Patent ID: 7356910

Claim:
A method for manufacturing a rotation angle detector comprising: a sensor core in which a plurality of teeth are formed on an inner circumferential portion of an annular yoke; a sensor coil composed of an excitation winding and an output winding each constructed by installing a conductor wire on said teeth; an insulator mounted to said sensor core so as to electrically insulate said sensor core and said sensor coil; a connector formed integrally with said insulator so as to be positioned on an outer circumferential side of said yokes, a sensor rotor rotatably disposed inside said yoke, a plurality of terminal pins of said connector formed on a first surface side of said insulator; and a plurality of winding hooking pins formed so as to project from the first surface side of said insulator, wherein first and second lead wire portions corresponding to a winding start end and a winding finish end of each of said conductor wires wound on said teeth are each hooked on one of the winding hooking pins and joined to one of the terminal pins so as to have a predetermined amount of slack, said method comprising the steps of: mounting said insulator on said sensor core; disposing a plurality of winding slackening pins at predetermined positions between said teeth and said terminal pins so as to project outwardly on the first surface side of said insulator; winding said conductor wires so as to dispose said first lead wire portion of each of said conductor wires wound on said teeth under tension between said teeth and said terminal pin by hooking said first lead wire portion onto one of the winding hooking pins and one of the winding slackening pins corresponding to the wire start end thereof, and so as to dispose said second lead wire portion of each of said conductor wires wound on said teeth under tension between said teeth and said terminal pin by hooking said second lead wire portion onto another of the winding hooking pins and another of the winding slackening pins corresponding to the wire finish end thereof; and removing said wiring slackening pins so that said first and second lead wire portions have a predetermined amount of slack.