Rotary position sensor
Apparatuses, systems, and methods for sensing rotary positions are provided. For example, an example rotary position sensor includes a rotor assembly having a rotor assembly opening for securing the rotor assembly to a shaft structure, a stator assembly having a stator assembly opening for receiving the shaft structure, and a base assembly secured to the stator assembly. In some examples, the base assembly (such as, but not limited to, a PCB assembly) comprises a plurality of primary coil elements printed on a first side of the base assembly and a plurality of secondary coil elements printed on a second side of the base assembly.
1 . A rotary position sensor comprising:
a rotor assembly comprising a rotor assembly opening for securing the rotor assembly to a shaft structure;
a stator assembly comprising a stator assembly opening for receiving the shaft structure; and
a base assembly secured to the stator assembly, wherein the base assembly comprises a plurality of primary coil elements printed on a first side of the base assembly and a plurality of secondary coil elements printed on a second side of the base assembly,
wherein radiuses of the plurality of primary coil elements are different,
wherein the rotor assembly comprises a plurality of rotor plates,
wherein the plurality of rotor plates are in an annular sector shape and have same size,
wherein the plurality of rotor plates are alternatingly positioned on the rotor assembly such that the plurality of rotor plates are not connected to one another,
wherein a rotor sector angle of each of the plurality of rotor plates is based on a rotor plate number such that the rotor sector angle equals 360 degrees divided by twice the rotor plate number, and
wherein the plurality of rotor plates comprise material having magnetic permeability.
2 . The rotary position sensor of claim 1 , wherein the base assembly is a printed circuit board (PCB) assembly, wherein the PCB assembly comprises a PCB assembly opening, wherein the PCB assembly opening is aligned with the stator assembly opening.
3 . The rotary position sensor of claim 2 , wherein the PCB assembly comprises at least two primary coil elements printed on a first side of the PCB assembly and at least four secondary coil elements printed on a second side of the PCB assembly.
4 . The rotary position sensor of claim 2 , wherein the plurality of primary coil elements are positioned radially away from the PCB assembly opening on the first side of the PCB assembly.
5 . The rotary position sensor of claim 2 , wherein a plurality of distances between a primary coil element center of each of the plurality of primary coil elements and a PCB assembly opening center of the PCB assembly opening are the same.
6 . The rotary position sensor of claim 2 , wherein the plurality of primary coil elements are distributed equally along a distribution circumference on the PCB assembly.
7 . The rotary position sensor of claim 2 , wherein the plurality of secondary coil elements comprises a plurality of secondary coil A elements and a plurality of secondary coil B elements, wherein each of the plurality of secondary coil A elements is positioned at a 90 degrees angle to one of the plurality of secondary coil B elements relative to a PCB assembly opening center of the PCB assembly opening, wherein the rotary position sensor further comprises:
a differential voltage detecting element electronically coupled to one of the plurality of secondary coil A elements and one of the plurality of secondary coil B elements to generate a differential voltage output indicating a voltage difference between the plurality of secondary coil A elements and the plurality of secondary coil B elements.
8 . The rotary position sensor of claim 2 , wherein the plurality of secondary coil elements comprises a plurality of sine coil elements and a plurality of cosine coil elements.
9 . The rotary position sensor of claim 8 , wherein each of the plurality of sine coil elements is positioned at a 90 degrees angle to one of the plurality of cosine coil elements relative to a PCB assembly opening center of the PCB assembly opening.
10 . The rotary position sensor of claim 8 , wherein the plurality of sine coil elements are electrically connected in series, wherein the plurality of cosine coil elements are electrically connected in series.
11 . The rotary position sensor of claim 10 , further comprising:
a sine voltage detecting element electronically coupled to the plurality of sine coil elements to generate a sine voltage output indicating a sine voltage of plurality of sine coil elements; and
a cosine voltage detecting element electronically coupled to the plurality of cosine coil elements to generate a cosine voltage output indicating a cosine voltage of plurality of cosine coil elements.
12 . The rotary position sensor of claim 2 , wherein the plurality of secondary coil elements are positioned radially away from the PCB assembly opening on the second side of the PCB assembly.
13 . The rotary position sensor of claim 2 , wherein a plurality of distances between a secondary coil element center of each of the plurality of secondary coil elements and a PCB assembly opening center of the PCB assembly opening are the same.
14 . The rotary position sensor of claim 2 , wherein the plurality of secondary coil elements are distributed equally along a distribution circumference on the PCB assembly.
15 . The rotary position sensor of claim 1 , wherein a secondary coil element number associated with the plurality of secondary coil elements is twice a primary coil element number associated with the plurality of primary coil elements.
16 . The rotary position sensor of claim 15 , wherein the primary coil element number corresponds to a resolver speed of the rotary position sensor.
17 . The rotary position sensor of claim 1 , wherein the stator assembly comprises a plurality of stator plates.
18 . The rotary position sensor of claim 17 , wherein a stator plate number associated with the plurality of stator plates is the same as a secondary coil element number associated with the plurality of secondary coil elements.
19 . The rotary position sensor of claim 17 , wherein a rotor plate number associated with the plurality of rotor plates is half of a stator plate number associated with the plurality of stator plates.
20 . The rotary position sensor of claim 19 , wherein the stator assembly comprises at least four stator plates, wherein the rotor assembly comprises at least two rotor plates.