Position error calculation of linear resolver under mechanical fault conditions

Position sensors are inseparable part of motion control systems. Linear resolvers (LRs) are electromagnetic position sensors that are suitable for high vibration, polluted environments. The accuracy of their detected position can be affected by different mechanical faults. In this study, variety of possible mechanical faults along with their mathematical index in LRs is introduced. Static eccentricity, dynamic eccentricity, inclined mover and run out error are the presented mechanical faults that are discussed independently and simultaneously. Then, three-dimensional non-linear, time-stepping finite element method is employed to investigate the performance of the studied resolver under different mechanical faults. Finally, the prototype of the studied sensor is built. An experimental test setup is designed and built in order to measure the output characteristic of the LR under studied mechanical faults. Good correlation between the experimental and simulation results is obtained.