Optimization and Performance Evaluation of a Multiturn, Outer Rotor VR Resolver for Enhanced Accuracy and Manufacturability

This article presents an optimized design for a multiturn outer rotor variable reluctance (VR) resolver, focusing on enhancing its accuracy, manufacturability, and overall performance. An analytical model is developed to evaluate the influence of key design parameters, including rotor contour, winding configuration, and the number of turns per layer. Through a comprehensive optimization process, the best combinations of these parameters are identified, improving both the precision and efficiency of the resolver. The study also explores the impact of rotor yoke thickness on sensor accuracy, offering insights into the tradeoffs between compactness and precision. Experimental validation is conducted by fabricating a prototype based on the optimized design and comparing its performance with simulation results. The prototype demonstrates excellent agreement with the simulations, exhibiting low position errors and confirming the effectiveness of the proposed design and optimization strategy. The findings provide a practical framework for designing high-precision VR resolvers, balancing accuracy, cost-effectiveness, and ease of construction.