Resolver Stator Protrusion Winding for Angle Detection
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Solution Overview
Problem
Existing resolvers face manufacturing errors and inefficient stator design due to variations in the number of turns of output signal coils, which complicates the detection of rotational angles in motors.
Innovation Solution
The method involves winding output signal coils alternately around protrusions of a core with the same number of turns, ensuring a consistent total number of turns across each protrusion, and using a signal source coil to generate an AC magnetic field, allowing for accurate detection of rotational angles with reduced errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the plurality of output signal coils are wound around each protrusion of the core by a different number of turns to obtain induced voltage signals of different phases, then the rotational angle detection is enabled, but manufacturing errors occur frequently and the stator structure becomes inefficient
Solution Approach 1:
The output signal coils are divided into multiple separate coils, with each coil wound around a specific protrusion of the core. This segmentation allows each coil to be independently positioned and wound with a consistent number of turns, eliminating the need for different turn counts across protrusions while still generating the required phase differences through spatial arrangement
Solution Approach 2:
Instead of varying the number of turns (one-dimensional parameter), the patent uses the spatial dimension by positioning multiple output signal coils around different protrusions of the core. The phase differences are achieved through the angular separation and spatial arrangement of these coils rather than through turn count variations, adding a dimensional approach to the problem solution
2Measurement precision
If the core of the stator is designed according to a protrusion having the greatest number of turns, then the rotational angle detection is enabled, but an efficient stator structure cannot be obtained
Solution Approach 1:
Each protrusion of the core is equipped with output signal coils having the same number of turns, creating local uniformity. This local quality consistency simplifies the overall stator design, as all protrusions can be manufactured with identical specifications, eliminating the need to design around the maximum turn count requirement and enabling more efficient stator structure
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 approach prevents manufacturing errors in the number of turns and enables an efficient stator design, improving the accuracy and reliability of rotational angle detection in motors.
Implementation Method 1
The signal source coil is wound around the protrusions of the core to generate an alternate current (AC) magnetic field when an input voltage signal is applied thereto. The plurality of output signal coils are wound around the protrusions of the core together with the signal source coil to generate induced voltage signals of different phases in response to the AC magnetic field generated by the signal source coil
Data Source
AI summary
Provided is a method of manufacturing a resolver having a stator mounted around a rotator and configured to detect a rotational angle of a motor, the method including: forming the stator to have a core with protrusions disposed at a predetermined interval along a rotational direction of the rotator; winding a signal source coil around the protrusions of the core to generate an alternate current (AC) magnetic field when an input voltage signal is applied thereto; and winding a plurality of output signal coils alternately along the rotational direction of the rotator around the protrusions of the core, along the rotational direction of the rotator, to generate induced voltage signals of different phases in response to the AC magnetic field generated by the signal source coil and the rotation of the rotator.