旋转变压器铁心锈蚀故障对输出性能及位置检测的影响分析与验证

doi:10.19595/j.cnki.1000-6753.tces.251395

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Abstract Laminated resolvers made of silicon steel sheets are widely used in harsh industrial environments, such as new energy vehicles and aerospace servo systems. However, their cores are prone to corrosion in humid and salt-spray conditions, leading to degraded core magnetic properties, distorted output signals, and increased position-detection errors. Existing research primarily focuses on faults caused by winding short circuits, eccentricity, and non-ideal factors. However, systematic investigation into core corrosion (particularly the more common form of uneven corrosion) remains insufficient.
First, an electromagnetic-coupling mathematical model for corrosion-induced faults is established using the magnetic flux-linkage method. The mechanisms by which uniform and non-uniform corrosion affect the magnetic circuit reluctance, the main flux distribution, and the stator-rotor mutual inductance are clarified. Characteristic expressions for output-signal amplitude imbalance, imperfect quadrature, magnetic-field deviation, and harmonic distortion are derived. Second, Ansys finite element software is employed to construct simulation models with varying levels of corrosion severity, distribution patterns, and pole-pair counts. The influence of corrosion parameters on output fault characteristics is analyzed. Finally, an experimental platform is established. Output voltage waveforms, harmonic characteristics, and position decoding errors are compared under normal and corroded conditions.
Simulation results indicate that resolvers exhibit amplitude imbalance, imperfect quadrature, and harmonic distortion under varying degrees and distributions of corrosion. Asymmetric corrosion patterns relative to the D-axis induce fixed angular deviations. The mathematical model developed using the magnetic flux method demonstrates its applicability to corrosion scenarios involving two-pole resolvers. An experimental platform was established to artificially accelerate corrosion and prepare fault samples. The simulation model divides the corrosion area into five zones to simulate non-uniform corrosion, achieving good consistency between simulation and experimental results. Core corrosion degrades output performance: the induced electromotive force amplitude decreases from 4.50 V/4.67 V to 4.33 V, accompanied by a phase shift, increased 2nd-4th harmonics, and a fixed-angle deviation of 0.218 rad. Compared with the simulated 0.189 rad, the rotor position fixed-angle error is only 13.3%. The second-order PLL method achieves higher detection accuracy than the inverse tangent method due to its filtering characteristics.
Conclusions are as follows. (1) Core corrosion causes degradation in output signal characteristics, with a fixed angular offset stemming from the asymmetric distribution of corroded areas relative to the D-axis. The severity of asymmetry correlates with corrosion damage, leading to large offset values. (2) The established mathematical model demonstrates good applicability across corrosion scenarios in resolvers with varying numbers of pole pairs. (3) Core corrosion induces signal distortion through magnetic field displacement, and two commonly used decoding algorithms cannot fully suppress the resulting fixed-angle deviation.

Key words： Resolver fault core rusting fault finite element simulation

Received: 10 August 2025

PACS:	TM382
	TP212

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	Ye Zhihao
	Zhou Yao
	Yang Qing
	Luo Xi
	Zeng Xianfeng
	Chen Cheng

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Ye Zhihao,Zhou Yao,Yang Qing等. Analysis and Verification of the Impact of Core Rust Faults in Resolvers on Output Performance and Position Detection[J]. Transactions of China Electrotechnical Society, 2026, 41(14): 4919-4932.

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