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Resolvers as position and speed sensors are widely used in many areas including the automotive industry, especially in the application of an electric drive for a hybrid electric vehicle. One of the disadvantages of using resolvers is that their complexity usually leads to quality issues during development that requires engineering resources and time to solve, which could be better served in solving the complex system issues of improving the hybrid system functionality. This paper describes the creation of a full resolver system simulation that can be used to prevent development issues, improve the hybrid system DFMEA, and act as a catalyst for solving development issues when they do happen.

A new Gas Flow Sensor was derived from the current air flow sensing technology. This sensor is targeted at measuring the amount of gaseous mass flow under high pressure and with varying gas temperature. Thermodynamical properties of CH4, air, N2He and CO2 have been compiled at different pressures and temperatures. This information is required for the simulation. A theoretical model has been developed to analyze the behavior of the sensor circuit with different gases at varying pressure and temperature. The theoretical model encompasses a model of the gas flow circuit as well as a flow model with an optimized fluid dynamic equation. Fluid dynamics have also been studied to demonstrate the usage of a bypass and a mesh screen for flow regulation. A finite element analysis (FEA) is also generated to study the velocity profile and potential turbulence areas.