2009　Motor, Drive & Automation Systems Conference

Principle and Applications of Resolvers

for Hybrid Electric Vehicles and others

Kanji Kitazawa, Ph.D.

Tamagawa Seiki Co. Ltd., Japan
 Resolver system for Hybrid Electric Vehicles
ECU board

Engine

R/D Converter IC
Generator Motor

VR-Resolvers (Angular sensors)

Power Unit of Hybrid Electric Vehicle (TOYOTA)

What is Resolver?

● Electro-magnetic induction type angle sensor

● Output voltage proportional to the rotational angle
by alternating current excitation.
● Basically consisting of electro-magnetic steel sheets
and coils.
● Superior performance to environmental conditions
MIL Standard type

Brushless type

Built-in type
VR type
 History of Resolvers
Period Developed items Market & application
● Resolver was developed ay MIT (Supported by U.S
1940s
Military)
● Vernier Resolver was developed in Bell Laboratory. ● Coordinate conversion computation (Polar
1950s ● MIL specifications (i.e. MIL-R-14346, MIL-S-2266 & coordinate to X-Y coordinate) for intercepting angle
MIL-R-2341) were established. detection of gun-ports.

● RD(SD) Conversion Circuit was developed. ● Various kinds of angle sensors in use of airplanes,
1960s missiles, warships and tanks.

● Brushless Resolver was developed. ● NC machine tools.

1970s ● Steel manufacturing lines.

● Multi-pole brushless Resolver was developed. ● Inertial navigation system for rockets.
● High accuracy multi-speed Resolver system was ● Radio telescopes for observatory.
1980s developed. ● Industrial robots, etc.
● Built-in brushless Resolver was developed.

● Resolver winding was automated for Smartsyn. ● Electric Vehicles

● Built-in type VR Resolver (Singlsyn) was developed. ● Hybrid Electric Vehicles
1990s
● RD conversion IC for vehicle-mount (Smartcoder)
was developed.
● Low cost VR-Resolver (Singlsyn) ● Electrical power steering system
2000s
 Trends in Resolvers

0.01”
(0.000003o)
Multi-speed resolver
0.1” systems (1x - 128x)
(0.00003o) Pursue Highest accuracy for
Multi-speed resolver angular sensors
systems (1x - 64x)
1”
(0.0003o) Multi-speed synchros
(1x - 128x)
10”
(0.003o)

1’ Multipole resolvers
(0.01o) (2x - 6x)

Built-in brushless
10’ Brushless resolvers Pursuit of low cost
resolvers (Smartsyn)
(0.2o)
Angle precision

Resolvers for aircraft

Part score
installation 21 VR-type resolvers 20
1o 20 (Singlsyn)
VR-type resolvers 10
(Singlsyn)
10o 5 0
1980 1990 2000 2010
Year
 48
History of down-sizing and parts-reduction of resolver
Number of integrated parts

40
(Size 21 resolver :Tamagawa-Seiki Co., ltd.)
30
30
21 20
20

10
5
0

MIL Standard type

Outline：
φ57×87
Weight：600g
Price of a resolver

Brushless type
Outline：φ57×121
Weight：800g

Built-in type
Outline：φ52×31
Weight：270g

Smartsyn
Outline：φ52×26 Outline：
Weight：220g Singlsyn φ52×12
Weight：85g
1960 1970 1980 1990 2000 2010
years
 All Types of Resolvers
Items Classification
• Resolver (Brush type)
Performances • Pancake type resolver (Pig-tale type)
(3) Brushless Resolver (Rotary transformer type)
(4) VR type Resolver
　Size (1) S08, S10, S11, S15, S23
(2) ------- Customer order size

　Construction (1) Shaft type

(2) Built-in type

　Number of (1) 1-phase excitation / 2-phase output (RX)

phases (2) 2-phase excitation / 1-phase output ( RT)
(3) 2-phase excitation / 2-phase output ( RS)

　Multi-pole • 1X type
(2) Multi-pole type (nX)
(3) Multi-speed type (1X-nX)

for Automotive (HEV) application

 Characteristics of an angular sensor
required for HEV traction motor (IPM motor)

1) Thin flat shape with large bore-hole

2) Wide operating temperature range of –40~ 150 ･C
3) High reliability under harsh environmental conditions
/Vibration /Shock /Oil-resistant
4) High resolution in angle detection
5) Absolute electrical angle detection
6) Low cost and mass production available
 Structure of VR Resolver
■ One-phase of exciting coil and two-phase output
coils are wound on the stator core.
■ Rotor consists of only electro-magnetic steel
Exciting coil
Output coil Rotor
sheets.

Stator ■ The contour of rotor is made as the permeance

of air-gap between the stator and rotor is varied in
θm
sinusoid depending on the shaft angle.
・
θm Rotor

Exciting
Cosine
voltage output
Ve
voltage
Vcos
Sine output
voltage
Vsin

Structure of 2X-VR Resolver

 Output based on number of rotor lobes
Available for Number of rotor lobes 2, 3 and 4 to increase Sin/Cos signal
resolution 2, 3 and 4 times respectively, and respond to the Motor poles
(4, 6 and 8 poles).
Stator
Rotor

N=2 (2lobs) N=3 (3 lobs) N=4 (4 lobs)

S1
R1
Exciter Cos output
ER1-R2 = E0 sinωt ES1-S3 = K E0 sinωt cosNθ
S3
R2
K　：　Transformation ratio S2 S4
N　：　Number of rotor lobes Sin output ES1-S4 = K E0 sinωt sinNθ
Θ ：　Rotor shaft angle
Shaft Angle　θ=（1/N )tan-1（ ES2-S4 / ES1-S3 ）
 Waveforms of VR-Resolver excitation and output voltage
Excitation

R1 S1

ER1-R2 ES1-S3

R2 S3
Excitation
ES2-S4 Output

S2 S4
Excitation: ER1-R2 = E1sinωt (1)
Output : ES1-S3 = kE1cosθsinωt (2) Cos output
　　　　 ES2-S4 = kE1sinθsinωt (3)

Ｅ：Excitation Voltage
ｆ：Excitation frequency
Ｋ：Transformation Ratio
θ：Shaft angle
Sin output
n： Number of Multiples (X)
Waveforms of Resolver excitation and output voltage
 Basic Principal of VR (Variable Reluctance) Resolver

Stator Teeth
Exciting current
i0 Coil A
φ

Rotor
δA iＡ

Cos output
δC

Θ
δB iB
δD
ψ
iC
iD
Coil B
Coil D Coil C
Sin output

Excitation　 ER1-R2 = E0 sinωt

Cos output ES1-S3 = K E0 sinωt cosθ
Sin output　ES2-S4 = K E0 sinωt sinθ
Angle 　θ=tan-1（ ES2-S4 / ES1-S3 ）
K = Transformation Ratio
Basic Principal of VR Resolver (for 1X)
 Advanced Singlsyn-Technology

・The low number of slots with multi-pole ・The terminal structure

winding technology realizes small size can be applied for mass
and high accuracy at low cost. production.

・The patented windings can cancel the

electric magnetic motor noise.

・The molded structure of the ・Automated wire binding

plastic insulation to the stator core achieves cost reduction
yields and improves reliability.
high strength.
・Any number of rotor lobes can be used ・Lead free by using
to correspond to the number of motor TIG welding .
poles.
 Characteristics of the VR Resolver
Characteristics of 2X-VR Resolver

Items Specification
　Outer Diameter 　　 132 mm
　Thickness of core-
　　　　4 mm
stack
　Number of slots 　　　　14

　Number of multiples 　　　　2 X

　Input / Output 1 phase ／ 2 phases

　Excitation Voltage 　　　7 Vrms

　Excitation frequency 　　　10 kHz

　Transformation Ratio 　　　0.23

2X-VR Resolver 　Input Impedance 　　　100 ohms

　Output Impedance 　　　250 ohms

 Description of Terms for Resolvers
Terms Unit Description

The multiplied speed ratio of the output angle signal is indicated. It shows as the
Number of － multiplied speed number followed with X. For example, in case of “2X” for shaft
Multiples angle multiplication, the output signal equivalent of 2 revolutions for 1 revolution of
shaft is generated. The number of poles is twice that of shaft angle multiplication.

－
Size Size, which is 2 digits, is the outer diameter as indicated in inches. (S52 = 5.2” OD)

Exciting side － The winding that power supply should be applied.

Power supply V,Hz Rated voltage and frequency applied to the exciting side.

Transformation
－ Ratio of maximum output voltage to the exciting voltage.
ratio (K)
Input
Ohms Minimum impedance of the exciting side, which is indicated as the symbol of Zro.
impedance
Output
Ohms Maximum impedance of the output side, which is indicated as the symbol of Zss
impedance
Phase shift Deg. Phase difference of waveforms between the exciting voltage and output voltage.

The accuracy of BRX type is mainly specified, which indicates the difference in the
Electrical error Minutes mechanical angle between the electrical angle presented by the ratio of output
voltages (i.e. ES1-S3 / ES2-S4) and the theoretical electrical angle.
 VR-Resolvers for Automotive
OD 80mm
OD 37mm

for EPS (7X type)

for EPS (7X type)

OD 100mm
OD 132mm

for HEV (2X type) for HEV (2X type)

 Features of VR - Resolvers (Singlsyn)

„„ Absolute
Absoluteangle
angledetection
detection
→
→Motor
MotorMagnetic
Magneticpole
poledetection
detectionand
andZeroZerospeed
speeddetection
detection
„„ High
Highresolution
resolution((12-bit
12-bitxxnXnX))
→　Smooth
→　Smoothmotion motionininrotation
rotation
„„ Thin
Thinflat
flatshape
shapewith
withlarge
largebore-hole
bore-hole
„„ High velocity→
-1
Highrotational
rotationalvelocity →30,000
30,000minmin-1orormore
more
„„ Capable
Capableof ofdesign
designfor
foreither
eitherinner
innerrotor
rotorororouter
outerrotor
rotortype
type
„„ Electric
Electricmagnetic
magneticmotor
motornoise
noisecanceling
cancelingresolver
resolverwinding
windingmethod
method

„„ Wide
Wideoperating
operatingtemperature
temperaturerange
range
→→　-40
　-40toto +150
+150deg.
deg.CC(+180
(+180deg.
deg.C)
C)
„„ Harsh
HarshEnvironmental
Environmentalresistance
resistance
→→　Vibration,
　Vibration,shock
shock&&oil
oilresistance
resistance
„„ High
Highreliability
reliability
→
→ Extremely
Extremelyreliable
reliableperformance
performancewith
withsimple
simpleconstruction
construction
„„ Simple
Simpleconstruction
construction
→
→Low
Lowcost
costand
andsuitable
suitablefor
formass
massproduction
production
 Comparison of Various Angular Sensors
for HEV motors
Type VR　Resolver Brushless Resolver Optical Encoder
Items ＋R/D ＭＲ Sensor Hall Sensor Incremental
＋R/D
△ ○ △ △ ◎
Accuracy
(0.3ﾟ～1ﾟ) (0.05ﾟ～0.2ﾟ) (0.3ﾟ～0.5ﾟ) (0.5ﾟ～1ﾟ) (0.02ﾟ～0.1ﾟ)
2,000～ 30,000 1000～ 200,000
Resolution 500～4,000P/R　
　　～500P/R　 ～5,000P/R
Pulse/rev Pulse/rev
Output Signal Absolute Absolute Incremental Incremental Incremental
　　　-1 　　　-1 　　　-1 　　 -1 　　　-1
Tracking Speed 　　>50,000rpm 　　>20,000rpm 　>20,000min 　>20,000min 　 >10,000min

Opera. Temp. ～+150℃ ～+150℃ ～+120℃ ～+120℃ ～+85℃

Vibration ◎ ◎ ○ ○ △

Reliability ◎ ◎ ○ ○ ○

Price ◎ ○ ◎ ◎ ○
Absolute position Absolute position Low EMI protection Low Cost 　　　High Accuracy
Features High Temp. High Temp. in High Resolution Low Temp
　　High Resolution High Resolution
Photo Diode　 LED

S
N
N スリット
S
S
N
N
S
S Rotor Magnet
N
Geared Rotor NS
S
MR Sensor
Magnet Coded rotary Disk
N
S Hall elements

◎：Better ○：Typical　△：Behind
 Factors for Angle Error of Resolver

Classific
Items Cause of Error
ation
Imprecise iron Dimensional error of concentricity between inner and outer
cores diameters, etc.
Internal
Effect to the induced voltage by irregularity of winding
factors Irregular winding
processes.

Slot harmonics Effect of magnetic ripples by slots

Mounting error Effect of eccentricity and inclination at mounting;

Error of 1 cycle per 1 electrical revolution is generated.

Load condition Unbalance between 2-phase outputs;

External Error of 2 cycles per 1 electrical revolution is generated.
factors
External magnetic
field Pulse noise by PWM magnetic field;
Error generated by waveform distortion of Resolver excitation
and output.
 Effect of Electrical Characteristics of Resolver
with Temperature Change

Performance changes at high temperature

Items
from room temperature

Impedance Impedance increases (i.e. current decreases) by

(Input current) approximate 2~ 5 % / 100 ･C.

Transformation ratio decreases by approximate

Transformation ratio
0.5 ~ 3 % / 100 ･C.

Phase shift deviates to lead direction by

Phase shift approximate 1~ 3 minutes / deg. C ,but no effect
on resolver angular error.

Angle error Almost no effect.

 Angle Error Caused by Stator Eccentricities
Size : S10, S15, S21
2X resolver :Error caused by Stator eccentricities 3X resolver :Error caused by Stator eccentricities

700 140
600 120
error [arc m in]

Error [arc m in]

500 100
S10 S10
400 80
S15 S15
300 60
S21 S21
200 40
100 20
0 0
0 0.05 0.1 0.15 0.2 0.25 0 0.05 0.1 0.15 0.2 0.25
Eccentricities [TIR m m ] Eccentricities [TIR m m ]

4X resolver :Error caused by Stator eccentricities

Center of shaft
140
120
Error [arc m in]

100
S10
80
S15
60
S21
40 Rotor
20 Stator
0
0 0.05 0.1 0.15 0.2 0.25
Eccentricities [TIR m m ] Stator eccentricities
 Angle Error Caused by Rotor Eccentricities
Size : S10, S15, S21
2X resolver :Error caused by R otor eccentricities 3X resolver :Error caused by R otor eccentricities

200 120
100

Error [arc m in]

Error [arc m in]

150
S10 80
S10
100 S15 60 S15
S21 40 S21
50
20
0 0
0 0.05 0.1 0.15 0.2 0.25 0 0.05 0.1 0.15 0.2 0.25
Eccentricities [TIR m m ] Eccentricities [TIR m m ]

4X resolver :Error caused by R otor eccentricities

Center of shaft
120
100
Error [arc m in]

80 S10
60 S15
40 S21

20 Rotor Stator
0
0 0.05 0.1 0.15 0.2 0.25
Eccentricities [TIR m m ]
Rotor eccentricities
 Angle error caused by axial alignment
Size : S10,S15,S21

Error caused by axialalignm ent

10

8
Error [arc m in]

6 2X
3X
4 4X
2

0
0 0.2 0.4 0.6 0.8 1 1.2
A xialalignm ent [m m ]
Center of shaft

Rotor
Stator Axial alignment
Resolver-to-Digital Conversion Technique

Structure of Resolver system

Exciting power supply

・
・ θm Rotor

COS output voltage Vcos R/D Converter Digital

output θRD

VR-Resolver SIN output voltage Vsin

Major R/D conversion method

(1) Tracking type R/D conversion IC
(2) R/D conversion by using a microprocessor
(3) Phase shift type R/D conversion (2-phase excitation / 1-phase output)
Block Diagram of Tracking type R/D Converter

Control deviation :
ε = K•sin θ• sin ωt × cos Φ - K•cosθ• sin ωt × sin Φ
　　　　　 = K•sin (θ-Φ) •sin ωt
　　

　　　ε = 0 　　→ 　 ∴ θ = Φ

Features: ■ Closed loop detection

■ High tracking rate
■ Superior noise immunity
■ High resolution
 Smartcoder　AU6802N1

High-speed, Digital-tracking, Complete Angle Detector

10/12-bit Resolver-to-Digital Converter IC
■ Features
(1) Vehicle-mount quality ：
　　　・Quality level ： Transportation equipment involved with safety
　　　・Operating temperature range ： -40℃ ～ +125℃
　(2) High accuracy　：　±2 LSB(10-bit) , ±4 LSB(12-bit)
　(3) Simple to use ：
　　　・Real-time output (High tracking rate ： 240,000 rpm for 10-bit resolution)
　　　・Simple power supply of DC5V （Integrated oscillator for exciting resolver ： 10/20kHz) ■ Outline
　　　・Small size ： 10×10mm , 0.65mm Pin interval ,52-pin TQFP
0.38
　　　・Light weight ： 0.27g 0.65
0.22
0.13 M
39 27
　　　・Built-In test (Abnormality detection) function
　　　・Pulse / Parallel / Bus + Serial interface (selectable) 40 26

　　　・Resolution of 10/12-bit (selectable)

　　　・Clock input(20MHz) ： Ext. CLK input/X’tal resonator/Ceramic resonator (selectable)

■ Specifications 52 14

Resolution 1,024 (=210) 4,096 (=212) 1

7.80 TYP
13

10.20 SQ
Tracking Rate 240,000 rpm 60,000 rpm 9.80
12.20
11.80 SQ
Conversion Accuracy ±2 LSB ±4 LSB 1.05
0.95
Settling time(180°input) 1 ms typ. (ACMD=“H”) 2.5 ms typ. (ACMD=“H”) Seating Plane
0.10
Acceleration 256,000 rad/sec2 64,000 rad/sec2 1.20 MAX

Response Time ±0.2°max. /10,000 rpm ±0.4°max. /10,000 rpm

Output Format 10/12-bit Bus-compatible, BIN code, Parallel, True-logic
2-phase pulse signal 256 P/T 1,024 P/T
Source Dissipation DC 5V±5% , 45 mA max.(30 mA typ.)
Operating Temperature -40℃ ~ +125℃
Storage Temperature -65℃ ~ +150℃
 Structure of Microprocessor Type R/D Converter
Microprocessor

Exciter
(Amp) D/A Start

θm Readout of X & Y data

kE 1 sin ω t ･ cos θm

Digital output　
E 1 sin ω t Ｘ
Input
Buffer Determination of quadrants
CPU

A/D 　　　　　
Computation of tan-1 (Y/X)
θRD
Input Ｙ
Compensation of quadrants
kE 1 sin ω t ･ sin θ m Buffer
Resolver
(1-phase excitation/ 2-phase output) Angle output
Software

Block Diagram of Microprocessor type R/D Converter θRD

R/D Conversion Routine

Features: ■ Open loop detection
■ Low cost by common use with the microprocessor for motor control
■ Capable of customized signal processing
■ Low tracking rate
■ Inferior noise immunity
 Examples of VR-Resolver Application (for Hybrid vehicles )
VR-resolvers (Singlsyn)
(Outer diameter: φ132）
Engine

For traction motor/generator of Hybrid electric vehicle [TOYOTA ]

RD Converter IC
(Smartcoder)
For Rack-Direct-Drive type EPS (Electrical power steering)

VR-resolver (Singlsyn)
（Outer diameter φ80）

Brushless motor
Rack-Direct-Drive type EPS [JTEKT]
 　VR-Resolvers for Automotive

For column type ＥＰＳ

For detection
of steering
angle
For variable gear
ratio steering
motor

For engine valve

control motor

For integrated
starter and
alternator
For HEV rear
motor

For Rack-Direct-
Drive type EPS
For electric brake
system
For HEV，EV
traction motors For wheel-in motors

Note: The car model of the illustration is reference.

 Another Resolver Application

• for XY robot motors

• for steering control of ship (tugboat)

Elevators

Outer rotor type VR-Resolver

• for traction motor of street car (LRT) • for flat winch elevator motors
 Multi-turn absolute angle detection system
with battery backup for single Resolver

Example１：
Input side Control side
<Detect shaft>
Input Smartｃoder
AU6802N1

BRX Serial communication Serial/ BUS

Multi-turn ASIC
Smartsyn Paralle CPU

～
～
or AUA70 （Cable） l
Conversion IC (28 bit)
Singlsyn
Battery

Advantage 　　: Capable of detecting absolute value even if cable is detached.

Disadvantage : Tracking speed is restricted by communication speed. (In case data does not jump.)
　　　　　　　 : Serial/parallel conversion IC is necessary.

Example ２： Input side Control side

Input <Detect shaft>
Smartcoder
AU6802N1

～
～
（Cable）
BRX Multi-turn ASIC BUS
Smartsyn CPU
AUA70 (28 bit)
or
Singlsyn
Battery

Advantage　　 : No need for serial/parallel conversion IC

Disadvantage : Incapable of detecting absolute value if cable is detached.
Multi-turn ASIC for Resolver 　　AUA70

Resolver VEXT（＋12～24V）

RS ＋5V
(BRX) Smartcoder

AC10KHz RSO AU6802N1 OSC

AMP
20MHz

COMP

PARALLEL SERIAL
COUNTER MIX TO RS485
SERIAL

12BIT
SEL BUS
BUS
TIMING
CS
RD

Intermittent pulse AUA70

at battery backup power mode. VOLTAGE
DETECTOR

REG

BATTERY
(＋3.6V)
＋5V
Multi-turn ASIC for Resolver 　　AUA70 ＊ This product is licensed by ABB Automation Technology Products.

The ASIC is used for a Resolver(Smartsyn or Singlsyn)to enable detecting the resolver shaft angle with plural revolution.
The product is operated by battery backup conjunction with Smartcoder (R/D converter chip AU6802N1).

■ Features :
　　1) Minimized backup consumer current　：　100μA（nominal）
　　2) Enable to detect multi-turn count of resolver shaft whether on normal or battery backup
　　　 power condition.
　　3) Affordable and easy handling:
　　　　・ Small size:　10×10mm　64PIN　TQFP.
　　　　・ Resolver shaft speed (poles pair) 1X/2X/4X.
　　　　・ Multi-turn detection:±32768 (=16BIT).
　　　　・ Optional serial communication output style:
　　　　・ Enable to replace easily from our optical encoders to resolver systems.
　　　　　　　・ Tamagawa 17BIT ABS Encoder interface compatible.
　　　　　　　・ Tamagawa 11BIT ABS Encoder interface compatible.
　　　　　　　・ Parallel BUS output.
　　　　・ Diagnostic for ASIC alarms ： Overspeed, Overflow, Battery error/ alarm, R/D error

■ Specifications : ■ Outline
ITEMS SPECIFICATIONS NOTES

Ｓingle-turn Resolution 4096 (=212) Ｓmartcoder　AU6802N1

Number of revolutions 65536 (=216) or ±32786 (=±215)　turn

60,000 rpm At normal state

Maximum tracking rate
60,000 rpm In backup timer
（Electric angle）
6,000 rpm When backing up

Voltage ＋2.7V ～ ＋3.6V

Backup power
Current 100μＡ (typ.)

Output Serial /Parallel BUS

Operating temperature -40℃ ～ +85℃

 Future View of Resolver Technologies

VR - Resolver
1. Further lowering cost by standardizing the shape and structure
2. Improving the angle accuracy
3. Further improvement of environmental resistance
( up to 180 deg. C)
4. Absolute angle and high accuracy by 1X type

R/D Converter IC
1. Small size and all-in-one functions
2. High speed conversion
3. High resolution
4. Built-in to the Micro-processor