Variable Reluctance Resolver with Thin Flat Magnetic Member
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Solution Overview
Problem
Existing variable reluctance resolvers have a large physical size due to their U-shaped core structure, which limits their downsizing potential.
Innovation Solution
A variable reluctance resolver design featuring a magnetic member with thin flat body portions and a connection portion that extends along the rotational axis direction, allowing for a U-shaped configuration that reduces the size of the magnetic member and the entire resolver, along with a production method involving bending and winding of coils around these portions to minimize magnetic flux leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a traditional U-shaped core structure is used in a variable reluctance resolver, then the magnetic connection between detection coils is achieved, but the physical size of the resolver becomes large
Solution Approach 1:
The magnetic member transitions from a traditional three-dimensional U-shaped core to a thin flat plate structure. This dimensional change reduces the volume and physical size of the resolver while maintaining the essential U-shape configuration for magnetic connection. The flat plate structure achieves magnetic coupling between detection coils through its planar geometry rather than bulky three-dimensional form.
Solution Approach 2:
The magnetic member is designed as a thin flat plate structure rather than a thick core. This thin film approach reduces the overall size of the resolver while maintaining sufficient magnetic permeability and coupling effectiveness. The thin plate configuration allows for compact integration of the detection coils around the body portions while achieving reliable magnetic connection.
2Volume of moving object
If the magnetic member is made thin and flat to downsize the resolver, then the physical size is reduced, but magnetic flux leakage between adjacent detection coils may increase
Solution Approach 1:
A magnetic partition structure is extracted and integrated into the magnetic member to specifically address magnetic flux leakage between adjacent detection coils. This partition divides the magnetic flux paths and prevents unwanted coupling between neighboring coils, solving the leakage problem that arises from the thin flat structure.
Solution Approach 2:
The magnetic member employs different structural characteristics in different regions: the body portions maintain thin flat geometry for size reduction, while the partition structure provides localized magnetic isolation to prevent flux leakage. This local differentiation of structural properties allows simultaneous achievement of compact size and effective magnetic isolation.
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
The design achieves a significant reduction in size and weight of the resolver while maintaining effective magnetic flux distribution, enabling a more compact and cost-effective solution for rotation detection in motor applications.
Implementation Method 1
a magnetic member that magnetically connects adjacent ones of the detection coils to each other
Implementation Method 2
variable reluctance resolver that detects rotation of a motor
Data Source
AI summary
A variable reluctance resolver includes a rotor that rotates about a rotational axis, a plurality of detection coils that detect rotation of the rotor, and a magnetic member that magnetically connects adjacent ones of the detection coils to each other. The magnetic member includes a pair of body portions around which the detection coils are wound, and a connection portion that connects the pair of body portions to each other. Both the body portions and the connection portion have a thin flat shape. The body portions are flat so that a direction of extension of the flat shape is along a rotational axis direction, and the magnetic member has a U shape as viewed from the rotational axis direction.