Design, Simulation, and Fault Resilience Analysis of a Wound Rotor Resolver Based on a Novel Resilience Function

Wound rotor (WR) resolvers are among the most critical position sensors, widely valued for their high accuracy, strong resistance-to-temperature variations, and extended operational lifespan. Recognizing the significant influence of winding configurations on the resolver performance, this article investigates the performance of rotational WR resolvers with different excitation winding arrangements and compares their effectiveness. The results indicate that the proposed resolver with a toroidal excitation winding exhibits notably high accuracy. Furthermore, given that both electrical and mechanical faults can substantially impact resolver functionality, the performance of each design is analyzed under various electrical and mechanical fault conditions. To quantitatively evaluate the resolver’s fault tolerance, a novel resilience function based on the cumulative distribution function (cdf) is introduced, which estimates the probability that the position error index [absolute average of position error (AAPE)] remains below a defined threshold under both healthy and various fault conditions. The simulation and theoretical results are finally validated through experimental testing on a fabricated prototype.