High-Precision Variable Reluctance Resolver With Segmented Sinusoidal Parameter Winding and Magnetic Wedge for New Energy Vehicle Applications

This study introduces a novel segmented sinusoidal parameter winding and magnetic wedge variable reluctance resolver (SSPWMW-VRR), designed to address the limitations of conventional variable reluctance resolver (VRR) in electric vehicle motor control applications. The SSPWMW-VRR integrates advanced features such as segmented sinusoidal windings, magnetic slot wedges, and printed circuit board (PCB) connections to enhance signal accuracy, reduce slot leakage flux fluctuations, and improve winding orthogonality. A comprehensive investigation, including magnetic equivalent circuit (MEC) modeling, finite-element analysis (FEA) with resolver-to-digital converter (RDC) co-simulations, and prototype testing, was conducted to validate the effectiveness of the proposed design. The results demonstrate significant improvements, with a reduction in signal error from ±15 to within ±5 arcminutes and a 67% decrease in harmonic amplitude. These advancements offer a cost-effective, high-precision solution for motor control in new energy vehicles, optimizing both performance and production efficiency in the automotive industry.