each coil 7a is formed around two protruding portions 24.

[0044] Two coil structures 7 are formed from two conducting wires 5, and one coil structure 7 is formed circumferentially offset by one protrusion 24 with respect to the other coil structure 7. Therefore, the two coil structures 7 overlap in the direction of the axis x, but a portion of the space surrounded by the coil 7 a of one coil structure 7 is circumferentially offset from a portion of the space surrounded by the coil 7 a of the other coil structure 7, and another portion of the space surrounded by the coil 7 a of one coil structure 7 overlaps in the circumferential direction with another portion of the space surrounded by the coil 7 a of the other coil structure 7. Specifically, the space surrounded by the coil 7 a of one coil structure 7 is offset in the circumferential direction from the space surrounded by the coil 7 a of the other coil structure 7 by half the width of the space surrounded by the coil 7 a of the one coil structure 7.

[0045] Like the coil structure 7 of the stator 3 described above, the number of coil structures 7 formed on the base 9 is not limited to the two described above. For example, like the coil structure 7 of the stator 3 described above, three coil structures 7 may be formed on the base 9 by three conductors 5. In this case, each conductor 5 is wound around the protrusions 24 alternately from the inner circumferential side and the outer circumferential side for each of three adjacent protrusions 24, in the same manner as described above.

[0046] 9, the electronic components 6 are also provided in the first region 4A of the base 9. The electronic components 6 are provided in the first region 4A of the back surface 22, which is the surface of the base 9 that does not face the rotor 2, and the lead wires 30, not shown, are provided on the back surface 22, which is the surface of the base 9 on which the electronic components 6 are mounted. Note that the electronic components 6 may also be provided in the first region 4A of the front surface 21 of the base 9, in which case the electronic components 6 are not provided on the same surface as the lead wires 30.

[0047] The angle sensor 1 having the stator 3A according to the modified example having the base 9 described above also functions in the same manner as the angle sensor 1 described above, and provides the same effects.

[0048] Next, an application of the angle sensor 1 will be described. Fig. 10 is an exploded perspective view of a specific example of a rotating device as an application of the angle sensor 1. Fig. 10 shows a rotating device 50 as a specific example of a rotating device in an exploded state. In Fig. 10, a part of the configuration of the rotating device 50 is shown in a see-through manner.

[0049] 10 , a rotating body 52 serving as a rotating device 50 includes an angle sensor 1, a rotating shaft 51, and a rotor 53. The rotating shaft 51 is fixed to the rotor 2 of the angle sensor 1, and the rotor 53 is fixed to the rotating shaft 51. In the rotating device 50, the axes of the rotating shaft 51 and the rotating body 52 coincide or approximately coincide with the axis x of the angle sensor 1. For this reason, in the following description, the axis of the rotating device 50 (rotating body 52) will be referred to as the axis x, and the axes of the angle sensor 1 and the rotating shaft 51 will be referred to as the axis x.

[0050] The rotating body 52 is, for example, a motor, and includes a rotor 53 and a stator 54, with a rotating shaft 51 fixed to the rotor 53. The motor 52 also includes a frame 55 and a cover 60. The frame 55 houses the rotor 53 and the stator 54. The frame 55 also has an opening 55a. The cover 60 covers the opening 55a of the frame 55.

[0051] An opening 55a of the frame 55 opens the internal space of the frame 55 to the outside of the frame 55. The rotor 53 and the stator 54 are housed in the internal space of the frame 55. The rotating shaft 51 protrudes from the opening 55a of the frame 55. As shown in Fig. 10, the frame 55 is, for example, a cylindrical member. The frame 55 has an annular end 55b that surrounds the opening 55a, and the end 55b faces in the direction of the axis x.

[0052] One end 51a of the rotating shaft 51 is inserted into the ring 12 of the rotor 2 of the angle sensor 1, and the rotor 2 is fixed to one end 51a of the rotating shaft 51. For example, an end face 51b of the end 51a of the rotating shaft 51 is flush or nearly flush with the opposing surface 11a of the rotor 2. Note that the end face 51b of the rotating shaft 51 may protrude from the rotor 2 or may be located within the ring 12 of the rotor 2.

[0053] In the rotating device 50, the base 4 is fixed to a predetermined position in use relative to the rotor 2. As shown in Fig. 10 , the rotating shaft 51 faces the surface 21 of the base 4 in the direction of the axis x. Specifically, the rotating shaft 51 faces the first region 4A of the surface 21 of the base 4 in the direction of the axis x. In other words, the end face 51b of the end 51a of the rotating shaft 51 faces the first region 4A of the surface 21 of the base 4 with a gap therebetween in the direction of the axis x.

[0054] The base 4 of the angle sensor 1 is fixed to a cover 60, for example, as shown in FIG. 10 . The cover 60 is a plate-shaped member having a pair of opposing surfaces 61 and 62, as shown in FIG. 10 . In the rotating device 50, one of the pair of opposing surfaces 61 and 62 of the cover 60, for example, the surface 61, covers the opening 55 a of the frame 55. That is, the cover 60 is fixed to the frame 55 with the surface 61 in contact with the end 55 b of the frame 55. For example, the surface 61 of the cover 60 is adhered to the end 55 b of the frame 55, thereby fixing the cover 60 to the frame 55. The cover 60 may be fixed to the frame 55 by a method other than adhesion. For example, the cover 60 may be fixed to the frame 55 by a fixing means such as a bolt or a locking means such as a claw, and a sealing member may be provided to improve the sealing between the surface 61 and the end 55 b.

[0055] The base 4 is attached to a surface 61, which is one of a pair of surfaces of the cover 60. For example, the surface 61 of the cover 60 is provided with a plurality of attachment portions (hereinafter referred to as "bosses") 63 formed so that the base 4 can be fixed. The bosses 63 are portions protruding from the surface 61, as shown in FIG. 10 . For example, the bosses 63 allow the base 4 to be fixed by a fixing member such as a bolt (not shown). In this case, the base 4 is formed with a structure such as a through-hole that can be engaged with a fixing member such as a bolt. The base 4 may also be provided with a resin protrusion or the like that corresponds to the bosses 63 and can be thermally caulked. The bosses 63 may also be capable of fixing the base 4 by other means such as engagement or adhesion. The cover 60 does not need to have the bosses 63 and may have another structure for fixing the base 4. In this way, the base 4 is fixed to the surface 61 of the cover 60, and the angle sensor 1 is provided between the surface 61 of the cover 60 and the end 51 a of the rotation shaft 51. Therefore, in the rotating device 50 , the angle sensor 1 is housed in the space inside the frame 55 .

[0056] As shown in Fig. 10, the boss portions 63 are preferably disposed at equal intervals in the circumferential direction. This allows the mounting position of the base 4 to be selected in the circumferential direction. Furthermore, the lead wires 30 are drawn out to the outside by passing between adjacent boss portions 63. By allowing the mounting position of the base 4 to be selected in the circumferential direction, it is also possible to select which gap between the multiple boss portions 63 the lead wires 30 are passed through. This allows the lead wires 30 to be drawn in the optimal direction, so that even if the mounting target is changed, the angle sensor 1 can be arranged without requiring design changes, etc.

[0057] The rotating device 50 has the above-described configuration, and when the motor 52 is driven and the rotating shaft 51 rotates, the rotor 2 of the angle sensor 1 fixed to the rotating shaft 51 rotates together with the rotating shaft 51 around the axis x. As a result, the metal body 10 of the rotor 2 rotates facing the multiple coils 7a formed by the multiple conductors 5 of the base 4, and the magnetic flux from the excitation coil 8 acting on each of the multiple coils 7a changes periodically. As a result, signals that change as the rotor 2 rotates are detected from the multiple conductors 5. Based on the detection signals from the multiple conductors 5, the electronic component 6 provided in the first region 4A of the base 4 calculates the rotation angle of the rotor 2 or a value corresponding to the rotation angle of the rotor 2.

[0058] As described above, the electronic component 6 is provided in the first region 4A of the base 4, and the region occupied by the base 4 in space is small. Therefore, the region occupied by the base 4 in the rotating device 50 is small. This allows the rotating device 50 to be miniaturized, and also increases the degree of freedom in the layout of the angle sensor 1 in the rotating device 50.

[0059] The rotating body of the rotating device according to the present invention is not limited to a motor. The rotating body of the rotating device according to the present invention also includes a rotating body such as a motor whose rotating shaft rotates by receiving a driving force inside the rotating body, and a rotating body whose rotating shaft rotates by receiving a driving force from an external source. For example, the rotating body of the rotating device according to the present invention includes a rotating body such as an automobile power steering, accelerator pedal, brake pedal, seat reclining mechanism, electric parking, or speed reducer. The base 9 according to the modified example is also provided in the rotating device 50.

[0060] Next, a modified example of the rotating device 50 described above will be described. Fig. 11 is an exploded perspective view of the rotating device 50 according to the modified example. The rotating device 50 according to the modified example differs from the rotating device 50 described above in that the positions at which the angle sensor 1 and the rotor 2 are provided are different. Hereinafter, regarding the configuration of the rotating device 50 according to the modified example, the same components as those of the rotating device 50 described above or components having similar functions will be assigned the same reference numerals and will not be described again, and different components will be described.

[0061] 11 , in a rotating device 50 according to a modified example, the angle sensor 1 is located outside the frame 55 and the cover 60. Specifically, the cover 60 is provided with a through-hole 64 penetrating the cover 60, and the rotating shaft 51 of the motor 52 extends to the outside through the through-hole 64 of the cover 60. For example, a bearing 56 is attached to the through-hole 64, and the rotating shaft 51 is rotatably supported by the bearing 56.

[0062] The rotor 2 is attached to the end 51 a of the rotating shaft 51 of the motor 52, which protrudes outside the cover 60, in the same manner as in the rotating device 50 described above, and is attached to the outside of the cover 60. The base 4 is provided outside the cover 60 and, like the rotating device 50 described above, is fixed so as to be in a predetermined position in use relative to the rotor 2. As shown in FIG. 11 , the rotating shaft 51 faces the surface 21 of the base 4 in the direction of the axis x. Specifically, outside the cover 60, the rotating shaft 51 faces the first region 4A of the surface 21 of the base 4 in the direction of the axis x. In other words, outside the cover 60, the end face 51 b of the end 51 a of the rotating shaft 51 faces the first region 4A of the surface 21 of the base 4 with a gap in the direction of the axis x. Also, outside the cover 60, the base 4 faces the rotor 2 in the direction of the axis x, like the rotating device 50 described above. In the rotating device 50 according to the modified example, the base 4 is also attached to the cover 60. For example, a boss portion 63 similar to that of the cover 50 of the rotating device 50 described above is formed on a surface 62 facing the outside of the cover 60, and the base 4 is provided with a fixing portion (not shown) that corresponds to the boss portion 63. Examples of the fixing portion include a through-hole into which a fixing member can be inserted, and a resin protrusion that can be thermally caulked.

[0063] As described above, in the rotating device 50 according to the modified example, the angle sensor 1 is not housed in the space inside the frame 55, but is located outside the frame 55 and exposed to the outside of the rotating device 50. The angle sensor 1 may be covered with a cup-shaped protective cover (not shown). Covering the angle sensor 1 with a protective cover can add waterproof and dustproof properties.

[0064] As shown in Fig. 11, the boss portions 63 are preferably disposed at equal intervals in the circumferential direction. This allows the mounting position of the base 4 to be selected in the circumferential direction. Furthermore, the lead wires 30 are drawn out to the outside by passing between adjacent boss portions 63. By allowing the mounting position of the base 4 to be selected in the circumferential direction, it is also possible to select which gap between the boss portions 63 the lead wires 30 are passed through. This allows the lead wires 30 to be drawn in the optimal direction, so that even if the mounting target is changed, the angle sensor 1 can be arranged without requiring design changes, etc.

[0065] Although the present invention has been described above through the above embodiments, the technical scope of the present invention is not limited to the scope described in the above embodiments. It will be apparent to those skilled in the art that various modifications and improvements can be made to the above embodiments. It is clear from the claims that such modifications and improvements can also be included within the technical scope of the present invention.

[0066] The above-described embodiments are intended to facilitate understanding of the present invention and are not intended to limit the scope of the present invention. Furthermore, the above-described embodiments do not limit the scope of the present invention, and the present invention may include any and all applications. The components of the above-described embodiments, as well as their arrangement, materials, conditions, shape, size, etc., are not limited to those illustrated and may be modified as appropriate. For example, the present invention includes differences that arise during implementation due to manufacturing tolerances, etc. Furthermore, components illustrated in different embodiments may be partially substituted or combined within the scope of technical inconsistency. Furthermore, the various configurations may be selectively combined as appropriate to achieve at least some of the above-described problems and effects.

[0067] 1 Angle sensor, 2 Rotor, 3, 3A Stator, 4, 9 Base, 4A First region, 4B Second region, 5 Conductor, 5A Inner undulating portion, 5B Outer undulating portion, 5a, 5b Conductor piece, 5a1, 5a2, 5b1, 5b2 Semi-conductive wire piece, 5c, 5d Connection piece, 5e Starting piece, 5f Inverted piece, 5g, 5h Lead wire, 6 Electronic component, 7 Coil structure, 7a Coil, 8 Excitation coil, 10 Metal body, 11 Convex, 11a Opposing surface, 11b Back surface, 12 Ring, 12a Outer peripheral surface, 12b Inner peripheral surface, 13 Opening, 21 Surface, 22 Back surface, 23 Outer edge, 24 Protrusion, 25 Protrusion, 25a Outer peripheral surface, 30 Lead wire, 50 Rotating device, 51 Rotating shaft, 51a End, 51b end surface, 52 motor, 53 rotor, 54 stator, 55 frame, 55a opening, 55b end, 56 bearing, 60 cover, 61, 62 surface, 63 mounting portion (boss portion), 64 through hole, L boundary, x axis

Claims

1. An angle sensor comprising: a rotor; a base axially facing the rotor; a plurality of conductors extending circumferentially; and electronic components electrically connected to the conductors, wherein the base has a first region and a second region surrounding the first region, the electronic components are provided in the first region, and the plurality of conductors provided in the second region form an undulating shape in the radial direction.

2. The angle sensor according to claim 1, wherein the electronic component is surrounded by the plurality of conducting wires.

3. The angle sensor according to claim 1 or 2, wherein the base has an annular excitation coil in the second region, and the excitation coil surrounds the plurality of conducting wires in the radial direction.

4. The angle sensor according to claim 3, wherein the base has an outer edge that surrounds the annular excitation coil.

5. An angle sensor according to any one of claims 1 to 4, wherein the plurality of conducting wires form a coil wound around the circumference.

6. The angle sensor according to claim 1 or 2, wherein the base has one surface and another surface in the axial direction, the one surface facing the rotor, and lead wires are provided on the other surface.

7. A rotating device comprising: an angle sensor according to any one of claims 1 to 6; a rotating shaft fixed to a rotor of said angle sensor; and a motor comprising a rotor fixed to said rotating shaft and a stator.

8. The rotating device according to claim 7, wherein the motor comprises: a frame that houses the rotor and the stator; and a cover that covers an opening of the frame; and the angle sensor is fixed to the cover.

9. The rotating device according to claim 7 or 8, wherein the rotating shaft and the first region face each other in the axial direction of the rotating shaft.

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