Multipolar Resolver Windings for High-Accuracy Miniaturization
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Solution Overview
Problem
Conventional resolvers face challenges in achieving high detection accuracy and stability while maintaining a small size, particularly for super small-sized resolvers, due to limitations in machining accuracy and increased manufacturing costs associated with higher pole counts.
Innovation Solution
The configuration of excitation windings and detection windings in a multipolar mode, with intermediate rotating windings forming closed circuits, allows for increased pole numbers while ensuring machining accuracy, and the placement of these windings in specific geometric arrangements reduces size and thickness, enabling higher detection accuracy and reliability in small-sized resolvers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the number of poles is increased to achieve higher detection accuracy, then detection accuracy is improved, but manufacturing cost increases and machining accuracy becomes more difficult to maintain
Solution Approach 1:
The excitation windings are divided into multiple sets (first set, second set, third set, etc.) with different pole numbers. Each set contributes to the overall magnetic field in a segmented manner, allowing the system to achieve high detection accuracy equivalent to a high pole-count single-set configuration while using multiple lower pole-count sets, thereby reducing manufacturing complexity and cost.
Solution Approach 2:
Multiple sets of excitation windings with different pole numbers are combined to work together in the same resolver structure. The magnetic fields generated by each set merge to produce the desired high-resolution detection effect, achieving the functionality of a high pole-count system while distributing the manufacturing complexity across multiple simpler winding sets.
2Measurement precision
If the number of poles is increased to achieve higher detection accuracy, then detection accuracy is improved, but machining accuracy becomes more difficult to maintain
Solution Approach 1:
The high pole-count requirement is segmented into multiple winding sets with lower individual pole counts. Each set can be machined with standard precision requirements, avoiding the need for ultra-precise machining that would be required for a single high pole-count winding configuration.
Solution Approach 2:
Different sets of excitation windings are assigned different pole numbers locally within the same resolver structure. This allows each local winding set to be optimized for standard machining capabilities while the collective arrangement achieves the global high detection accuracy requirement.
3Volume of moving object
If the pitch between conductors in the radial direction is reduced to achieve smaller resolver size, then size is reduced, but the number of poles must be increased which increases manufacturing complexity
Solution Approach 1:
The conductor arrangement is segmented into multiple winding sets with different pole numbers. This segmentation allows the system to achieve high detection accuracy (equivalent to high pole count) without requiring an excessively high pole count in any single winding, thereby reducing the complexity associated with small pitch requirements.
Solution Approach 2:
Instead of achieving high detection accuracy solely through increasing pole count in a single winding (one-dimensional approach), the invention uses multiple winding sets with different pole numbers arranged in spatial dimensions. This multi-dimensional approach achieves the same detection accuracy with reduced pole count requirements for individual windings.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances detection accuracy and stability, facilitates size reduction, and reduces manufacturing costs, allowing for the creation of thin, narrow, or super small-sized resolvers with improved magnetic-flux density and detection efficiency.
Implementation Method 1
a resolver having excitation windings in two phases provided by being fixed to spatial positions with a phase difference by an electric angle of 90° and to which excitation signals are input and a detection winding provided on a rotating shaft and from which a detection signal is output
Data Source
AI summary
Excitation windings 2X, 2Y and a detection winding configured in a multipolar mode are disposed coaxially with a fixed body, a plurality of sets (M1, M2) of intermediate rotating windings M1 . . . configured by a pair of winding portions Mx1, My1 . . . configured by the multipolar mode and with predetermined electrical phases D made different are disposed coaxially with a rotating body, and the winding portions in the same phase (Mx1 and Mx2, My1 and My2) of the plural sets of the intermediate rotating windings M1, M2 are connected so as to form closed circuits H . . . , respectively.