Multi-resolver rotation angle sensor with integrated housing

Abstract

A rotation angle sensor includes: (a) a multi-resolver housing with a high precision structure; (b) stator terminals that do not cause deformation or loosening of terminal pins from the substrates to which they are attached; and (3) a signal line connection structure that is not affected by thermal stress. The housing ( 10 ) includes divisional housings ( 10 a , 10 b ), and one resolver is installed in each of the divisional housings ( 10 a , 10 b ). The divisional housings ( 10 a , 10 b ) are assembled by aligning respective openings therein in an axial direction. The lead lines of stator windings are connected to printed circuit substrates ( 51 ) installed on insulators ( 20 a , 20 b ) , and pins ( 54 ) connect the printed circuit substrates ( 51 ) to a connecting signal output line via flexible connectors ( 61, 64 ).

1 - 9 . (canceled) 
   
   
       10 . A stator configuration for a multi-resolver rotation angle sensor, comprising:
 at least two stators, each including:   a ring-shaped stator stack;   a pair of insulators each located on one side of the ring-shaped stator stack, each being ring-shaped to correspond to the ring-shaped stator stack, and each including a plurality of supporters projecting orthogonally from a respective surface thereof;   a pair of printed circuit substrates each defining a plurality of holes in which the plurality of supporters of a corresponding one of the pair of insulators are secured, and each being connected to respective lead lines of the stator windings to relay rotation angle signals from the stator windings.   
   
   
       11 . The stator configuration of  claim 10 , further comprising a plurality of pins secured to one of the pair of printed circuit substrates to connect the respective lead lines of the stator windings to an external signal output line. 
   
   
       12 . The stator configuration of  claim 11 , wherein the pins are connected to the external signal output line through flexible connection lines to absorb distortion and vibration generated by thermal stress to therefore maintain an electrical connection between the respective lead lines of the stator windings and the external signal output line. 
   
   
       13 . The stator configuration of  claim 12 , wherein the flexible connection lines each comprise one of a flexible printed circuit substrate and a flexible wire. 
   
   
       14 . The stator configuration of  claim 12 , wherein each of the flexible connection lines includes a backlash. 
   
   
       15 . The stator configuration of  claim 12 , further comprising:
 a housing in which the at least two stators are mounted; and   a connection substrate fastened to the housing for connecting the flexible connection lines to the external signal output line.   
   
   
       16 . The stator configuration of  claim 10 , further comprising:
 a housing in which the at least two stators are mounted; and   a connection substrate fastened to the housing for connecting the respective lead lines of the stator windings to an external signal output line.   
   
   
       17 . The stator configuration of  claim 11 , wherein each of the pair of printed circuit substrates is ring-shaped to correspond to the ring-shaped stator stack, and the one of the pair of printed circuit substrates that includes the plurality of pins includes a reinforced substrate and a wiring lead portion through which the plurality of pins are secured. 
   
   
       18 - 20 . (canceled)