JP6945955B2 - Angle detector and manufacturing method of angle detector - Google Patents

Description

The present invention relates to an angle detector that detects the rotation angle of a rotor included in a motor, a generator, and the like, and a method for manufacturing the angle detector.

In order to detect the rotation angle of a motor rotor arranged around a housing conventionally used as a shaft, an annular resolver rotor is fixed to the motor rotor, and an annular resolver stator core is fixed to the housing to detect the resolver stator core. Is known as a resolver in which the resolver is placed inside the rotor. The rotation angle of the motor rotor is detected based on the induced electromotive force generated in a plurality of coils provided in the resolver stator core (see, for example, Patent Document 1).

Japanese Patent No. 5892196

In the conventional resolver shown in Patent Document 1, the resolver stator is fixed to a housing used as a shaft. Therefore, for a plurality of motors having different outer diameters of the housing, it is necessary to prepare a plurality of types of resolver stator cores according to the outer diameter of each housing. Therefore, the number of types of resolver stator cores increases, and the manufacturing cost of the resolver increases.

The present invention has been made to solve the above problems, and an object of the present invention is to obtain an angle detector capable of reducing costs and a method for manufacturing the angle detector.

The angle detector according to the present invention includes an annular detector rotor and an annular detector stator arranged inside the detector rotor, and the detector stator is an annular stator core and a stator. It has a plurality of coils provided on the iron core, and the stator core is an annular first stator core portion provided with the plurality of coils and an annular shape arranged inside the first stator core portion. The outer peripheral portion of the second stator core portion fits into the inner peripheral portion of the first stator core portion, and the stator core has a first stator core. A stator slot that intersects the boundary between the inner peripheral portion of the portion and the outer peripheral portion of the second stator core portion is provided.

According to the angle detector according to the present invention and the method for manufacturing an angle detector, a detector stator that can be attached to each of a plurality of fixed shafts having different outer diameters can be obtained. As a result, the cost of the angle detector can be reduced.

It is a perspective view which shows the rotary electric machine to which the resolver according to Embodiment 1 of this invention is attached. It is a front view which shows the rotary electric machine of FIG. It is sectional drawing along the line III-III of FIG. It is a perspective view which shows the resolver of FIG. FIG. 5 is a layout diagram showing a second reference hole, a plurality of stator elongated holes, and a plurality of rotor mounting holes formed by the first step of press working in the first embodiment of the present invention. It is a layout figure which shows the boundary formed by the 2nd step of the press working in Embodiment 1 of this invention. FIG. 5 is a layout diagram showing the outer shape of each core piece of the first stator core portion and the detector rotor formed by the third step of press working in the first embodiment of the present invention. It is a front view which shows the state which attached the resolver to the fixed shaft which has the outer diameter larger than the outer diameter of the fixed shaft of FIG. FIG. 5 is a cross-sectional view taken along the line IX-IX of FIG. It is sectional drawing which shows the positional relationship between the fixing bolt which fixes a detector stator to the fixing shaft of FIG. 3 and the fixing bolt which fixes a detector stator to the fixing shaft of FIG. It is a front view which shows the rotary electric machine to which the resolver by the comparative example is attached. It is sectional drawing along the XII-XII line of FIG. It is a perspective view which shows the resolver of FIG. It is a layout figure which shows the outer shape of each core piece of a detector rotor and a stator core formed by press working in a comparative example. It is sectional drawing which shows the state which the resolver of FIG. 13 is attached to the fixed shaft which the outer diameter of the main body shaft part is larger than the outer diameter of a back yoke part. It is a front view which shows the rotary electric machine to which the resolver according to Embodiment 2 of this invention is attached. FIG. 5 is a layout diagram showing the outer shape of each core piece of the first stator core portion and the second stator core portion formed by the third step of press working in the second embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Embodiment 1.
FIG. 1 is a perspective view showing a rotary electric machine to which a resolver according to the first embodiment of the present invention is attached. Further, FIG. 2 is a front view showing the rotary electric machine of FIG. Further, FIG. 3 is a cross-sectional view taken along the line III-III of FIG. In the figure, the rotary electric machine 1 includes a fixed shaft 2 fixed to a support member (not shown), a tubular rotary electric machine rotor 4 rotatably supported by the fixed shaft 2 via a bearing 3, and a rotary electric machine rotor. It has a rotary electric stator which is an armature (not shown) arranged inside 4.

As shown in FIG. 3, the fixed shaft 2 has a main body shaft portion 5 and a protruding shaft portion 6 projecting from the end surface of the main body shaft portion 5. The protruding shaft portion 6 is arranged coaxially with the main body shaft portion 5. Further, the outer diameter of the protruding shaft portion 6 is smaller than the outer diameter of the main body shaft portion 5. As a result, on the fixed shaft 2, a step portion 7 is formed along the circumferential direction of the fixed shaft 2 by the end surface of the main body shaft portion 5 and the outer peripheral surface of the protruding shaft portion 6.

The rotary electric machine rotor 4 is rotatable about the axis of the fixed shaft 2 with respect to the rotary electric machine stator. In the rotary electric machine 1, the rotary electric machine rotor 4 rotates with respect to the rotary electric machine stator by supplying power to the rotary electric machine stator. The rotary electric machine rotor 4 has a cylindrical boss portion 8 through which a fixed shaft 2 is passed. The bearing 3 is fitted between the inner peripheral surface of the boss portion 8 and the outer peripheral surface of the main body shaft portion 5.

The rotary electric machine 1 is provided with a resolver 11 which is an angle detector for detecting the rotation angle of the rotary electric machine rotor 4. The resolver 11 has an annular detector rotor 12 fixed to the boss portion 8 of the rotary electric machine rotor 4 and an annular detector stator 13 fixed to the fixed shaft 2.

FIG. 4 is a perspective view showing the resolver 11 of FIG. The detector rotor 12 is an annular rotor core made of a magnetic material. On the inner peripheral surface of the detector rotor 12, a plurality of convex portions arranged at equal intervals in the circumferential direction of the detector rotor 12 are formed.

The detector rotor 12 is provided with a plurality of rotor mounting holes 14 at intervals in the circumferential direction. Each rotor mounting hole 14 penetrates the detector rotor 12. In this example, each rotor mounting hole 14 is a round hole.

As shown in FIG. 3, the detector rotor 12 is fixed to the boss portion 8 of the rotary electric machine rotor 4 by a plurality of fixing bolts 15 passed through the rotor mounting holes 14. Further, the detector rotor 12 is arranged coaxially with the fixed shaft 2. As a result, the detector rotor 12 rotates integrally with the rotary electric machine rotor 4 about the axis of the fixed shaft 2.

The detector stator 13 is arranged inside the detector rotor 12. As a result, the outer peripheral portion of the detector stator 13 faces the inner peripheral portion of the detector rotor 12 via a gap in the radial direction of the fixed shaft 2. Further, the detector stator 13 has an annular stator core 16 fixed to the fixed shaft 2 and a plurality of coils 17 provided on the stator core 16.

The stator core 16 has an annular first stator core portion 18 and an annular second stator core portion 19 arranged inside the first stator core portion 18. Each of the first stator core portion 18 and the second stator core portion 19 is arranged coaxially with the fixed shaft 2. In this example, each of the first stator core portion 18 and the second stator core portion 19 has an annular shape.

The first stator core portion 18 is formed with a first reference hole surrounded by an inner peripheral portion of the first stator core portion 18. The second stator core portion 19 is formed with a second reference hole surrounded by the inner peripheral portion of the second stator core portion 19. The inner diameter of the first reference hole is larger than the inner diameter of the second reference hole.

The first stator core portion 18 has an annular back yoke portion 20 and a plurality of teeth portions 21 projecting radially outward from the outer peripheral portion of the back yoke portion 20. The plurality of teeth portions 21 are provided at equal intervals in the circumferential direction of the first stator core portion 18.

The plurality of coils 17 are individually provided in the plurality of teeth portions 21. As a result, the plurality of coils 17 are arranged at equal intervals in the circumferential direction of the first stator core portion 18. In the resolver 11, when the detector rotor 12 rotates, an induced electromotive force corresponding to the rotation of the detector rotor 12 is generated in the plurality of coils 17. The rotation angle of the rotary electric machine rotor 4 is detected based on a signal corresponding to the induced electromotive force generated in the plurality of coils 17.

The outer peripheral portion of the second stator core portion 19 fits tightly into the inner peripheral portion of the first stator core portion 18. Further, the second stator core portion 19 is removable from the first stator core portion 18. When the outer peripheral portion of the second stator core portion 19 is fitted into the inner peripheral portion of the first stator core portion 18, the first stator core portion 18 is coaxial with the second stator core portion 19. Have been placed. In this example, as shown in FIG. 2, the shape of the boundary 22 between the inner peripheral portion of the first stator core portion 18 and the outer peripheral portion of the second stator core portion 19 is circular.

Each of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 is a laminated body in which a plurality of plate-shaped core pieces are laminated. The stacking direction of the core pieces in each of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 coincides with the axial direction of the fixing shaft 2. As a result, the increase in iron loss due to the eddy current in each of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 is suppressed. In this example, a laminated steel plate formed by laminating thin plates as core pieces is used as each of the detector rotor 12, the first stator core portion 18, and the second stator core portion 19. ..

As shown in FIG. 4, the stator core 16 has a plurality of stator lengths intersecting the boundary 22 between the inner peripheral portion of the first stator core portion 18 and the outer peripheral portion of the second stator core portion 19. The hole 23 is provided as a mounting hole. That is, a plurality of first notches opened inward in the radial direction are provided on the inner peripheral portion of the first stator core portion 18. A plurality of second notches open to the outside in the radial direction are provided on the outer peripheral portion of the second stator core portion 18. In a state where the outer peripheral portion of the second stator core portion 19 is fitted into the inner peripheral portion of the first stator core portion 18, the position of each first notch portion and the position of each second notch portion A plurality of stator elongated holes 23 are formed in the stator core 16 by matching the two in the circumferential direction. The plurality of stator elongated holes 23 are provided so as to be spaced apart from each other in the circumferential direction of the stator core 16. In this example, the major axis direction of each stator slot 23 coincides with the radial direction of the stator core 16.

As shown in FIG. 3, the stator core 16 is arranged in the stepped portion 7 with the protruding shaft portion 6 passed inside the second stator core portion 19. Further, the stator core 16 is fixed to the end surface of the main body shaft portion 5 by a plurality of fixing bolts 24 passed through the stator elongated holes 23. As shown in FIG. 2, each of the fixing bolts 24 has the inner peripheral portion of the first stator core portion 18 and the outer peripheral portion of the second stator core portion 19 at a position straddling the boundary 22 together with the main body shaft portion 5. It is fixed to the end face of.

In this example, the outer diameter of the protruding shaft portion 6 coincides with the inner diameter of the second reference hole of the second stator core portion 19. Therefore, the outer peripheral surface of the protruding shaft portion 6 fits tightly into the inner peripheral portion of the second stator core portion 19. As a result, the stator core 16 is positioned with respect to the fixed shaft 2 in the radial direction of the fixed shaft 2.

Next, a method of manufacturing the detector rotor 12 and the stator core 16 will be described. When manufacturing the detector rotor 12 and the stator core 16, first, the core pieces of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 are manufactured. Each core piece of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 is formed by pressing the same thin plate made of a magnetic material. .. In press working on a thin plate, a core piece is punched out from the thin plate using a die.

Further, when manufacturing the core pieces of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19, the second reference hole of the second stator core portion 19, The first step of punching out each stator slot 23 of the stator core 16 and each rotor mounting hole 14 of the detector rotor 12 from the thin plate is performed. After that, the second step of forming the boundary 22 between the first stator core portion 18 and the second stator core portion 19 on the thin plate is performed. After that, a third step is performed in which the outer shapes of the core pieces of the detector rotor 12 and the stator core 16 are punched out from the thin plate.

FIG. 5 is a layout diagram showing a second reference hole, a plurality of stator elongated holes 23, and a plurality of rotor mounting holes 14 formed by the first step of press working in the first embodiment of the present invention. In the first step, by using a mold, the second reference hole of the second stator core portion 19, each rotor mounting hole 14 of the detector rotor 12, and each stator slot 23 of the stator core 16 Is punched out from the thin plate 100. As a result, in the thin plate 100, each of the inner portion 103 of the stator core 16, the inner portion 104 of each rotor mounting hole 14, and the inner portion 105 of each stator slot 23 becomes scraps.

FIG. 6 is a layout diagram showing a boundary 22 formed by the second step of press working in the first embodiment of the present invention. In the second step, by using a die, the outer shape of the core piece of the second stator core portion 19 is punched out from the thin plate 100, and the first stator core portion 18 and the second stator core portion 19 are formed. Boundary 22 is formed on the thin plate 100. At this time, the second stator core portion 19 is punched once with respect to the thin plate 100 in the die, and then the second stator core portion 19 is returned to the inside of the thin plate 100 by pushback processing. As a result, the second stator core portion 19 is punched out from the thin plate 100 in a state where the outer peripheral portion of the second stator core portion 19 is in contact with the thin plate 100 at the boundary 22.

FIG. 7 is a layout diagram showing the outer shape of each core piece of the first stator core portion 18 and the detector rotor 12 formed by the third step of press working in the first embodiment of the present invention. In the third step, the outer shape of each core piece of the detector rotor 12 and the stator core 16 is punched out from the thin plate 100 by using a die. As a result, the outer portion 101 of the core piece of the detector rotor 12 and the portion 102 between the core piece of the detector rotor 12 and the core piece of the stator core 16 become scraps. The scraps 101 to 105 remaining after the core pieces of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 are punched from the thin plate 100 are discarded.

After that, the detector rotor 12 and the stator core 16 are completed by laminating the core pieces of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19.

After that, the resolver 11 is completed by providing the coils 17 in each of the teeth portions 21 of the stator core 16.

Next, a case where the resolver 11 is attached to the rotary electric machine 1 in which the outer diameters of the main body shaft portion 5 and the protruding shaft portion 6 of the fixed shaft 2 are larger than those of the fixed shaft 2 shown in FIG. 2 will be described. FIG. 8 is a front view showing a state in which the resolver 11 is attached to the fixed shaft 2 having an outer diameter larger than the outer diameter of the fixed shaft 2 of FIG. Further, FIG. 9 is a cross-sectional view taken along the line IX-IX of FIG. The outer diameter D2 of the main body shaft portion 5 of the fixed shaft 2 shown in FIGS. 8 and 9 is larger than the outer diameter D1 of the main body shaft portion 5 of the fixed shaft 2 shown in FIGS. 2 and 3. Further, the outer diameter of the protruding shaft portion 6 of the fixed shaft 2 shown in FIGS. 8 and 9 is also larger than the outer diameter of the main body shaft portion 5 of the fixed shaft 2 shown in FIGS. 2 and 3. Further, the outer diameter D2 of the main body shaft portion 5 shown in FIGS. 8 and 9 is larger than the inner diameter of the first stator core portion 18, that is, the inner diameter of the first reference hole. Further, the outer diameter of the protruding shaft portion 6 shown in FIGS. 8 and 9 is larger than the inner diameter of the second stator core portion 19, that is, the inner diameter of the second reference hole.

When the outer diameter of the protruding shaft portion 6 of the rotary electric machine 1 is larger than the inner diameter of the second stator core portion 19, that is, the inner diameter of the second reference hole, it protrudes inward of the second stator core portion 19. The shaft portion 6 cannot be passed through. In this case, the detector stator 13 is attached to the fixing shaft 2 in a state where the second stator core portion 19 is removed from the first stator core portion 18.

In a state where the second stator core portion 19 is removed from the first stator core portion 18, the second stator core portion 19 disappears from the inside of the first stator core portion 18. The protruding shaft portion 6 can be passed through the inside of the first stator core portion 18. Further, in a state where the second stator core portion 19 is removed from the first stator core portion 18, the radial inner portion of each stator slot 23 disappears, so that the first stator core portion is formed. A plurality of first notches formed in the inner peripheral portion of 18 are opened into the first reference hole.

When the outer diameter of the protruding shaft portion 6 is larger than the inner diameter of the second stator core portion 19, the second stator core portion 19 is removed from the first stator core portion 18 and the first The stator core 16 is arranged in the stepped portion 7 with the protruding shaft portion 6 passed inside the stator core portion 18. Further, when the outer diameter of the protruding shaft portion 6 is larger than the inner diameter of the second stator core portion 19, each first notch formed in the inner peripheral portion of the first stator core portion 18 is formed. The stator core 16 is fixed to the end face of the main body shaft portion 5 by a plurality of fixing bolts 24 passed through the portions.

As shown in FIGS. 8 and 9, the inner diameter of the first stator core portion 18 coincides with the outer diameter of the protruding shaft portion 6 protruding from the end surface of the main body shaft portion 5 having the outer diameter D2. Therefore, when the protruding shaft portion 6 protruding from the end surface of the main body shaft portion 5 having the outer diameter D2 is passed inside the first stator core portion 18, the outer peripheral surface of the protruding shaft portion 6 becomes the first stator. It fits tightly into the inner peripheral portion of the iron core portion 18. As a result, the stator core 16 is positioned with respect to the fixed shaft 2 in the radial direction of the fixed shaft 2.

FIG. 10 is a cross-sectional view showing a positional relationship between a fixing bolt 24 for fixing the detector stator 13 to the fixing shaft 2 of FIG. 3 and a fixing bolt 24 for fixing the detector stator 13 to the fixing shaft 2 of FIG. Is. As shown in FIG. 10, the position of the fixing bolt 24 for fixing the detector stator 13 to the fixed shaft 2 in which the outer diameter of the main body shaft portion 5 is D2 is such that the outer diameter of the main body shaft portion 5 is larger than that of D2. It is located radially outside by a distance t from the position of the fixing bolt 24 that fixes the detector stator 13 to the fixed shaft 2 which is a small D1. As a result, even if the outer diameter of the protruding shaft portion 6 becomes large, it is possible to prevent the fixing bolt 24 from interfering with the protruding shaft portion 6.

Next, a resolver according to a comparative example for comparison with the resolver 11 according to the present embodiment will be described. FIG. 11 is a front view showing a rotary electric machine to which a resolver according to a comparative example is attached. Further, FIG. 12 is a cross-sectional view taken along the line XII-XII of FIG. Further, FIG. 13 is a perspective view showing the resolver of FIG. Among the configurations of the resolver 11a according to the comparative example, the configurations other than the detector stator 13a are the same as the configurations of the resolver 11 according to the present embodiment.

The detector stator 13a of the resolver 11a according to the comparative example has an annular stator core 31 and a plurality of coils 17 provided on the stator core 31. The configuration of the plurality of coils 17 according to the comparative example is the same as that of the coils 17 of the present embodiment.

The stator core 31 according to the comparative example has an annular back yoke portion 31a and a plurality of tooth portions 31b protruding radially outward from the outer peripheral portion of the back yoke portion 31a. The stator core 31 is formed with a reference hole surrounded by the inner peripheral portion of the back yoke portion 31a. The plurality of tooth portions 31b are provided at equal intervals in the circumferential direction of the stator core 31. Further, the stator core 31 according to the comparative example is a laminated body in which a plurality of plate-shaped core pieces are laminated, as in the present embodiment.

As shown in FIG. 13, a plurality of stator mounting holes 32 are formed in the back yoke portion 31a. The plurality of stator mounting holes 32 are arranged so as to be spaced apart from each other in the circumferential direction of the stator core 31. Each stator mounting hole 32 is a round hole.

When the detector stator 13a is attached to the fixed shaft 2 of the rotary electric machine 1, the stator core 31 is arranged in the stepped portion 7 with the protruding shaft portion 6 passed inside the back yoke portion 31a. Further, when the detector stator 13a is attached to the fixing shaft 2, the stator core 31 is fixed to the end surface of the main body shaft portion 5 by a plurality of fixing bolts 24 passed through the stator mounting holes 32.

When the outer diameter of the main body shaft portion 5 of the fixed shaft 2 is smaller than the outer diameter of the back yoke portion 31a, each coil has the detector stator 13a attached to the fixed shaft 2 as shown in FIG. 17 is arranged radially outside the outer peripheral surface of the main body shaft portion 5. Therefore, in this case, the detector stator 13a is attached to the fixed shaft 2 without the coils 17 interfering with the main body shaft portion 5.

When each of the detector rotor 12 and the stator core 31 of the resolver 11a according to the comparative example is manufactured, the core pieces are prepared and then the prepared core pieces are laminated. When the core pieces of the detector rotor 12 and the stator core 31 are manufactured, the outer shape of each core piece of the detector rotor 12 and the stator core 31 is punched from the same thin plate. In the comparative example, when the core pieces of the detector rotor 12 and the stator core 31 are produced, the second step including pushback processing is not performed.

FIG. 14 is a layout diagram showing the outer shape of each core piece of the detector rotor 12 and the stator core 31 formed by press working in the comparative example. In the comparative example, when the outer shape of each core piece of the detector rotor 12 and the stator core 31 is punched out from the thin plate 100, each rotor mounting hole 14 and each stator mounting hole 32 are also punched out from the thin plate 100 at the same time. .. As a result, of the thin plate 100, the outer portion 101 of the core piece of the detector rotor 12, the portion 102 between the core piece of the detector rotor 12 and the core piece of the stator core 31, and the stator core 31. The inner portion 103, the inner 104 of the rotor mounting hole 14, and the inner 105 of the stator mounting hole are each end materials. The scraps 101 to 105 remaining after the core pieces of the detector rotor 12 and the stator core 31 are punched out from the thin plate 100 are discarded.

Comparing FIG. 7 and FIG. 14, the core piece of the second stator core portion 19 according to the present embodiment is produced by using a part of the scrap 103 of FIG. 14 which is discarded in the comparative example. You can see that. Therefore, in the present embodiment, the amount of offcuts emitted from the thin plate 100 when the core piece is produced is smaller than that in the comparative example. Further, the size of the thin plate 100 required for producing the core piece is the same in the present embodiment and the comparative example.

FIG. 15 is a cross-sectional view showing a state in which the resolver 11a of FIG. 13 is attached to the fixed shaft 2 in which the outer diameter of the main body shaft portion 5 is larger than the outer diameter of the back yoke portion 31a. When the outer diameter of the main body shaft portion 5 of the fixed shaft 2 is larger than the outer diameter of the back yoke portion 31a, each coil 17 is attached to the end surface of the main body shaft portion 5 when the detector stator 13a is attached to the fixed shaft 2. May interfere with. Therefore, when the outer diameter of the main body shaft portion 5 of the fixed shaft 2 is larger than the outer diameter of the back yoke portion 31a, the circumferential groove 33 for avoiding interference with each coil 17 is provided on the main body shaft portion 5. It is formed on the outer peripheral portion of the end face. Therefore, in order to attach the detector stator 13a according to the comparative example to the fixed shaft 2 in which the outer diameter of the main body shaft portion 5 is larger than the outer diameter of the back yoke portion 31a, the outer circumference of the end surface of the main body shaft portion 5 of the fixed shaft 2 is attached. It is necessary to process the portion to form a circumferential groove 33.

Further, when the detector stator 13a according to the comparative example is attached to the fixed shaft 2 in which the outer diameter of the main body shaft portion 5 is larger than the outer diameter of the back yoke portion 31a, a circumferential groove 33 is provided in the main body shaft portion 5 of the fixed shaft portion 2. In order to eliminate the need for forming, another stator core 31 having an outer diameter of the back yoke portion 31a larger than the outer diameter of the main body shaft portion 5 can be manufactured, or the end face of the main body shaft portion 5 and the back yoke can be manufactured. It is necessary to add a bracket which is a separate component to be interposed between the portion 31a and the portion 31a.

On the other hand, in the resolver 11 according to the present embodiment, the outer peripheral portion of the second stator core portion 19 is fitted into the inner peripheral portion of the first stator core portion 18. Further, the stator core 16 is provided with a stator slot 23 that intersects the boundary 22 between the inner peripheral portion of the first stator core portion 18 and the outer peripheral portion of the second stator core portion 19.

Therefore, when the inner diameter of the second stator core portion 19 is larger than the outer diameter of the protruding shaft portion 6 of the fixed shaft 2, the protruding shaft portion 6 is passed inside the second stator core portion 19. The detector stator 13 can be attached to the fixed shaft 2 in this state. When the inner diameter of the second stator core portion 19 is smaller than the outer diameter of the protruding shaft portion 6 of the fixing shaft 2, the second stator core portion 19 is removed from the first stator core portion 18. Therefore, the detector stator 13 can be attached to the fixing shaft 2 in a state where the protruding shaft portion 6 is passed inside the first stator core portion 18. That is, it is possible to obtain a detector stator 13 that can be attached to each of the plurality of fixed shafts 2 having different outer diameters.

As a result, a plurality of detector stators corresponding to each of the plurality of fixed shafts 2 having different outer diameters can be manufactured, and another component to be interposed between the end face of the main body shaft portion 5 and the detector stator can be added. You can eliminate the trouble of doing it. Further, it is possible to eliminate the trouble of forming a circumferential groove 33 on the outer peripheral portion of the end surface of the main body shaft portion 5. Therefore, it is possible to reduce the costs of the resolver 11 and the rotary electric machine 1.

Further, each of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 is a laminated body in which a plurality of plate-shaped core pieces are laminated. Therefore, it is possible to suppress an increase in iron loss due to eddy currents in each of the detector rotor 12, the first stator core portion 18, and the second stator core portion 19. Further, each of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 can be easily manufactured.

Further, in the method for manufacturing the resolver 11 according to the present embodiment, the cores of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 are respectively formed by pressing the same thin plate 100. Form a piece. Therefore, each core piece of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 can be manufactured from the same thin plate 100, and the manufacturing cost of the resolver 11 can be reduced. Can be achieved.

Embodiment 2.
FIG. 16 is a front view showing a rotary electric machine to which a resolver according to the second embodiment of the present invention is attached. A recess 41 is provided in the inner peripheral portion of the first stator core portion 18. In this example, the concave portion 41 has a rectangular shape. Further, in this example, the depth direction of the recess 41 coincides with the radial direction of the stator core 16.

A convex portion 42 that fits into the concave portion 41 is provided on the outer peripheral portion of the second stator core portion 19. The convex portion 42 fits into the concave portion 41 without a gap. Therefore, in this example, the shape of the convex portion 42 is rectangular. Further, the convex portion 42 projects radially outward from the second stator core portion 19. The convex portion 42 fits into the concave portion 41 by fitting the outer peripheral portion of the second stator core portion 19 into the inner peripheral portion of the first stator core portion 18. Other configurations are the same as those in the first embodiment.

The method for producing the resolver 11 according to the present embodiment is also the same as that of the first embodiment. Therefore, the core pieces of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19 are each formed by pressing the same thin plate made of a magnetic material. Form. When manufacturing the core pieces of the detector rotor 12, the first stator core portion 18 and the second stator core portion 19, the second reference hole and the stator of the second stator core portion 19 The first step of punching each stator slot 23 of the iron core 16 and each rotor mounting hole 14 of the detector rotor 12 from the thin plate is performed. After that, the second step of forming the boundary 22 between the first stator core portion 18 and the second stator core portion 19 on the thin plate is performed. After that, a third step is performed in which the outer shapes of the core pieces of the detector rotor 12 and the stator core 16 are punched out from the thin plate.

FIG. 17 is a layout diagram showing the outer shape of each core piece of the first stator core portion 18 and the second stator core portion 19 formed by the third step of press working in the second embodiment of the present invention. Is. In the second step of the press working, the boundary 22 between the core piece of the inner peripheral portion of the first stator core portion 18 and the core piece of the second stator core portion 19 is pushed back as in the first embodiment. Formed by processing. Further, the outer shape of each core piece of the detector rotor 12 and the stator core 16 formed by the third step of press working is the outer shape of each core piece of the detector rotor 12 and the stator core 16 of FIG. It is the same as the outer shape.

The shape of the boundary 22 between the inner peripheral portion of the core piece of the first stator core portion 18 and the outer peripheral portion of the core piece of the second stator core portion 19 is different from that of the first embodiment, and a part of the circle is formed. It has a deformed shape. Of the boundary 22 between the inner peripheral portion of the core piece of the first stator core portion 18 and the outer peripheral portion of the core piece of the second stator core portion 19, the portion deviating from the circle is the concave portion 41 and the convex portion 42. It is formed as a boundary with. The concave portion 41 and the convex portion 42 are formed at the same time as the core pieces of the first stator core portion 18 and the second stator core portion 19 are formed.

In such a resolver 11, a recess 41 is provided in the inner peripheral portion of the first stator core portion 18. Further, a convex portion 42 that fits into the concave portion 41 is provided on the outer peripheral portion of the second stator core portion 19. Therefore, by fitting the convex portion 42 into the concave portion 41, the positioning of the second stator core portion 19 in the circumferential direction with respect to the first stator core portion 18 can be easily performed. As a result, the positions of the first notches formed on the inner peripheral portion of the first stator core portion 18 and the second cuts formed on the outer peripheral portion of the second stator core portion 19 are formed. The position of the notch can be easily matched in the circumferential direction. Therefore, it is possible to prevent the shape of each stator slot 23 from being deformed when the resolver 11 is attached to the fixing shaft 2, and the detector stator 13 is fixed to the fixing shaft 2 by the fixing bolt 24. The work can be facilitated.

In the above example, the recess 41 is provided on the inner peripheral portion of the first stator core portion 18, and the convex portion 42 that fits into the recess 41 is provided on the outer peripheral portion of the second stator core portion 19. .. However, the recess 41 may be provided on the outer peripheral portion of the second stator core portion 19, and the convex portion 42 fitted in the recess 41 may be provided on the inner peripheral portion of the first stator core portion 18.

Further, in the above example, each of the concave portion 41 and the convex portion 42 has a rectangular shape. However, the present invention is not limited to this, and the shapes of the concave portion 41 and the convex portion 42 may be elliptical, triangular, or the like.

Further, in the above example, the depth direction of the recess 41 coincides with the radial direction of the stator core 16, but the depth direction of the recess 41 is inclined in the circumferential direction with respect to the radial direction of the stator core 16. You may.

Further, in each of the above-described embodiments, the major axis direction of each stator slot 23 coincides with the radial direction of the stator core 16. However, the major axis direction of each stator slot 23 may be inclined in the circumferential direction with respect to the radial direction of the stator core 16.

Further, in each of the above-described embodiments, the number of the stator elongated holes 23 provided in the stator core 16 is a plurality. However, the number of the stator slot 23 may be one. That is, the number of the stator slot 23 provided in the stator core 16 may be one or more.

11 Resolver (angle detector), 12 Detector rotor, 13 Detector stator, 16 Stator core, 17 coil, 18 1st stator core, 19 2nd stator core, 23 Stator length Holes, 41 concaves, 42 convexes, 100 thin plates.

Claims (4)

It is provided with an annular detector rotor and an annular detector stator located inside the detector rotor.
The detector stator has an annular stator core and a plurality of coils provided on the stator core.
The stator core includes an annular first stator core portion provided with the plurality of coils and an annular second stator core portion arranged inside the first stator core portion. Have and
The outer peripheral portion of the second stator core portion is fitted into the inner peripheral portion of the first stator core portion.
An angle detector provided with a stator slot that intersects the boundary between the inner peripheral portion of the first stator core portion and the outer peripheral portion of the second stator core portion. Of the inner peripheral portion of the first stator core portion and the outer peripheral portion of the second stator core portion, one is provided with a concave portion, and the other is provided with a convex portion that fits into the concave portion. The angle detector according to claim 1. The detector rotor, the first stator core portion, and the second stator core portion are each a laminated body in which a plurality of plate-shaped core pieces are laminated according to claim 1 or 2. The angle detector described. The method for manufacturing the angle detector according to claim 3.
A method for manufacturing an angle detector that forms the core pieces of the detector rotor, the first stator core portion, and the second stator core portion by press working on the same thin plate.

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