Proposal of an Integrated Wound-Rotor PCB-Resolver With a PCB Rotary Transformer

Simplicity of structure is a crucial factor in selecting position sensors for mass production and industrial applications. Using printed circuit board (PCB) winding is a recent and effective method to reduce the complexity of the sensor’s manufacturing process. This paper proposes an integrated configuration for the axial flux wound rotor (AFWR) resolver and rotary transformer (RT) using PCB technology. The main advantages of the developed sensor include high precision, ease of manufacturing, simple structure, and relatively low manufacturing cost. A comprehensive design algorithm, along with practical techniques for enhancing sensor performance, is thoroughly discussed. A modified hybrid model is implemented to evaluate the sensor’s performance. Experimental tests on the prototype sensor were conducted at 300, 600, 3000, and 6000 rpm, with results showing a maximum position error of 0.121°. The proposed sensor demonstrates significant potential for industrial applications, offering a novel solution that combines simplicity with high performance.