Resolver Comb-Shaped Coils Reduce Lamination Deviations
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Solution Overview
Problem
Conventional resolvers face challenges in achieving high angle detection accuracy due to weak magnetic flux and signal intensity, which can be exacerbated by increased manufacturing costs and lamination deviations, particularly in sheet coil designs and rectangular coil patterns.
Innovation Solution
The resolver incorporates excitation and detection coils formed on sheet-shaped substrates with comb-shaped closed coils, where sine and cosine coils are disposed on the same layer, reducing lamination deviations and ensuring uniform signal intensity by equalizing axial distances and coil areas, thereby enhancing angle detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of layers is increased to increase signal intensity, then signal intensity is improved, but manufacturing complexity and cost increase due to lamination deviation
Solution Approach 1:
The patent transitions from a multi-layer vertical stacking approach to a single-layer planar arrangement. The excitation and detection windings are disposed side-by-side on the same magnetic sheet, eliminating the need for multiple laminated layers while maintaining sufficient signal intensity through optimized winding geometry and magnetic circuit design.
Solution Approach 2:
The patent combines the excitation winding and detection winding into a single layer structure rather than separating them into multiple layers. This merging approach reduces manufacturing complexity by eliminating lamination processes while maintaining the functional separation of excitation and detection paths through spatial arrangement.
2Reliability
If the number of layers is increased to increase signal intensity, then signal intensity is improved, but manufacturing cost increases
Solution Approach 1:
The patent moves from a vertical multi-layer configuration to a horizontal single-layer configuration, eliminating costly lamination processes. The single-layer design reduces material waste, assembly time, and quality control requirements associated with multi-layer stacking, thereby reducing manufacturing cost while maintaining signal intensity through optimized winding patterns.
3Ease of manufacture
If L-shaped closed coils are used to form magnetic poles, then manufacturing is simplified, but signal intensity difference between magnetic poles increases due to unequal axial distances
Solution Approach 1:
The patent employs asymmetric U-shaped closed coils with deliberately different configurations for first and second magnetic poles. The U-shaped winding includes a first leg and a second leg with different lengths or positions, allowing precise adjustment of axial distances to achieve equal magnetic flux paths and uniform signal intensity while maintaining manufacturability.
Solution Approach 2:
The patent adjusts geometric parameters of the U-shaped closed coils, specifically the lengths and positions of the first and second legs, to optimize the axial distances between windings and magnetic poles. By varying these parameters, the design achieves equal magnetic coupling for both poles, ensuring uniform signal intensity while retaining the manufacturing simplicity of closed coil structures.
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 improves signal intensity per layer, reduces signal intensity differences, and significantly enhances the accuracy of rotation angle detection while minimizing manufacturing complexities and costs.
Implementation Method 1
an excitation coil provided at the rotor or the stator and formed on a sheet-shaped substrate, and a detection coil provided at the rotor or the stator and formed on the sheet-shaped substrate
Implementation Method 2
sine coil patterns of a pair of comb-shaped closed coils connected to each other to form a magnetic pole
Data Source
AI summary
A resolver includes an excitation coil provided at the rotor or the stator and formed on a sheet-shaped substrate, and a detection coil provided at the rotor or the stator and formed on the sheet-shaped substrate. At least one of the excitation coil and the detection coil is a sine coil and a cosine coil. In the sine coil, sine coil patterns of a pair of comb-shaped closed coils are disposed on the identical layer of the substrate. In the cosine coil, cosine coil patterns of a pair of comb-shaped closed coils are disposed on the identical layer of the substrate. Each of the pair of comb-shaped closed coils includes a first comb-shaped closed coil including an inward first projection and a second comb-shaped closed coil including an outward second projection.