Unlock EMI-Resistant Performance: Why Resolvers Excel in Modern Electric Drive Systems

White Paper: Automotive

SPONSORED BY:

Gain practical engineering insights and design strategies to enhance resolver integration, durability, and performance in modern electric drivetrains with our detailed white paper. Inside, you’ll discover:

• Key insights into trends in electrification.
• Learn about the engineering challenges of compact, high-power electric drive systems.
• Discover why resolvers are preferred for accurate rotor position sensing in harsh environments.
• Gain insights into effective resolver integration, EMC strategies, and design optimizations.

Download this white paper to gain critical insights and proven strategies for overcoming key design challenges and maximizing resolver performance in next-generation electric drive systems.

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Overview

The document titled "Why Resolvers Excel in EMI-Intensive eDrive Systems" by TE Connectivity discusses the critical role of resolvers in modern electric drivetrains, particularly in the context of increasing electrification in the automotive industry. As manufacturers aim to reduce reliance on internal combustion engines (ICE) and meet regulatory sustainability goals, electric motors, especially in e-axle architectures, are becoming central to drivetrain design.

Resolvers are highlighted as a reliable solution for rotor-position sensing in electric motors, which face unique challenges such as tighter packaging, increased electromagnetic interference (EMI), and higher thermal and mechanical stress. These challenges arise as motors are designed to deliver more power in smaller, more efficient packages, which can compromise signal integrity due to stronger electromagnetic fields generated in close proximity to high-power components.

The document emphasizes that while resolvers are inherently more resistant to EMI than alternative sensors, they are not completely immune. Excessive interference can still affect their accuracy, leading to potential inaccuracies in rotor position and rotation measurements. To mitigate these risks, the document suggests employing thoughtful shielding, careful component placement, and comprehensive system-level design strategies.

TE Connectivity’s Single Coil Resolver (SCR) is presented as a customizable product that offers significant advantages, including ±1° electrical accuracy, a wide operational temperature range from -40°C to +150°C, and compliance with ASIL D system-level standards. The SCR also features options for integrated NTC temperature sensing and various stator/rotor diameters, making it adaptable to specific mechanical, electrical, and environmental needs.

The document outlines design strategies to enhance resolver integration, such as utilizing aluminum housings for electric motors that provide structural support, thermal management, and EMI shielding. Additionally, placing the resolver at the end of the motor with a metal plate can serve as a first line of defense against EMI.

In conclusion, the white paper positions TE Connectivity as a partner for OEMs and Tier 1 suppliers, offering expertise and support in integrating resolver solutions into electrified platforms, ultimately aiming to streamline design processes and accelerate development in the evolving automotive landscape.