Resolver Fault Compensation

Principle of the Resolver Fault Compensation

Why do we have a Resolver Fault?

The resolver as a feedback system is using an induction principle: In two stator windings (sin/cos
winding) a voltage is induced in that way that the resulting voltage induced in the rotating
reference winding is zero. From the amplitude and phase of the source voltages can be concluded to
the position of the rotor of the resolver. The sin/cos voltages are converted to a rotor position value
inside the servo controller:

Illustration 1: principal mounting of stator/rotor winding of a resolver (one pole)

In the real construction of a resolver there is always a slight non-linearity between the physical rotor
angle and the position signal evaluated from the sinus and cosinus voltage. The reason for this is
because ...

• ... the air gap between rotor and stator of the resolver varies depending on the eccentrically
mounting. This influences the magnetic coupling of between rotor and stator winding and leads
to slight signal distortions.

• ... the stator and rotor windings show slight variations in the electrical values of resistance and
inductance.

Seen from this aspect the non-linearity between physical rotation angle and the measured resolver
position value show the following characteristic:
ϕmeasure ϕmeasure
360° 360°
measured resolver position

∆ϕ
∆ϕ(ϕmeasure)

ϕphysical
physical rotor position 360°

∆ϕ(ϕphysical)

ϕphysical
360°

Illustration 2: typical characteristic between physical rotation angle and the measured resolver position

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 Resolver Fault Compensation

The diagram shows an oscillation of the deviation angle ∆ϕ = f(ϕphysical) over one resolver revolution.
This characteristic is unique for each resolver. Converting the characteristic to speed signals it
becomes clear that the oscillation because of the resolver fault ∆ϕ will increase with higher speeds
of the resolver:

nreal

360° 360°

nreal

360° 360°
resolver position t resolver position t
resolver speed (physical) resolver speed (physical)
resolver speed (measured) resolver speed (measured)

Illustration 3: measured speed signal at low speed Illustration 4: measured speed signal at high speed

It can easily be seen that the oscillation of the speed signal resulting from the resolver fault will lead
to reduced performance of the drive, in particular when the resolver speed increases.

How does Resolver Fault Compensation work?

If the resolver fault can be compensated the speed signal concluded from the resolver position can
be smoothened. For this purpose the resolver fault compensation principle requires the knowledge
of the compensation function ∆ϕ = f(ϕmeasure) as shown in illustration 2. When knowing the
calibration curve ∆ϕ = f(ϕmeasure) it is possible to conclude to the physical resolver position:
ϕ physical = ϕmeasure + ∆ϕ (ϕmeasure )

In the following the principles of resolver fault compensation are introduced shortly.

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 Resolver Fault Compensation

Compensation via Code C04161:

During the motor’s final testing in the Lenze factory it is possible to run a calibration sequence for
the resolver: The motor is equipped with an additional reference position sensor. By slowly rotating
the motor shaft the reference position ϕmeasured and the resolver position ϕmeasured will be compared
resulting in the calibration curve ∆ϕ-1 = f-1(ϕmeasured). This curve will be analysed in its harmonics. The
amplitude and phase of the basic oscillation and the first harmonic will be evaluated and printed on
the motor nameplate. The only thing left to be done by the user is to read this number from the
motor nameplate and put it into code number C0416.

8 digit number for resolver fault

compensation
(transfer this value to code C0416)

Illustration 5: resolver fault compensation data for C0416 on motor nameplate

Note: The C0416 value always is an 8 digit value with the following format:

C0416:
amplitude of the basic oscillation (coded*)
phase shift of the basic oscillation (coded*)
amplitude of the first harmonic (coded*)
phase shift of the first harmonic (coded*)

* The amplitude as well as the phase is scaled in a special coding.

Illustration 6: meaning of the 8 digit number for resolver fault compensation C0416

 Note:
The resolver fault compensation via code number C0416 is implemented on servo controller series
9300 as well as on the 9400 series up to firmware V5.0.
Since firmware V7.0 there is another principle of measuring the resolver fault on 9400. The code
C0416 will not have any effect anymore. Instead there will be a device command C0002 = 59 which is
introduced on the next page.

1 on 9300 as well as on 9400 up to firmware V5.0

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 Resolver Fault Compensation

Compensation via Device Command C0002 = 59 (9400 since firmware V7.0):

On the later firmware releases of 9400 the principle of measuring the resolver fault has been
changed: A device command C0002 = 59 (‘resolver fault identification’) is available which allows the
usere to find the correct compensating parameters on his own. The sequence is as follows:

Start
Requirements:
2
• The drive is running with a constant speed nmotor > 500[rpm] .

Is the motor turning with a constant speed above 500[rpm]?

?
NO
⇒ Start
YES

Activate the resolver fault identification sequence using the following device
Step 1 command:

Monitor the progress of the resovler fault identification in the Engineer software:
Step 2

Note: During the resolver fault identification the motor speed does not have to fall
below 500[rpm].

Has the resolver fault identification finished?

?
NO
⇒2
YES

2 i.e. by using the manual jog function in conjunction with an appropriate jog speed.

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 Resolver Fault Compensation

After the resolver fault identification has been finished successfully the following
Step 3 parameters may have changed against the default settings:
Code settings: Note
Default range
C0416 0 0 ... ... 99999999 Resolver fault compensation code – see motor nameplate
Note: This code will not have any effect from firmware V7.0
or higher.
C0417 100 100 ... {1[%]} ... 1000 amplification factor for resolver evaluation

C0418 0 0: inactive Selection code: activation/deactivation of the resolver fault

1: active correction via code number C0417, C2862/1, C2862/2 and
C2863
C2862 0 ... ... 100 Correction factors for the sinus/cosinus track amplification of
1 100 the resolver (resolver fault compensation):
2 100 • subcode 1: resolver sinus track
• subcode 2: resolver cosinus track
C2863 0 -100 ... ... 100 Correction angle for the resolver fault compensation

Store these values non-volatile in the drive’s memory using the device command
C0002 = 11 in the Engineer software:

End

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