Improved Winding Proposal for Wound Rotor Resolver Using Genetic Algorithm and Winding Function Approach

Among position sensors, resolvers are superior from reliability point of view. However, obtaining lower output voltage harmonics and simple manufacturing process is a challenge in the design and optimization of resolvers. In this paper, a metaheuristic optimization algorithm is used to minimize total harmonic distortion of the output signals, and consequently the estimated position error in concentrated coil wound field resolvers. Meanwhile, to minimize total coil numbers, manufacturing costs, and complexity of the winding process, modified objective function and constraints are proposed. In this way, a modified winding function method is employed for performance analysis of the axial flux resolver. Then, the merits of the optimized winding configuration with respect to fractional slot concentrated windings are shown. The results of the proposed configurations are verified with a three-dimensional time-stepping finite-element method. Finally, the prototype of the studied axial flux resolver is constructed and tested. Good agreement is obtained between simulation and experimental results, confirming the effectiveness of the optimization process.