US 12,341,385 B2
Rotary electrical machine with remote position sensor
James C. Bach, Westfield, IN (US)
Assigned to BorgWarner Inc., Auburn Hills, MI (US)
Filed by BorgWarner Inc., Auburn Hills, MI (US)
Filed on Jul. 29, 2022, as Appl. No. 17/876,826.
Prior Publication US 2024/0039372 A1, Feb. 1, 2024
Int. Cl. H02K 11/33 (2016.01); G01B 7/30 (2006.01); G01D 5/14 (2006.01); H02K 11/215 (2016.01); H02K 11/25 (2016.01); H02K 11/27 (2016.01)
CPC H02K 11/33 (2016.01) [G01B 7/30 (2013.01); G01D 5/145 (2013.01); H02K 11/215 (2016.01); H02K 11/25 (2016.01); H02K 11/27 (2016.01); H02K 2211/03 (2013.01)] 20 Claims
OG exemplary drawing
 
1. An electronically controlled electric machine, comprising:
a rotating electric machine comprising a casing and a rotor shaft rotatably supported by the casing, the rotor shaft having a drive end and an opposite end;
a sensor target mounted on said opposite end of the rotor shaft;
a sensor board supported by the casing and comprising a shaft angle sensor positioned at said opposite end of the rotor shaft and configured to generate an electrical signal in response to movement of the sensor target relative to the shaft angle sensor;
a machine control board located outside the casing and comprising a controller; and
an electrical harness interconnecting the sensor board and the machine control board, wherein the electrical harness transmits from the sensor board to the machine control board a differential pair of electrical signals corresponding to the electrical signal generated by the shaft angle sensor,
wherein the shaft angle sensor generates a plurality of digital single-ended electrical signals comprising ABI signals and SPI signals in response to rotation of the rotor shaft, each single-ended electrical signal being converted to a corresponding differential pair of electrical signals to transmit from the sensor board to the machine control board via the electrical harness, and each differential pair of electrical signals received by the machine control board being converted to a corresponding single-ended electrical signal indicative of the angular position of the rotor shaft,
wherein shaft angle information is communicated between the shaft angle sensor and the controller via the SPI signals at start-up of the rotating electric machine and until an index pulse is generated, and
wherein the controller relies on the ABI signals to determine shaft angle and ignores the SPI signals for purposes of rotating electric machine control after the index pulse is generated.