The variable reluctance resolver (VRR) is commonly used in the automotive industry as a rotor position sensor. Its use in the Aerospace and Defense Industries has been limited due to inadequate accuracy performance. However, recent interest in the Aerospace Industry for VRRs as a viable alternative to conventional resolvers has driven the development of higher accuracy VRRs for use in angular position feedback applications. This paper presents the progression in the development of the VRR and provides information on the lessons learned during the completion of the first generation of single speed and multi-speed engineering units of VRRs. This first generation of engineering units was evaluated to identify potential design and manufacturing process improvements. Incorporating the lessons learned from the development of the first generation units resulted in an improvement in performance and manufacturability in the second generation of VRRs, making it a desirable option for future use in commutation of brushless DC motors.
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